2000-2010 Cummins Signature/ISX/QSX15 Engines OEM Service & Repair Manual

Service Manual Signature, ISX, and QSX15 Volume 1

Foreword This manual contains instructions for troubleshooting and repairing this engine in the chassis, complete rebuild procedures and specifications. Disassembly, cleaning, inspection, and assembly instructions are included. A listing of accessory and component suppliers is located in Section M - Component Manufacturers. Suppliers can be contacted directly for any information not covered in this manual. Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i - Introduction. The manual is organized to guide a service technician through the logical steps of identifying and correcting problems related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment manufacturer for repair procedures. The repair procedures in this manual are based on the engine or component removed from chassis. Some rebuild procedures require the use of special service tools. Make sure the correct tools are used as described in the procedures. When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used in place of the recommended item. A series of specific service manuals (for example: Troubleshooting and Repair, Specifications, and Alternative Repair) are available and can be ordered by Contacting your local area Cummins Regional office. A Cummins Regional office listing is located in Service Literature (Section L). Cummins Inc. encourages the user of this manual to report errors, omissions, and recommendations for improvement. Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for communicating your comments. The specifications and rebuild information in this manual is based on the information in effect at the time of printing. Cummins Inc. reserves the right to make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact a Cummins Authorized Repair Location or call 1-800-DIESELS (1-800-343-7357) toll free in the U.S. and Canada. The latest technology and the highest quality components are used to manufacture Cummins engines. When replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts.

Table of Contents Section Introduction .............................................................................................................................................. i Engine and System Identification ............................................................................................................ E Familiarization .......................................................................................................................................... F Troubleshooting Symptoms ..................................................................................................................... TS Troubleshooting Symptoms (New Format) .............................................................................................. TT Complete Engine - Group 00 .................................................................................................................... 0 Engine Disassembly Group 00 ................................................................................................................. DS Engine Assembly - Group 00 ................................................................................................................... AS Cylinder Block - Group 01 ........................................................................................................................ 1 Cylinder Head - Group 02 ......................................................................................................................... 2 Rocker Levers - Group 03 ........................................................................................................................ 3 Back .......................................................................................................................................................... back

Signature™, ISX, and QSX15 Section i - Introduction Page i-a Section i - Introduction Section Contents Page About the Manual ...............................................................................................................................................i-1 General Information...........................................................................................................................................i-1 Acronyms and Abbreviations ...........................................................................................................................i-15 General Information..........................................................................................................................................i-15 General Cleaning Instructions ......................................................................................................................... i-10 Abrasive Pads and Abrasive Paper...................................................................................................................i-10 Definition of Clean............................................................................................................................................i-10 Fuel System.....................................................................................................................................................i-13 Gasket Surfaces...............................................................................................................................................i-11 Plastic Bead Cleaning......................................................................................................................................i-12 Solvent and Acid Cleaning................................................................................................................................i-11 Steam Cleaning................................................................................................................................................i-12 General Repair Instructions ...............................................................................................................................i-8 General Information...........................................................................................................................................i-8 Welding on a Vehicle with an Electronic Controlled Fuel System........................................................................i-9 General Safety Instructions ...............................................................................................................................i-6 Important Safety Notice......................................................................................................................................i-6 How to Use the Manual ......................................................................................................................................i-2 General Information...........................................................................................................................................i-2 Illustrations .........................................................................................................................................................i-5 General Information...........................................................................................................................................i-5 Symbols ..............................................................................................................................................................i-4 General Information...........................................................................................................................................i-4

Signature™, ISX, and QSX15 Page i-b Section i - Introduction This Page Left Intentionally Blank

Signature™, ISX, and QSX15 About the Manual Section i - Introduction Page i-1 About the Manual General Information This Service Manual is intended to aid in determining the cause of engine related problems and to provide recommended repair procedures. Additionally the manual is intended to aid mechanics in disassembly, inspecting parts for reuse, rebuilding and assembly of components. The manual is divided into sections. Each section is equivalent to a group used in Cummins' filmcard system. Some sections contain reference numbers and procedure numbers. Reference numbers provide general information, specifications, diagrams, and service tools where applicable. Procedure numbers are used to identify and reference specific repair procedures for correcting the problem and describe specific rebuild procedures. This manual does not contain fuel systems electronic troubleshooting. Use the troubleshooting trees in this manual, if there are no electronic fault codes. This manual is designed so the troubleshooting trees are used to locate the cause of an engine problem. The troubleshooting trees then direct the user to the correct repair procedure. The repair procedures within a section are in numerical order. However, the repair steps within a given procedure are organized in the order the repair must be performed regardless of the numerical order of the steps. The user must use the contents pages or the index at the back of the manual to locate specific topics when not using the troubleshooting trees.

How to Use the Manual Signature™, ISX, and QSX15 Page i-2 Section i - Introduction How to Use the Manual General Information The troubleshooting and repair section of this manual is organized to provide an easy system installation and flow from problem identification to problem correction. System Installation The installation guidelines section has been designed to provide instructions for installing the system. A technician should read the instruction, learn the intent of the step, and install the component in a fashion that will comply to the vehicle's configuration. Each deviation from the specific instructions provided in this procedure should be noted. Refer to the OEM service manual for OEM specifications. A list of troubleshooting symptoms containing the most common engine problems is in the Troubleshooting Symptoms, Section (TS). The manual is designed to use the Troubleshooting Symptoms as a guide to locating the problem and directing the end user to the correct procedure for making the repair. Complete the following steps to locate and correct the problem. (Step 1) Locate the symptom on the Section Contents pages of Section TS. Reference to the page number where the Troubleshooting Symptom Tree is found is made to the right of the symptom tree title. (Step 2) The left column of boxes in the Troubleshooting Symptom Charts indicates a probable cause of the problem, starting at the top with the simplest and easiest to repair, and continuing downward to the most difficult. The right column of boxes provides a brief description of the corrective action with a reference number to the correct procedure used to make the repair. (Step 3) Locate the probable cause in the left column then turn to the procedure referenced in the right column. (Step 4) The Troubleshooting Symptom Charts are based on the following assumptions: The engine has been installed according to the manufacturer's specifications. The easiest repairs are done first. "Generic" solutions to cover problems with the most common applications and Original Equipment Manufacturer (OEM). The disassemble/assemble sections of this manual is divided into the same group system used for previous manuals and the Cummins' filmcard system. Section 00 is organized into a logical sequence of engine disassemble/assemble, all other sections are in numerical sequence. Refer to the Table of Contents at the front of the book to determine the section that details the desired information. Each section contains the following in sequence: • Table of Contents • Required Service Tool Listings • General Information containing the basic service, maintenance, design and revision information necessary to assist in the rebuild of an engine or a component • Procedure instructions for the disassembly, inspection, maintenance, and assembly that can be required to rebuild an engine; additional procedures that are not necessary during every rebuild, but can be necessary, are included. These procedures depend on the length of time an engine has been in service and the conditions of the parts. All the procedures are identified with a name and a number. Each digit in the procedure number has a specific meaning. The first three digits of the number refer to the specific section that the procedure can be found within the manual. In this example, “001” represents Section 01 — Cylinder Block. This number will range from 000 to 022.

Signature™, ISX, and QSX15 How to Use the Manual Section i - Introduction Page i-3 The second three digits of the number are unique and refer to a specific subject. In this example, “028” represents Cylinder Liner. This number will range from 001 to 999. Refer to Section V for specifications recommended by Cummins Engine Company, Inc. for your engine. Specifications and torque values for each engine system are given in that section. NOTE: Discharge of oil or oily water into or upon the water is a direct violation of today's laws. Violators are subject to a penalty of various monetary charges. Dispose of these substances in accordance with standard set by the EPA.

2000-2010 Cummins Signature/ISX/QSX15 Engines OEM Service & Repair Manual

You're Reading a Preview

Recently Viewed