Cummins QSX15 Industrial Power Generation Engines Operation And Maintenance Manual

CUMMINS QSX15 ENGINE OWNERS MANUAL "Portions copyright CUMMINS INC. REPRODUCED FOR LIMITED LICENSED USE ONLY, WITH PERMISSION FROM CUMMINS INC. UNLICENSED USE AND/OR REPRODUCTION ARE EXPRESSLY PROHIBITED" Book 22523849 (5/07)

Copyright Protected Information provided to Ingersoll Rand by permission Cummins Inc. Owners Manual QSX15 Industrial and Power Generation Engines Copyright© 2007 Bulletin 4915540 Cummins Inc. Printed 02-MAY-2007 All rights reserved

Copyright Protected Information provided to Ingersoll Rand by permission Cummins Inc. Foreword This manual contains information for the correct operation and maintenance of your Cummins engine. Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i - Introduction. Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the new owner. The information, specifications, and recommended maintenance guidelines in this manual are based on information in effect at the time of printing. Cummins Inc. reserves the right to make changes at any time without obligation. If you find differences between your engine and the information in this manual, contact your local 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 were used to produce this engine. When replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts. NOTE: Warranty information is located in Section W. Make sure you are familiar with the warranty or warranties applicable to your engine.

Copyright Protected Information provided to Ingersoll Rand by permission Cummins Inc. Table of Contents Section Introduction .............................................................................................................................................. i Engine Identification ................................................................................................................................ E Operating Instructions ............................................................................................................................. 1 Maintenance Guidelines ........................................................................................................................... 2 Service Literature ..................................................................................................................................... L Maintenance Specifications ..................................................................................................................... V Warranty ................................................................................................................................................... W

Copyright Protected Information provided to Ingersoll Rand by permission Cummins Inc. Important Reference Numbers Fill in the part name and number in the blank spaces provided below. This will give you a reference whenever service or maintenance is required. Name Number Number Engine Model Engine Serial Number (ESN) Control Parts List (CPL) Fuel Pump Part Number Electronic Control Module (ECM) Electronic Control Module Serial Numbers (ECM) Filter Part Numbers: • Air Cleaner Element • Lubricating Oil • Fuel • Fuel-Water Separator • Coolant • Crankcase Ventilation • Cummins Particulate Filter Governor Control Module (GCM) (if applicable) Belt Part Numbers: • • • Clutch or Marine Gear (if applicable): • Model • Serial Number • Part Number • Oil Type • Sea Water Pump - Model - Part Number

QSX15 Section i - Introduction Page i-a Copyright Protected Information provided to Ingersoll Rand by permission Cummins Inc. Section i - Introduction Section Contents Page Acronyms and Abbreviations .............................................................................................................................i-5 General Information...........................................................................................................................................i-5 General Safety Instructions ...............................................................................................................................i-3 Important Safety Notice......................................................................................................................................i-3 Illustrations .........................................................................................................................................................i-2 General Information...........................................................................................................................................i-2 Symbols ..............................................................................................................................................................i-1 General Information...........................................................................................................................................i-1

QSX15 Page i-b Section i - Introduction This Page Left Intentionally Blank

QSX15 Symbols Section i - Introduction Page i-1 Copyright Protected Information provided to Ingersoll Rand by permission Cummins Inc. Symbols General Information The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below:

Illustrations QSX15 Page i-2 Section i - Introduction Copyright Protected Information provided to Ingersoll Rand by permission Cummins Inc. Illustrations General Information Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition. The illustrations are intended to show repair or replacement procedures. The procedure will be the same for all applications, although the illustration can differ.

QSX15 General Safety Instructions Section i - Introduction Page i-3 Copyright Protected Information provided to Ingersoll Rand by permission Cummins Inc. General Safety Instructions Important Safety Notice WARNING Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation or other personal injury or death. Read and understand all of the safety precautions and warnings before performing any repair. This list contains the general safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply. • Work in an area surrounding the product that is dry, well lit, ventilated, free from clutter, loose tools, parts, ignition sources and hazardous substances. Be aware of hazardous conditions that can exist. • Always wear protective glasses and protective shoes when working. • Rotating parts can cause cuts, mutilation or strangulation. • Do not wear loose-fitting or torn clothing. Remove all jewelry when working. • Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work. Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a "Do Not Operate" tag in the operator's compartment or on the controls. • Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or damage to the fan blade(s) causing premature fan failure. • If an engine has been operating and the coolant is hot, allow the engine to cool before slowly loosening the filler cap to relieve the pressure from the cooling system. • Always use blocks or proper stands to support the product before performing any service work. Do not work on anything that is supported ONLY by lifting jacks or a hoist. • Relieve all pressure in the air, oil, fuel, and cooling systems before any lines, fittings, or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury. • To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect liquid refrigerant (Freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the atmosphere. Federal law requires capturing and recycling refrigerant. • To reduce the possibility of personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded. • Corrosion inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the substance in eyes. Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. • Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF CHILDREN. • To reduce the possibility of burns, be alert for hot parts on products that have just been turned off, exhaust gas flow, and hot fluids in lines, tubes, and compartments. • Always use tools that are in good condition. Make sure you understand how to use the tools before performing any service work. Use ONLY genuine Cummins or Cummins ReCon® replacement parts. • Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of lesser quality if replacements are necessary. • Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning. • Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. • Liquified petroleum gas is heavier than air and can accumulate near the floor, in sumps, and low-lying areas. • Natural gas is lighter than air and can accumulate under hood and awnings. • To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect natural gas and liquified petroleum gas lines in a well ventilated area. • Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations. • The catalyst reagent contains urea. Do not get the substance in your eyes. In Case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of contact, immediately wash skin with soap and water. Do not swallow internally. In the event the catalyst reagent is ingested, contact a physician immediately.

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Cummins QSX15 Industrial Power Generation Engines Operation And Maintenance Manual

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