Vol1

Cummins Inc.
Service Manual
Service Manual Signature, ISX and QSX15 Volume 1

Box 3005
Columbus, Indiana, U.S.A., 47202 Signature, ISX and QSX15
Registered Office Volume 1
Cummins Ltd.
49 - 51 Gresham Road,
Staines,
Middlesex TW18 2BD,
England
Registration 573951 England
Copyright 2010
Cummins Inc.
Bulletin 3666239
Printed in U.S.A. 27-APRIL-2010 p41
302158_Cummins_Vol1.indd 1 5/11/10 9:35 AM

Service Manual
Signature, ISX, and QSX15
Volume 1
Copyright 2010 Bulletin 3666239

Cummins Inc. Printed 27-APRIL-2010
All rights reserved
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
Back .......................................................................................................................................................... back

Signature, ISX, and QSX15 Eng [...]
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
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
Illustrations .........................................................................................................................................................i-5
Symbols ..............................................................................................................................................................i-4
Page i-b Section i - Introduction
This Page Left Intentionally Blank

Signature, ISX, and QSX15 Eng [...] 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 Eng [...]
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 Eng [...] How to Use the Manual
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.
Symbols Signature, ISX, and QSX15 Eng [...]
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:
Signature, ISX, and QSX15 Eng [...] Illustrations
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.
General Safety Instructions Signature, ISX, and QSX15 Eng [...]
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.
When necessary, the removal and replacement of any guards covering rotating components, drives, and/or belts
should only be carried out be a trained technician. Before removing any guards the engine must be turned off and
any starting mechanisms must be isolated. All fasteners must be replaced on re-fitting the guards.
Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.
Signature, ISX, and QSX15 Eng [...] General Safety Instructions
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.
Do not connect the jumper starting or battery charging cables to any ignition or governor control wiring. This can
cause electrical damage to the ignition or governor.
Always torque fasteners and fuel connections to the required specifications. Overtightening or undertightening
can allow leakage. This is critical to the natural gas and liquefied petroleum gas fuel and air systems.
Always test for fuel leaks as instructed, as odorant can fade.
Close the manual fuel valves prior to performing maintenance and repairs, and when storing the vehicle inside.
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.
The catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of
California to cause cancer. Always wear protective gloves and eye protection when handling the catalyst assembly.
Do not get the catalyst material 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.
The Catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of
California to cause cancer. In the event the catalyst is being replaced, dispose of in accordance with local
regulations.
California Proposition 65 Warning - Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
General Repair Instructions Signature, ISX, and QSX15 Eng [...]
General Repair Instructions

General Information
This engine incorporates the latest technology at the time it was manufactured; yet, it is designed to be repaired using
normal repair practices performed to quality standards.
CAUTION
Cummins Inc. does not recommend or authorize any modifications or repairs to engines or components
except for those detailed in Cummins Service Information. In particular, unauthorized repair to safety-related
components can cause personal injury or death. Below is a partial listing of components classified as safety-
related:
1 Air Compressor
2 Air Controls
3 Air Shutoff Assemblies
4 Balance Weights
5 Cooling Fan
6 Fan Hub Assembly
7 Fan Mounting Bracket(s)
8 Fan Mounting Capscrews
9 Fan Hub Spindle
10 Flywheel
11 Flywheel Crankshaft Adapter
12 Flywheel Mounting Capscrews
13 Fuel Shutoff Assemblies
14 Fuel Supply Tubes
15 Lifting Brackets
16 Throttle Controls
17 Turbocharger Compressor Casing
18 Turbocharger Oil Drain Line(s)
19 Turbocharger Oil Supply Line(s)
20 Turbocharger Turbine Casing
21 Vibration Damper Mounting Capscrews
Follow all safety instructions noted in the procedures

- Follow the manufacturer's recommendations for cleaning solvents and other substances used during the repair of
the engine. Some solvents and used engine oil have been identified by government agencies as toxic or
carcinogenic. Avoid excessive breathing, ingestion and contact with such substances. Always use good safety
practices with tools and equipment.
Provide a clean environment and follow the cleaning instructions specified in the procedures
- The engine and its components must be kept clean during any repair. Contamination of the engine or components
will cause premature wear.
Perform the inspections specified in the procedures
Replace all components or assemblies which are damaged or worn beyond the specifications
Use genuine Cummins new or ReCon service parts and assemblies
- The assembly instructions have been written to use again as many components and assemblies as possible. When
it is necessary to replace a component or assembly, the procedure is based on the use of new Cummins or
Cummins ReCon components. All of the repair services described in this manual are available from all Cummins
Distributors and most Dealer locations.
Follow the specified disassembly and assembly procedures to reduce the possibility of damage to the components
Signature, ISX, and QSX15 Eng [...] General Repair Instructions
Welding on a Vehicle with an Electronic Controlled Fuel System

CAUTION
Disconnect both the positive (+) and negative (-) battery cables from the battery before welding on the
vehicle. Attach the welder ground cable no more than 0.61 meters [2 feet] from the part being welded. Do not
connect the ground cable of the welder to the ECM cooling plate or ECM. Welding on the engine or engine
mounted components is not recommended or damage to the engine or components can result.
General Cleaning Instructions Signature, ISX, and QSX15 Eng [...]
General Cleaning Instructions

Definition of Clean
Parts must be free of debris that can contaminate any engine system. This does not necessarily mean they have to
appear as new.
Sanding gasket surfaces until the factory machining marks are disturbed adds no value and is often harmful to forming
a seal. It is important to maintain surface finish and flatness tolerances to form a quality sealing surface. Gaskets are
designed to fill small voids in the specified surface finish.
Sanding gasket surfaces where edge-molded gaskets are used is most often unnecessary. Edge-molded gaskets are
those metal carriers with sealing material bonded to the edges of the gasket to seal while the metal portion forms a
metal to metal joint for stability. Any of the small amounts of sealing material that can stick to the parts are better
removed with a blunt-edged scraper on the spots rather than spending time polishing the whole surface with an air
sander or disc.
For those gaskets that do not have the edge molding, nearly all have a material that contains release agents to prevent
sticking. Certainly this is not to say that some gaskets are not difficult to remove because the gasket has been in
place a long time, has been overheated or the purpose of the release agent has been defeated by the application of
some sealant. The object however is just to remove the gasket without damaging the surfaces of the mating parts
without contaminating the engine (don't let the little bits fall where they can not be removed).
Bead blasting piston crowns until the dark stain is removed is unnecessary. All that is required is to remove the carbon
build-up above the top ring and in the ring grooves. There is more information on bead blasting and piston cleaning
later in this document.
Cummins Inc. does not recommend sanding or grinding the carbon ring at the top of cylinder liners until clean metal
is visible. The liner will be ruined and any signs of a problem at the top ring reversal point (like a dust-out) will be
destroyed. It is necessary to remove the carbon ring to provide for easier removal of the piston assembly. A medium
bristle, high quality, steel wire wheel that is rated above the rpm of the power tool being used will be just as quick and
there will be less damage. Yes, one must look carefully for broken wires after the piston is removed but the wires are
more visible and can be attracted by a magnet.
Oil on parts that have been removed from the engine will attract dirt in the air. The dirt will adhere to the oil. If possible,
leave the old oil on the part until it is ready to be cleaned, inspected and installed, and then clean it off along with any
attracted dirt. If the part is cleaned then left exposed it can have to be cleaned again before installation. Make sure
parts are lubricated with clean oil before installation. They do not need to be oiled all over but do need oil between
moving parts (or a good lube system priming process conducted before cranking the engine).
Bead blasting parts to remove exterior paint is also usually unnecessary. The part will most likely be painted again
so all that needs happen is remove any loose paint.
Abrasive Pads and Abrasive Paper
The keyword here is "abrasive". There is no part of an engine designed to withstand abrasion. That is they are all
supposed to lock together or slide across each other. Abrasives and dirt particles will degrade both functions.
WARNING
Abrasive material must be kept out of or removed from oil passages and parts wear points. Abrasive material
in oil passages can cause bearing and bushing failures that can progress to major component damage beyond
reuse. This is particularly true of main and rod bearings.
Cummins Inc. does not recommend the use of emery cloth or sand paper on any part of an assembled engine or
component including but not limited to removing the carbon ridge from cylinder liners or to clean block decks or
counterbores.
Great care must be taken when using abrasive products to clean engine parts, particularly on partially assembled
engines. Abrasive cleaning products come in many forms and sizes. All of them contain aluminum oxide particles,
silicon carbide, or sand or some other similar hard material. These particles are harder than most of the parts in the
engine. Since they are harder, if they are pressed against softer material they will either damage the material or
become embedded in it. These materials fall off the holding media as the product is used. If the products are used
with power equipment the particles are thrown about the engine. If the particles fall between two moving parts, damage
to the moving parts is likely.
If particles that are smaller than the clearance between the parts while they are at rest (engine stopped), but larger
than the running clearance then damage will occur when the parts move relative to each other (engine started). While
the engine is running and there is oil pressure, particles that are smaller than the bearing clearance are likely to pass
between the parts without damage and be trapped in the oil filter. However, particles larger than the bearing clearance
will remove material from one part and can become embedded in one of the parts. Once embedded in one part it will
Signature, ISX, and QSX15 Eng [...] General Cleaning Instructions
abrade the other part until contact is no longer being made between the two parts. If the damage sufficiently degrades
the oil film, the two parts will come into contact resulting in early wear-out or failure from lack of effective lubrication.
Abrasive particles can fly about during cleaning it is very important to block these particles from entering the engine
as much as possible. This is particularly true of lubricating oil ports and oil drilling holes, especially those located
downstream of the lubricating oil filters. Plug the holes instead of trying to blow the abrasive particles and debris with
compressed air because the debris is often simply blown further into the oil drilling.
All old gasket material must be removed from the parts gasket surfaces. However, it is not necessary to clean and
polish the gasket surface until the machining marks are erased. Excessive sanding or buffing can damage the gasket
surface. Many newer gaskets are of the edge molded type (a steel carrier with a sealing member bonded to the steel).
What little sealing material that can adhere is best removed with a blunt-edged scraper or putty knife. Cleaning gasket
surfaces where an edge-molded gasket is used with abrasive pads or paper is usually a waste of time.
WARNING
Excessive sanding or grinding the carbon ring from the top of the cylinder liners can damage the liner beyond
reuse. The surface finish will be damaged and abrasive particles can be forced into the liner material which
can cause early cylinder wear-out or piston ring failures.
Tape off or plug all openings to any component interior before using abrasive pads or wire brushes. If really necessary
because of time to use a power tool with abrasive pads, tape the oil drillings closed or use plug and clean as much
of the surface as possible with the tool but clean around the oil hole/opening by hand so as to prevent contamination
of the drilling. Then remove the tape or plug and clean the remaining area carefully and without the tool. DO NOT use
compressed air to blow the debris out of oil drilling on an assembled engine! More likely than not, the debris can be
blown further into the drilling. Using compressed air is fine if both ends of the drilling are open but that is rarely the
case when dealing with an assembled engine.
Gasket Surfaces
The object of cleaning gasket surfaces is to remove any gasket material, not refinish the gasket surface of the part.
Cummins Inc. does not recommend any specific brand of liquid gasket remover. If a liquid gasket remover is used,
check the directions to make sure the material being cleaned will not be harmed.
Air powered gasket scrapers can save time but care must be taken to not damage the surface. The angled part of
the scraper must be against the gasket surface to prevent the blade from digging into the surface. Using air powered
gasket scrapers on parts made of soft materials takes skill and care to prevent damage.
Do not scrape or brush across the gasket surface if at all possible.
Solvent and Acid Cleaning
Several solvent and acid-type cleaners can be used to clean the disassembled engine parts (other than pistons. See
Below). Experience has shown that the best results can be obtained using a cleaner that can be heated to 90 to 95
Celsius (180 to 200 Fahrenheit). Kerosene emulsion based cleaners have different temperature specifications, see
below. A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best results.
Cummins Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer's instructions.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before
putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible, steam clean the
parts before putting them in the cleaning tank.
WARNING
When using solvents, acids, or alkaline materials for cleaning, follow the manufacturers recommendations
for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
Experience has shown that kerosene emulsion based cleaners perform the best to clean pistons. These cleaners
should not be heated to temperature in excess of 77C (170F). The solution begins to break down at temperatures
in excess of 82C (180F) and will be less effective.
Do not use solutions composed mainly of chlorinated hydrocarbons with cresols, phenols and/or cresylic components.
They often do not do a good job of removing deposits from the ring groove and are costly to dispose of properly.
Solutions with a pH above approximately 9.5 will cause aluminum to turn black; therefore do not use high alkaline
solutions.
Chemicals with a pH above 7.0 are considered alkaline and those below 7.0 are acidic. As you move further away
from the neutral 7.0, the chemicals become highly alkaline or highly acidic.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before
putting the parts in a cleaning tank. Be careful to not damage any gasket surfaces. When possible use hot high
pressure water or steam clean the parts before putting them in the cleaning tank. Removing the heaviest dirt before
placing in the tank will allow the cleaner to work more effectively and the cleaning agent will last longer.
Rinse all the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all the
capscrew holes and the oil drillings.
If the parts are not to be used immediately after cleaning, dip them in a suitable rust proofing compound. The rust
proofing compound must be removed from the parts before assembly or installation on the engine.
Steam Cleaning
Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good method
for cleaning the oil drillings and coolant passages
WARNING
When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
Do not steam clean the following components:
Electrical Components
Wiring Harnesses
Injectors
Fuel Pump
Belts and Hoses
Bearings (ball or taper roller)
Electronic Control Module (ECM)
ECM Connectors
Dosing Control Unit
NOx Sensor.
Plastic Bead Cleaning
Cummins Inc. does not recommend the use of glass bead blast or walnut shell media on any engine part. Cummins
Inc. recommends using only plastic bead media, Part Number 3822735 or equivalent on any engine part. Never use
sand as a blast media to clean engine parts. Glass and walnut shell media when not used to the media manufacturer's
recommendations can cause excess dust and can embed in engine parts that can result in premature failure of
components through abrasive wear.
Plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning process is
controlled by the use of plastic beads, the operating pressure and cleaning time.
CAUTION
Do not use bead blasting cleaning methods on aluminum pistons skirts or the pin bores in any piston, piston
skirt or piston crown. Small particles of the media will embed in the aluminum or other soft metal and result
in premature wear of the cylinder liner, piston rings, pins and pin bores. Valves, turbocharger shafts, etc.,
can also be damaged. Follow the cleaning directions listed in the procedures.
CAUTION
Do not contaminate wash tanks and tank type solvent cleaners with the foreign material and plastic beads.
Remove the foreign material and plastic beads with compressed air, hot high pressure water or steam before
placing them in tanks or cleaners. The foreign material and plastic beads can contaminate the tank and any
other engine parts cleaned in the tank. Contaminated parts may cause failures from abrasive wear.
Plastic bead blasting media, Part Number 3822735, can be used to clean all piston ring grooves. Do not sure any
bead blasting media on piston pin bores or aluminum skirts.
Follow the equipment manufacturer's cleaning instructions. Make sure to adjust the air pressure in the blasting
machine to the bead manufacturer's recommendations. Turning up the pressure can move material on the part and
cause the plastic bead media to wear out more quickly. The following guidelines can be used to adapt to
manufacturer's instructions:
1. Bead size: U.S. size Number 16 20 for piston cleaning with plastic bead media, Part Number 3822735
2. Operating Pressure 270 kPa (40 psi) for piston cleaning. Pressure should not cause beads to break.
3. Steam clean or wash the parts with solvent to remove all of the foreign material and plastic beads after cleaning.
Rinse with hot water. Dry with compressed air.
Signature, ISX, and QSX15 Eng [...] General Cleaning Instructions
CAUTION
The bead blasting operation must not disturb the metal surface. If the metal surface is disturbed the engine
can be damaged due to increased parts clearance or inadequate surface finish on parts that move against
other parts.
When cleaning pistons, it is not necessary to remove all the dark stain from the piston. All that is necessary is to
remove the carbon on the rim and in the ring grooves. This is best done by directing the blast across the part as
opposed to straight at the part. If the machining marks are disturbed by the blasting process, then the pressure is too
high or the blast is being held on one spot too long. The blast operation must not disturb the metal surface.
Walnut shell bead blast material is sometimes used to clean ferrous metals (iron and steel). Walnut shell blasting
produces a great amount of dust particularly when the pressure if the air pressure on the blasting machine is increased
above media manufacturer's recommendation. Cummins Inc. recommends not using walnut shell media to clean
engine parts due to the risk media embedment and subsequent contamination of the engine.
Cummins Inc. now recommends glass bead media NOT used to clean any engine parts. Glass media is too easily
embedded into the material particularly in soft materials and when air pressures greater than media manufacturer's
recommend are used. The glass is an abrasive so when it is in a moving part, that part is abrading all the parts in
contact with it. When higher pressures are used the media is broken and forms a dust of a very small size that floats
easily in the air. This dust is very hard to control in the shop, particularly if only compressed air (and not hot water)
is used to blow the media after it is removed from the blasting cabinet (blowing the part off inside the cabinet may
remove large accumulations but never removes all the media).
Bead blasting is best used on stubborn dirt/carbon build-up that has not been removed by first steam/higher pressure
washing then washing in a heated wash tank. This is particularly true of pistons. Steam and soak the pistons first then
use the plastic bead method to safely remove the carbon remaining in the grooves (instead of running the risk of
damaging the surface finish of the groove with a wire wheel or end of a broken piston ring. Make sure the parts are
dry and oil free before bead blasting to prevent clogging the return on the blasting machine.
Always direct the bead blaster nozzle "across" rather than directly at the part. This allows the bead to get under the
unwanted material. Keep the nozzle moving rather than hold on one place. Keeping the nozzle directed at one-place
too long causes the metal to heat up and be moved around. Remember that the spray is not just hitting the dirt or
carbon. If the machining marks on the piston groove or rim have been disturbed then there has not been enough
movement of the nozzle and/or the air pressure is too high.
Never bead blast valve stems. Tape or use a sleeve to protect the stems during bead blasting. Direct the nozzle across
the seat surface and radius rather than straight at them. The object is to remove any carbon build up and continuing
to blast to remove the stain is a waste of time.
Fuel System
When servicing any fuel system components, which can be exposed to potential contaminants, prior to disassembly,
clean the fittings, mounting hardware, and the area around the component to be removed. If the surrounding areas
are not cleaned, dirt or contaminants can be introduced into the fuel system.
The internal drillings of some injectors are extremely small and susceptible to plugging from contamination. Some
fuel injection systems can operate at very high pressures. High pressure fuel can convert simple particles of dirt and
rust into a highly abrasive contaminant that can damage the high pressure pumping components and fuel injectors.
Electrical contact cleaner can be used if steam cleaning tools are not available. Use electrical contact cleaner rather
than compressed air, to wash dirt and debris away from fuel system fittings. Diesel fuel on exposed fuel system parts
attracts airborne contaminants.
Choose lint free towels for fuel system work.
Cap and plug fuel lines, fittings, and ports whenever the fuel system is opened. Rust, dirt, and paint can enter the
fuel system whenever a fuel line or other component is loosened or removed from the engine. In many instances, a
good practice is to loosen a line or fitting to break the rust and paint loose, and then clean off the loosened material.
When removing fuel lines or fittings from a new or newly-painted engine, make sure to remove loose paint flakes/
chips that can be created when a wrench contacts painted line nuts or fittings, or when quick disconnect fittings are
removed.
Fuel filters are rated in microns. The word micron is the abbreviation for a micrometer, or one millionth of a meter.
The micron rating is the size of the smallest particles that will be captured by the filter media. As a reference, a human
hair is 0.003 mm [3/1000 in] in diameter. One micron measures 0.00004 mm [4/100,000 in]. The contaminants being
filtered out are smaller than can be seen with the human eye, a magnifying glass, or a low powered microscope.
The tools used for fuel system troubleshooting and repair are to be cleaned regularly to avoid contamination. Like fuel
system parts, tools that are coated with oil or fuel attract airborne contaminants. Remember the following points
regarding your fuel system tools:
Fuel system tools are to be kept as clean as possible.

Clean and dry the tools before returning them to the tool box.
If possible, store fuel system tools in sealed containers.
Make sure fuel system tools are clean before use.
Signature, ISX, and QSX15 Eng [...] Acronyms and Abbreviations
Acronyms and Abbreviations

General Information
The following list contains some of the acronyms and abbreviations used in this manual.
API American Petroleum Institute
ASTM American Society of Testing and Materials
BTU British Thermal Unit
BTDC Before Top Dead Center
C Celsius
CO Carbon Monoxide
CCA Cold Cranking Amperes
CARB California Air Resources Board
C.I.B. Customer Interface Box
C.I.D. Cubic Inch Displacement
CNG Compressed Natural Gas
CPL Control Parts List
cSt Centistokes
DEF Diesel Exhaust Fluid
DOC Diesel Oxidation Catalyst
DPF Diesel Particulate Filter
ECM Electronic Control Module
EGR Exhaust Gas Recirculation
EPA Environmental Protection Agency
F Fahrenheit
ft-lb Foot-Pound Force
FMI Failure Mode Indentifier
GVW Gross Vehicle Weight
Hg Mercury
hp Horsepower
H2O Water
inHg Inches of Mercury
in H20 Inches of Water
ICM Ignition Control Module
km/l Kilometers per Liter
kPa Kilopascal
LNG Liquid Natural Gas
LPG Liquified Petroleum Gas
LTA Low Temperature Aftercooling
MIL Malfunction Indicator Lamp
MPa Megapascal
mph Miles Per Hour
mpq Miles Per Quart
Nm Newton-meter
NOx Mono-Nitrogen Oxides
NG Natural Gas
OBD On-Board Diagnostics
OEM Original Equipment Manufacturer
PID Parameter Identification Descriptions
ppm Parts Per Million
Acronyms and Abbreviations Signature, ISX, and QSX15 Eng [...]
psi Pounds Per Square Inch

PTO Power Takeoff
RGT Rear Gear Train
rpm Revolutions Per Minute
SAE Society of Automotive Engineers
SCA Supplemental Coolant Additive
SCR Selective Catalytic Reduction
STC Step Timing Control
SID Subsystem Identification Descriptions
VDC Volts of Direct Current
VS Variable Speed
VSS Vehicle Speed Sensor
Section E - Engine and System Identification Page E-a
Section E - Engine and System Identification

Section Contents
Page
Engine Diagrams ...............................................................................................................................................E-3
Engine Views....................................................................................................................................................E-3
Automotive with CM870.................................................................................................................................E-4
Automotive With CM871.................................................................................................................................E-7
Industrial CM570 and Power Generation without CM570..............................................................................E-11
Engine Identification .........................................................................................................................................E-1
ECM Dataplate.................................................................................................................................................E-1
Automotive with CM870 and CM871...............................................................................................................E-1
Automotive, Industrial with CM570 and Power Generation without CM570......................................................E-1
Power Generation..........................................................................................................................................E-2
Engine Dataplate..............................................................................................................................................E-1
Page E-b Section E - Engine and System Identification

Signature, ISX, and QSX15 Eng [...] Engine Identification
Section E - Engine and System Identification Page E-1
Engine Identification
Engine Dataplate
The engine dataplate, located on top of the rocker lever cover, provides the model identification and other important
data about the engine.
Have the following engine data available when communicating with a Cummins Authorized Repair Location. The
data on the dataplate are mandatory when sourcing service parts:
1. Engine serial number (ESN)
2. Control parts list
3. Model
4. Advertised horsepower and rpm.
ECM Dataplate
Automotive with CM870 and CM871
The electronic control module (ECM) dataplate is located
on the front of the ECM.
The abbreviations on the dataplate are explained as
follows:
P/N = part number
S/N = serial number
D/C = date code.
Automotive, Industrial with CM570 and Power

Generation without CM570
follows:
P/N = part number
S/N = serial number
D/C = date code.
Engine Identification Signature, ISX, and QSX15 Eng [...]
Page E-2 Section E - Engine and System Identification
Power Generation
follows:
P/N = part number
S/N = serial number
D/C = date code.
Signature, ISX, and QSX15 Eng [...] Engine Diagrams
Engine Diagrams
Engine Views
The following illustrations show the location of the major external engine components, filters, and other service and
maintenance points. Some external components will be at different locations for different engine models.
Engine Diagrams Signature, ISX, and QSX15 Eng [...]
Automotive with CM870
ISX Automotive with CM870 - Left Side View

1. ECM cooling plate
2. ECM
3. EGR mixer
4. Intake manifold air temperature sensor
5. Fuel pump
6. Intake manifold pressure sensor
7. EGR differential pressure sensor mounting location
8. Fuel lift pump
9. EGR connection tube
10. Recirculated exhaust gas temperature sensor ( not shown)
11. Starter
12. Fuel filter
13. Lubricating oil dipstick
14. Centinel oil control valve
15. Turbocharger control shutoff valve filter
16. Engine speed sensor
17. Air compressor
18. Fan hub
19. Crankcase breather tube.
ISX Automotive with CM870 - Right Side View

1. Variable geometry turbocharger
2. Variable geometry actuator
3. Turbocharger speed sensor ( not shown)
4. EGR valve
5. Exhaust gas pressure sensor mounting location
6. Thermostat housing
7. Turbocharger control valve
8. Refrigerant compressor
9. Alternator
10. Turbocharger oil supply
11. Water pump
12. Coolant filter
13. Turbocharger oil drain
14. Optional dipstick locations
15. Lubricating oil drain
16. Combination full-flow/bypass lubricating oil filter
17. Flywheel housing
18. Lubricating oil cooler assembly
19. EGR cooler
20. Exhaust manifold.
ISX Automotive with CM870 - Front View

1. Refrigerant drive belt
2. EGR mixer
3. Crankcase breather tube
4. Oil fill
5. Water pump drive belt
6. Vibration damper
7. Water pump
8. Belt tensioner, water pump
9. Alternator
11. Belt tensioner, refrigerant compressor
12. Refrigerant compressor.
Automotive With CM871
ISX Automotive with CM871 - Front View

1. Crankcase breather pressure sensor
2. Intake manifold connection
3. Oil fill tube
4. Water pump drive belt
5. Oil pan
6. Vibration damper
7. Dual outlet water pump
8. Belt tensioner, water pump
9. Alternator
11. Belt tensioner, refrigerant compressor
12. Refrigerant compressor
13. Refrigerant compressor drive belt.
ISX Automotive with CM871 - Left Side View

1. ECM
2. Air intake connection
3. Front EGR connection tube
4. EGR differential pressure sensor
5. EGR differential pressure sensor tubes
6. Fuel pump
7. EGR valve mounting bracket
8. EGR valve
9. Starter
10. Fuel filter
12. Crankcase breather vent tube
13. Air compressor
14. Lubricating oil fill tube
15. Open crankcase ventilation filter housing
16. Fan hub.
ISX Automotive with CM871 Rear View

1. Aftertreatment Injector fuel supply line
2. Aftertreatment injector coolant supply line
3. Aftertreatment injector adapter tube
4. Aftertreatment injector assembly
5. Aftertreatment injector coolant return line
6. Flywheel
7. Rear EGR connection tube.
ISX Automotive with CM871 - Right Side View

2. Turbocharger speed sensor
3. Variable geometry actuator
4. EGR cooler coolant inlet tube
5. Dual outlet water pump
6. Coolant filter
7. Turbocharger oil drain tube
8. Lubricating oil filter
9. Lubricating oil drain plug
11. EGR cooler coolant return tube
12. Lubricating oil cooler
13. EGR cooler
14. Exhaust manifold.
Industrial CM570 and Power Generation without CM570
QSX15 Industrial with CM570 - Front View

1. Accessory drive belt
2. Water pump/fan drive belt
3. Lubricating oil fill
4. Water pump/fan drive belt tensioner
5. Accessory drive belt tensioner.
QSX15 Industrial with CM570 - Left Side View

1. Gear housing
2. ECM
3. Air intake
4. Engine dataplate
5. Fuel pump
6. Starter
7. Fuel filter
9. Crankshaft timing pin port
10. Vibration dampers
11. Barring device/air compressor
12. Fan hub.
QSX15 Industrial with CM570 - Right Side View

1. Exhaust manifold
2. Turbocharger
3. Oil inlet to turbocharger
4. Wastegate actuator
5. Thermostat housing vent
7. Engine coolant outlet (to radiator)
8. Freon compressor
9. Coolant temperature sensor
10. Alternator
11. Water pump
12. Coolant filter
13. Lubricating oil drain
14. Turbocharger oil drain
18. Engine serial number.
QSX15 Power Generation without CM570 - Front View

1. Accessory drive belt
2. Water pump/fan drive belt
3. Oil fill/crankcase breather
4. Water pump/fan drive belt tensioner
5. Accessory drive belt tensioner.
QSX15 Power Generation without CM570 - Left Side View

1. Gear cover
2. Engine dataplate
3. Air intake
4. Fuel pump
5. Fuel filter
6. Starter
7. Lubricating oil pan
8. Lubricating oil drains
9. Crankshaft timing pin port
11. Vibration dampers
12. Lubricating oil fill/barring device
13. Fan hub.
QSX15 Power Generation without CM570 - Right Side View

1. Exhaust manifold
2. Lubricating oil Inlet to turbocharger
3. Turbocharger
4. Thermostat housing vent
6. Engine coolant outlet (to radiator)
7. Coolant temperature sensor
8. Water pump
9. Coolant filter
10. Lubricating oil drains
14. Engine serial number
15. Turbocharger lubricating oil drain.
Fuel System - Left Side View

1. Intake manifold pressure/temperature sensor 6. ECM/engine harness port (OEM)
2. Fuel outlet 7. ECM
3. Fuel inlet 8. ECM/engine harness port (actuator)
4. Fuel shutoff valve 9. ECM/sensor port
5. Oil pressure/temperature sensor 10. Cooling plate (behind ECM).
Fuel System - Left Side View (continued)

11. Camshaft position sensor
12. Crankshaft position sensor
13. Ambient air pressure sensor
14. Water-in-Fuel sensor
15. Fuel pressure sensor
16. Front and rear rail sensors*
17. Timing actuators
18. Fueling actuators.
* Eliminated on most engines
Fuel Delivery Housing - Front View

1. Priming bypass valve (internal)
2. 320 psi pressure regulator
3. 36-micron filter screen
4. Fuel inlet
5. Quick disconnect pressure tap - suction side
6. Water-In-Fuel sensor
7. 250 psi pressure regulator
8. Fuel shutoff valve
9. Quick disconnect pressure tap - pressure side
10. Fuel pressure sensor
11. Front rail actuator
12. Front timing actuator
13. Rear timing actuator
14. Rear rail actuator.
QSX15 with CM570 Fuel Delivery Housing - Rear View

1. Fuel pump assembly
2. Front rail pressure sensor*
3. Fuel filter
4. Rear rail pressure sensor*.
* Eliminated on most engines.
Section F - Familiarization Page F-a
Section F - Familiarization
Section Contents
Page
Air Intake System - Overview .........................................................................................................................F-34
General Information........................................................................................................................................F-34
Variable Geometry.......................................................................................................................................F-34
Automotive with CM870................................................................................................................................F-34
Automotive With CM871...............................................................................................................................F-35
All Applications............................................................................................................................................ F-36
Complete Engine - Overview ............................................................................................................................F-1
General Information..........................................................................................................................................F-1
Compressed Air System - Overview ...............................................................................................................F-51
Single Cylinder.............................................................................................................................................F-51
Cooling System - Overview ............................................................................................................................ F-24
Cylinder Block - Overview ................................................................................................................................F-3
Cylinder Head - Overview .................................................................................................................................F-4
Electrical Equipment - Overview .................................................................................................................... F-54
Engine Testing - Overview ..............................................................................................................................F-56
Fuel Flow Measurement on Engine or Chassis Dynamometer..........................................................................F-57
Exhaust System - Overview ............................................................................................................................F-40
Flow Diagram, Air Intake System ...................................................................................................................F-37
Flow Diagram..................................................................................................................................................F-37
Automotive, Industrial with CM570 and Power Generation without CM570....................................................F-37
With CM870.................................................................................................................................................F-38
Flow Diagram, Compressed Air System .........................................................................................................F-52
Flow Diagram..................................................................................................................................................F-52
Flow Diagram, Cooling System ...................................................................................................................... F-26
Flow Diagram..................................................................................................................................................F-26
Single Thermostat........................................................................................................................................F-33
Flow Diagram, Exhaust System ......................................................................................................................F-44
Flow Diagram..................................................................................................................................................F-44
With CM870.................................................................................................................................................F-46
Flow Diagram, Fuel System ..............................................................................................................................F-9
Flow Diagram....................................................................................................................................................F-9
Automotive with CM570..................................................................................................................................F-9
Industrial CM570 and Power Generation without CM570.............................................................................. F-13
Flow Diagram, Lubricating Oil System ...........................................................................................................F-18
Flow Diagram..................................................................................................................................................F-18
Page F-b Section F - Familiarization
All Applications............................................................................................................................................ F-21

Fuel System - Overview ....................................................................................................................................F-5
Automotive with CM870..................................................................................................................................F-6
Automotive With CM871.................................................................................................................................F-7
Installation Recommendations..........................................................................................................................F-7
Injectors and Fuel Lines - Overview ...............................................................................................................F-15
Lubricating Oil System - Overview .................................................................................................................F-15
Lubricating Oil..............................................................................................................................................F-15
Lubricating Oil Filters...................................................................................................................................F-16
Lubricating Oil System....................................................................................................................................F-16
New Engine Break-in Oils................................................................................................................................F-17
Oil Drain Intervals...........................................................................................................................................F-17
Rocker Levers - Overview .................................................................................................................................F-5
General Information.......................................................................................................................................F-5
Vehicle Braking - Overview .............................................................................................................................F-59
Signature, ISX, and QSX15 Eng [...] Complete Engine - Overview
Section F - Familiarization Page F-1
Complete Engine - Overview (000-999)

General Information
Engine Nomenclature
To assist the reader of this manual in accurately identifying the appropriate engine version to repair, the manual is
using the engine's ECM model number as the identifier in the task title of each procedure. The engine(s) for the
corresponding ECM model number nomenclature are as follows:
All Applications
Includes all ISX automotive engines, Signature engines, QSX industrial engines, and all power generation engines,
regardless of ECM model.
Includes ISX automotive EGR engines built with CM870 model ECM, introduced in 2002.
Automotive, Industrial with CM570 and Power Generation without CM570
Includes ISX automotive engines, Signature engines, QSX industrial engines built with CM570 model ECM, and all
power generation engines supplied with their unique control module
ISX automotive and Signature engines built with CM570 model ECM, built 1998 through 2002.
QSX industrial engines built with CM570 model ECM and power generation engines supplied with their unique control
module.
If the user of this manual is not sure of the ECM model number, the ECM model number can be identified by reviewing
the electronic data plate using INSITE electronic service tool.
Repair
Concern has been generated at both the factory and in the field about engine failures that occur a short time after an
in-frame repair. Analyses of the returned parts indicate many of the failures are the result of dirt entering the engine
during repair. In particular, investigation of the failure of ISX engine connecting rod and main bearings very soon after
field repairs of the oil cooler, front cover, or cylinder head has shown that 30 percent of the failures are the result of
contamination of some main oil drillings. Investigation into the type and source of the contamination indicates it is
appropriate to restate, review and revise parts cleaning instructions for all engines.
The statement A person can spend too much time cleaning parts, but a person can not get them too clean is even
more relevant as customer expectations and regulatory requirements increase. These demands, coupled with
increased diesel engine product complexity, place more pressure on the field technician in terms of time required to
perform a quality repair. In an effort to reduce customer down time, many different labor saving devices, techniques,
and shortcuts are being used to meet customer expectations. However, some of the shortcuts and labor saving efforts
are the very things that can cause contamination of internal engine components that lead to additional failures.
Review the General Cleaning Instructions in this manual. Field shops are strongly encouraged to review these
instructions with all technicians and to include general cleaning instructions in technician training programs and new
technician orientation programs.
Magnetism
If the engine is found to be magnetized, the engine will need to be disassembled and examined for:
Engine inspection for electrical pass-through damage
Magnetism of ferrous components
Debris through the lubrication system
Damage to bearings and bushings, including: crankshaft thrust bearings, main bearings, connecting rod
bearings, and camshaft bushings
Component or wear damage.
The Disassembly and Assembly sections of this manual can be used to disassemble and assemble the engine.
Complete Engine - Overview Signature, ISX, and QSX15 Eng [...]
Page F-2 Section F - Familiarization
Acceptable Magnetism Levels

Injectors and Ferrous Injector Components All Other Ferrous Components
5 or less gauss units 15 or less gauss units
Measure each ferrous component with a gauss meter and record the results. If the magnetism is out of specification,
the engine must be treated in general as if:
Debris (fine particles) have been traveling throughout the lubrication system, resulting in wear and damage to
components.
Components with measured gauss units greater than specification must be demagnetized or replaced. A facility
capable of magnetic testing (Magnaflux) of the engine components is capable of demagnetizing (degaussing)
components.
Check components in the lubrication system closely and thoroughly clean the oil galleries.
Replace all main bearings, thrust bearings, connecting rod bearings, and camshaft bushings.
NOTE: Do not attempt to demagnetize sensors, engine control modules, or actuators.
There are two methods for demagnetizing components:
Passing the part through an alternating current coil (50 or 60 cycles per second)
Passing a reversing, 30 point step-down current through the part.
The alternating current coil is suggested for smaller parts.
For larger mass parts, the reversing 30 point step-down is suggested.
Parts with acceptable levels of magnetization must be cleaned and inspected for reuse.
It is recommended to have the alternating current coil just large enough for the parts to pass through. A small part
passed through a large coil will not be demagnetized as well as if it were passed through a smaller coil.
The coil must be located so the longest part axis of the part is perpendicular to the coil when passing through. Parts
must pass through a minimum of 457.2 to 609.6 mm [18 to 24 in] beyond the coil for the most effective
demagnetization.
Do not attempt to demagnetize small parts by loading them into a basket and passing the basket through a coil. Do
not attempt to demagnetize a whole engine assembly.
Direct current demagnetization can be accomplished by using the magnetizing unit. Clamp the part between the head
and tail stock. Activate the demagnetization controls, and the reversing, step-down current passes through the part.
Check all parts with the gauss meter.
When tiny pits occur in clearly defined patterns, or surfaces are fluted, electric current can be the problem. The
patterns will vary with metals, sources, and movement.
For insert bearings, pitting is a chief indication. In anti-friction bearings, such as ball bearings, fluted surfaces, or wavy
lines of pitting in patterns differing with rotation, vibration, and current are the chief indications.
Sources of electrical damage are:
Electrically actuated components (such as a clutch).
Static current from belts or other moving parts.
Grounding of electrical system through the crankshaft when some component such as the generator or engine
block has not been grounded properly.
An improperly grounded six volt system.
Contaminated Intake Air
For engines that have experienced dust outs because of an intake air system component failure that resulted in
cylinder liner and piston ring wear; these engines must be treated as if the lubricating oil system has been
contaminated with debris. The engine must be disassembled and cleaned appropriately to remove debris from the
oil galleries, block cavities, cylinder head, and air intake system. Do not forget the camshafts and rocker lever pins
and rollers; these must be thoroughly cleaned and examined for wear.
Signature, ISX, and QSX15 Eng [...] Cylinder Block - Overview
The procedures required to replace an engine will vary

with different engine models, the type of equipment,
optional equipment, and the shop facilities. Use the
following procedures as a guide.
All replacement steps will not apply to all types of
equipment. Complete only the steps that apply to the
equipment involved. Use the equipment manufacturer's
recommendations and precautions for removal of chassis
parts to gain access to the engine.
Cylinder Block - Overview (001-999)

General Information
Some Signature, ISX, and QSX15 engines are equipped
with articulated pistons.
The articulated piston is a two-piece piston consisting of
a forged steel crown and an aluminum skirt.
An open chamber oil gallery is located on the underside
crown of the piston to provide more oil contact with the
piston and give better piston cooling.
Piston cooling nozzle targeting is critical because the oil
is captured in shaker trays.
Some engines are equipped with single-piece pistons.

The single-piece piston is a one-piece piston, that does
not have a bushing and is forged from a high-strength,
alloy steel.
A cover plate, that is not removable, is located on the
underside of the piston to capture oil and cool the piston.
Do not remove this cover plate under any circumstances.
CAUTION
All pistons within a given engine must be of the same
design. All are to be either the articulated design or
the single piece design. Do not mix piston designs in
the same engine. Single piece pistons must have
drilled connecting rods and connecting rod bearings.
Articulated pistons can use either drilled or non-
drilled connecting rods and connecting rod bearings.
Cylinder Head - Overview Signature, ISX, and QSX15 Eng [...]
Connecting Rod
The ISX connecting rods big bore is straight-cut with a four capscrew design. With the introduction of the single-piece
piston the connecting rod I-beam is drilled to provide oil to the piston pin. Single piece pistons must use drilled
connecting rods.
Cylinder Liner
The cylinder liners are of a mid-stop cylinder liner design. The EGR engine cylinder liners are induction hardened.
There are two different designs of cylinder liners used in the Signature, ISX and QSX15 engines. The design used in
a particular engine is dependent on the engine's production vintage.
Engines assembled prior to engine serial number 14022615 have groove-top cylinder liners. They are characterized
by a groove machined into the top surface of the cylinder liner flange.
Engines assembled with engine serial number 14022615 and after have flat-top cylinder liners. They are characterized
by a cylinder liner flange that is flat, except for the fire dam.
Cylinder Head - Overview (002-999)

General Information
The cylinder head is a single slab head design with dual overhead camshafts.
The cylinder head group consists of the cylinder head, valves, valve guides, valve springs, valve seat inserts,
crossheads, and injector sleeves. The exhaust valves are manufactured from a material capable of operating at a
higher temperature than the intake valves. In addition to being made from different materials, the intake and exhaust
valves are different sizes.
Mark, label, or tag the cylinder head parts such as crossheads, valves, and valve springs with the cylinder number
and location from which they were removed. It is also recommended that the intake and exhaust valve positions be
marked on the combustion face of the cylinder head using a paint pen to facilitate installing the correct parts in the
correct locations.
There are two different designs of cylinder liners used in the Signature, ISX and QSX15 engines. The design used in
a particular engine is dependent on the engine's production vintage.
Engines assembled prior to engine serial number 14022615 have groove-top cylinder liners. They are characterized
by a groove machined into the top surface of the cylinder liner flange.
Engines assembled with engine serial number 14022615 and after have flat-top cylinder liners. They are characterized
by a cylinder liner flange that is flat, except for the fire dam.
CAUTION
Cylinder head gaskets are different depending on the cylinder liner design. The cylinder head gasket designed
to be used with groove-top cylinder liners can not be used with flat-top liners, and the cylinder head gasket
designed to be used with the flat-top cylinder liners can not be used with groove-top cylinder liners.
Engines built with groove-top cylinder liners must use a cylinder head gasket and fire rings.
Engines built with flat-top liners must use a one-piece cylinder head gasket without fire rings.
Two different valve guides and valve guide seals are used
on Signature, ISX, and QSX15 engines.
Engines built prior to engine serial number 14010274 use
non-grooved valve guides and small valve guide seals.
These engines require the valve stem seal installer, Part
Number 3163294, to be used when installing the valve
guide seals.
Signature, ISX, and QSX15 Eng [...] Fuel System - Overview
Engines with serial number 14010274 and all engines built

after use a larger valve guide seal.
These seals are designed to be installed by hand without
the seal driver.
The new seals snap into a groove machined on the valve
guide. The new style seals are not compatible with the old
style non-grooved valve guides.
Rocker Levers - Overview (003-999)

General Information
General Information
Valves, injectors, and engine brakes (if equipped) must be correctly adjusted for the engine to operate efficiently.
Valve, injector, and engine brake adjustment must be performed using the values listed in this section.
Adjust the valves, injectors, and engine brakes every 800,000 km [500,000 mi], 10,000 hours, or 5 years (whichever
occurs first). Adjustment must be made after any major repair, and the adjustment interval again becomes every
800,000 km [500,000 mi], 10,000 hours, or 5 years (whichever occurs first).
Refer to Procedure 003-004 for valve, engine brake, and injector adjustment values.
Fuel System - Overview (005-999)

General Information
WARNING
Depending on the circumstance, diesel fuel is
flammable. When inspecting or performing service or
repairs on the fuel system, to reduce the possibility of
fire and resulting severe personal injury, death or
property damage, never smoke or allow sparks or
flames (such as pilot lights, electrical switches, or
welding equipment) in the work area.
CAUTION
Tampering with the fuel system can void the engine
warranty and lower the performance of the engine.
NOTE: Warranty repairs are not to be made to the
Signature, ISX, or QSX fuel system unless the work is
performed in a shop that meets all requirements
established by Cummins Inc. to accurately calibrate, test,
and repair the fuel systems on Cummins engines.
The performance of the engine is defined by the control
parts list and the fuel system code. The fuel system
calibration must be within published specifications. Fuel
system calibration is certified by several emissions
agencies.
Fuel System - Overview Signature, ISX, and QSX15 Eng [...]
NOTE: There is no mechanical throttle on the Signature,

ISX, or QSX15 fuel system.
The Signature, ISX, and QSX15 fuel system is an
integrated, multi-part system.
It is comprised of the following:
Supply pump
Regulators
Filters
Timing and fueling actuators
Camshaft-driven injectors 1 through 6
ECM, sensors (fuel system control).
The fuel system is split into two banks:

Front bank (cylinders 1-2-3)
Rear bank (cylinders 4-5-6).

System Operation
Fuel is drawn from the tank through a fuel filter by a gear pump (supply pump)
The supply pump pressure is regulated at 1689 to 2206 kPa [245 to 320 psi] at 2100 rpm
Fuel passes through a pressure side filter (36 microns)
Fuel then passes through a rapid restart-style fuel shutoff valve
Fuel enters a passage feeding the front and rear banks, which connects directly to the fuel actuators
Within a given bank, the fuel and timing actuators are commanded by the ECM to open
The opening of each actuator sends a pressure pulse to each injector within the bank
The timing of these events is tied to engine position
Due to the firing order (1-5-3-6-2-4) and cam position, only one injector within the bank receives fuel.
The Signature, ISX, and QSX fuel system assembly, integrated fuel system module, or fuel delivery housing is located
on the intake side of the engine.
Fuel for the Engine
Fuel passes through a rapid restart-style fuel shutoff valve
Fuel enters a passage feeding the front and rear banks, which connects directly to the fuel actuators
Signature, ISX, and QSX15 Eng [...] Fuel System - Overview
Aftertreatment Injector Fuel Flow.

System Operation
Fuel is drawn from the tank through a fuel filter by a gear pump (supply pump)
The supply pump pressure is regulated at 1689 to 2220 kPa [245 to 322 psi] at 2100 RPM
Fuel passes through a pressure side filter (10 microns).
Fuel goes to the engine and the aftertreatment system.
Fuel For the Engine
Fuel passes through a rapid restart-style fuel shutoff valve
Fuel enters a passage feeding the front and rear banks, connecting directly to the fuel actuator.
Fuel For the Aftertreatment System
Fuel flows down to the aftertreatment shutoff valve
When the valve opens, the fuel passes the aftertreatment fuel pressure sensor
Fuel then flows around the back of the engine to the aftertreatment fuel injector
When the aftertreatment fuel injector opens, fuel is sprayed into the exhaust stream
When the fuel is not flowing to the aftertreatment fuel injector, remaining fuel in the line between the first
aftertreatment shutoff valve and aftertreatment fuel injector is sent through the second aftertreatment shutoff
valve to drain.
Installation Recommendations
Overhead Tank Installation Requirements:
WARNING
If a fuel line shutoff valve is not installed, the
overhead tank can drain when the fuel filter is
changed, causing an extreme fire hazard.
Cummins Inc. recommends a ball-type valve and not a
gate-type valve.
Install a fuel shutoff valve between the filter and the fuel
tank.
Fuel System - Overview Signature, ISX, and QSX15 Eng [...]
Install a check valve in the fuel drain line when the

maximum fuel level in the fuel tank is even or above the
fuel drain that is in the cylinder head. Install the valve with
the fuel flow arrow toward the fuel tank.
Signature, ISX, and QSX15 Eng [...] Flow Diagram, Fuel System
Flow Diagram, Fuel System (200-001)

Flow Diagram
9 9
11 11
10 8
Cummins Inc. Cummins 3Inc.
Cummins Inc.
11
8 2
5
Cummins Inc. 6
Cummins Inc.
7 1
4
05c00127
With Lift Pump

1. Fuel supply from tank 7. Timing actuator
2. Fuel lift pump 8. Fueling supply to injector
3. Fuel pump 9. Timing fuel supply to injector
4. Pressure fuel filter 10. Injector
5. Fuel shutoff valve 11. Fuel drain to tank.
6. Fueling actuator
Flow Diagram, Fuel System Signature, ISX, and QSX15 Eng [...]
Flow Diagram, Fuel System (200-001)

Flow Diagram
3 10
7 8 8 7
5 6 6
3 5
8 10
9 8 10
Cummins Inc. Cummins Inc.
10
7 4 1
2
Cummins Inc.
7
5 1
Cummins Inc.
6 Cummins Inc.
4
2
00c00001
Without Lift Pump

2. Fuel filter 7. Rail metering supply to injector
3. Gear pump 8. Timing fuel supply to injector
4. Fuel shutoff valve 9. Injector
5. Rail metering actuator 10. Fuel drain to tank.

14
4
Cummins Inc.
13
Cummins Inc.
3
10 7 6 15 1
Cummins Inc.
12
15
12
11
9
8 Cummins Inc.
1
5 Cummins Inc.
2 2
5
05c00225
With Lift Pump and ECM Cooling Plate

1. Fuel supply from tank 9. Engine fuel temperature sensor
2. Fuel lift pump 10. Compuchek fitting (rail fuel pressure)
3. Compuchek fitting (fuel inlet restriction) 11. Hot start and stall orifice
4. Fuel pump 12. Fuel inlet to ECM cooling plate
5. Pressure fuel filter 13. ECM cooling plate
6. Fuel shutoff valve 14. Fuel from ECM ccoling plate to fuel pump
7. 250-psi regulator 15. Fuel drain to tank.
8. Rail fuel pressure sensor

14 4
13 3 19

12
18
15
Cummins Inc. 1
21
10 7 6
20
12
19
Cummins Inc.
17 Cummins Inc.
11 1 16
9 8
5 2 5 2 20
00c00099
ISX With Lift Pump and Aftertreatment

1. Fuel supply from tank 12. Fuel flow to ECM cooler
2. Fuel lift pump 13. ECM cooler
3. Compuchek fitting (fuel inlet restriction) 14. Fuel flow to fuel pump
4. Fuel pump 15. Fuel flow to aftertreatment fuel shutoff valve
5. Pressure fuel filter 16. Aftertreatment fuel shutoff valve
6. Fuel shutoff valve 17. Fuel pressure sensor
7. 250-psi regulator 18. Fuel drain line
8. Rail fuel pressure sensor 19. Fuel return to fuel tank
9. Engine fuel temperature sensor 20. Fuel flow to aftertreatment injector
10. Compuchek fitting (rail fuel pressure) 21. Aftertreatment injector.
11. Hot start and stall orifice
9 9
11 11
Cummins
10 Inc. Cummins Inc. 8
3
Cummins Inc.
11
8 2
5
7 1
6 4
05c00222
QSX15 With Lift Pump

2. Fuel lift pump 8. Fueling supply to injector
3. Fuel pump 9. Timing fuel supply to injector
4. Pressure fuel filter 10. Injector
5. Fuel shutoff valve 11. Fuel drain to tank.
6. Fueling actuator
3 10
7 8 8 7
5 6 6
3 5
8 10
9 8 10
10
7 4 1
2
Cummins Inc.
7
5 1
Cummins Inc.
6 Cummins Inc.
4
2
00c00001
QSX15 Without Lift Pump

2. Fuel filter 7. Rail metering supply to injector
3. Gear pump 8. Timing fuel supply to injector
4. Fuel shutoff valve 9. Injector
5. Rail metering actuator 10. Fuel drain to tank.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil System - Overview
Injectors and Fuel Lines - Overview (006-999)

General Information
The 2002 ISX engine uses a 15-micron pressure side fuel filter. The pressure side fuel filter is mounted to the integrated
fuel system module in the same location as the previous integrated fuel system module-mounted suction side fuel
filter. Pressure side filtration allows for improved diagnostics and improved filtration. The fuel filter has a 40,234 km
[25,000 mi] change interval.
For fuel filter pressure and vacuum information, refer to Procedure 006-015.
For fuel inlet restriction, refer to Procedure 006-020.
ECM Cooling Plate
A fuel-cooled ECM was introduced with the 2002 ISX engine.
The ECM cooling plate is located on the intake side of the cylinder head, directly between the ECM and cylinder head.
The ECM cooling plate receives fuel from the 1724 kPa [250 psi] regulator and returns it to the suction side of the fuel
pump. The 2002 ISX engine uses a different gasket between the cooling plate and the cylinder head than the air-
cooled ECM cooling plate found on the previous ISX engines. To isolate the cooling plate from the heat of the cylinder
head, a new ECM cooling plate gasket is used. Unlike the air-cooled ECM cooling plate gasket, the fuel-cooled ECM
cooling plate gasket does not have a cutout in the lower section. This gasket is not reversible and uses an interference
tab that will not allow the gasket to be installed backward.
Lubricating Oil System - Overview (007-999)

General Information
Lubricating Oil
ISX engines built after February 2004, (ESN first 79035023) have the lubricating oil filter head adapter (spud) staked
to the lubricating oil filter housing to reduce the possibility of the adapter backing out.
The use of quality engine lubricating oils, combined with appropriate lubricating oil drain and filter change intervals,
is a critical factor in maintaining engine performance and durability.
Cummins Inc. recommends the use of a high quality 15W-40 multiviscosity heavy-duty engine lubricating oil that meets
the requirements of Cummins Engineering Specification CES 20071 or CES 20076 (such as Valvoline Premium Blue
or Premium Blue 2000). American Petroleum Institute (API) specification CH-4 can be used as an alternative to CES
20071. Oils that meet API specification CG-4 can be used, but at a reduced drain interval. Refer to Procedure 102-002
in the Operation and Maintenance Manual Industrial and Power Generation QSX15 Engines, Bulletin 3666423 or
Procedure 102-002 in the Operation and Maintenance Manual Signature and ISX Engines, Bulletin 3666251. The oil
grades CC, CD, CE, and CF have been obsoleted by API and must not be used.
Shortened drain intervals can be required with monograde oils as determined by close monitoring of the oil condition
with scheduled oil sampling. Use of single-grade oils can affect engine oil control.
Synthetic engine oils, API category III, are recommended for use in Cummins engines operating in ambient
temperature conditions consistently below -25C [-13F]. Above this temperature, it is recommended the petroleum
based multigrade lubricants be used. Synthetic 0W-30 oils that meet API category III can be used in operations where
the ambient temperature never exceeds 0C [32F]. 0W-30 oils do not offer the same level of protection against fuel
dilution as do higher multigrade oils. Higher cylinder wear can be experienced when using 0W-30 oils in high-load
situations.
For further details and an explanation of engine lubricating oils for Cummins engines, refer to Cummins Engine Oil
Recommendations, Bulletin 3810340.
Additional information regarding lubricating oil availability throughout the world is available in the Engine
Manufacturing Association (EMA) Lubricating Oils Data Book for Heavy-Duty Automotive and Industrial Engines. The
data book can be ordered from: Engine Manufacturers Association, Two North LaSalle Street, Suite 2200, Chicago,
IL, 60602; Phone: (312) 644-6610, Fax: (312) 827-8737.
The integrated Centinel system is a continuous lubricating oil replacement system of electromechanical design. The
Centinel system extends lubricating oil and lubricating oil filter change intervals through continuous lubricating oil
exchange. This is accomplished by injecting engine lubricating oil at a controlled rate, proportional to fuel consumed,
into the fuel system for consumption. Makeup lubricating oil (fresh) is introduced into the engine at a rate equal to the
lubricating oil consumed. The Centinel system will also monitor the lubricating oil level in the make up tank.
Lubricating Oil System - Overview Signature, ISX, and QSX15 Eng [...]
Lubricating Oil Filters

A combination lubricating oil filter is used on the engine. The upper portion of the combination lubricating oil filter
contains the full-flow filter element while the lower portion contains the bypass filter element.
Lubricating oil circulates through the full-flow portion of the lubricating oil filter, into the lubricating oil cooler housing
and is directed to the engine lubricating oil rifles.
A smaller portion of the lubricating oil circulates through the lower bypass portion of the lubricating oil filter and is
directed to the engine lubricating oil rifles.
Lubricating Oil System
The demand flow and cooling lubricating system
incorporates a lubricating oil pump (1) with a pressure-
sensitive regulator circuit (2) and a high-pressure relief
valve (3).
The API service symbol locations are shown in the

accompanying illustration.
1. The upper half of the symbols displays the
appropriate oil categories.
2. The lower half contains words to describe oil energy-
conserving features.
3. The center section identifies the SAE oil viscosity
grade.
Lubricating oil viscosity must be chosen according to the

typical climate conditions experienced by the user. Use of
15W-40 is recommended for the best engine durability at
higher ambient temperature. For cold temperature
conditions, 10W-30 or 5W-30 viscosity can be used for
easier starting, improved lubricating oil flow, and
improved fuel economy.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil System - Overview
New Engine Break-in Oils

Special break-in engine lubricating oils are not
recommended for new or rebuilt Cummins engines. In
general, use the same lubricating oil during break-in as
that used in normal operation. Synthetic or partially
synthetic engine lubricating oils, however, can not be
used during break-in of a new or rebuilt engine. To make
sure the piston rings seat properly, use a high quality
petroleum-based engine lubricating oil during the first
engine lubricating oil drain period.
Oil Drain Intervals

As the engine lubricating oil becomes contaminated,
essential lubricating oil additives are depleted. Lubricating
oils protect the engine as long as these additives are
functioning properly. Progressive contamination of the
lubricating oil between lubricating oil and filter change
intervals is normal. The amount of contamination will vary
depending on the operation of the engine, kilometers or
miles on the lubricating oil, fuel consumed, and new
lubricating oil added.
Extending lubricating oil and filter change intervals
beyond the recommendations will decrease engine life
because of factors such as corrosion, deposits, and wear.
Use the lubricating oil drain chart in this section to
determine which lubricating oil drain interval to use for an
application.
Flow Diagram, Lubricating Oil System Signature, ISX, and QSX15 Eng [...]
Flow Diagram, Lubricating Oil System (200-002)

Flow Diagram
4 1

8 1 10 11
9 4
3
4
Cummins Inc. 1
2
3
6
Cummins
3
5 Inc. Cummins Inc.
12
13
7
00c00003
Vertical Bypass
1. Lubricating oil flow from oil pump 8. Flow to turbocharger
2. Thermostat 9. Flow to main oil rifle
3. Oil cooler bypass flow 10. Oil drain from turbocharger
4. Flow through oil cooler 11. Thermostat open - oil flows through oil cooler
5. Flow return to filter head 12. Thermostat closed - oil flows directly to oil filter
6. Filter bypass valve 13. Flow to oil filter.
7. Oil filter
Signature, ISX, and QSX15 Eng [...] Flow Diagram, Lubricating Oil System
Flow Diagram, Lubricating Oil System (200-002)

Flow Diagram
4
4
5 1
10
3Cummins Inc. 9
Cummins Inc.
3
14 8
11
6 3
4
9
Cummins Inc. 1
1
15 13
Cummins
7 Inc. 2 Cummins Inc. 12
9
07c00248
Horizontal Bypass
1. Lubricating oil flow from oil pump 9. Flow to main oil rifle
2. Thermostat 10. Oil drain from turbocharger
3. Oil cooler bypass flow 11. Thermostat open - oil flows through oil cooler
4. Flow through oil cooler 12. Thermostat closed - oil flows directly to oil filter
5. Oil cooler flow return to filter head 13. Flow to oil filter
6. Filter bypass valve 14. Bypass valve open - oil flows to oil filter
7. Oil filter 15. Bypass valve closed - oil flows directly to main oil rifle
8. Flow to turbocharger
Cummins Inc. Cummins Inc. 4

4 1
14
5 10 3
9
9 3 Cummins8 Inc. 11
3
4 1
15
6 1
Cummins Inc. Cummins
13 Inc.
9 2 12
7
07c00217
Lubricating Oil Filter, Cooler and Bypass

3. Oil transfer to rear oil cooler 11. Thermostat open - oil flows through oil cooler
4. Flow through oil coolers 12. Thermostat closed - oil flows directly to oil filter
5. Oil cooler flow return to filter head 13. Flow to oil filter
6. Filter bypass valve 14. Bypass valve closed - oil flows to oil filter
7. Oil filter 15. Bypass valve open - oil flows directly to main oil rifle.
All Applications
10
11 10 12
10

7
6
8
9 Cummins Inc.
13 5 13
2

1 5 14
15 3 4 3
4 00c00002
Lubricating Oil Pump and Power Components

1. Lubricating oil flow from oil pan through suction tube 9. Flow from main bearing to crankshaft
2. Flow from suction tube to oil pump 10. Flow to cylinder head
3. Pressure regulator 11. Flow to piston cooling nozzle
4. High-pressure relief valve 12. Flow to idler gears
5. Flow from oil pump to oil cooler/filter head housing 13. Oil transfer from main oil rifle
6. Oil return from oil cooler/filter head housing to main 14. Flow to air compressor
oil rifle 15. Rifle sensing regulator dump to inlet.
7. Main oil rifle
8. Flow to main bearing
All Applications
2 6
3 13
5
4

3
2
10
Cummins Inc.
1
9
14
Cummins Inc. 8 Cummins Inc.
12
11 1
1 7
00c00049
Overhead Components
1. Lubricating oil flow from cylinder block to cylinder 8. Flow to valve rocker levers
head 9. Flow to valve camshaft journal bearings
2. Flow around grooved head to drilled camshaft and 10. Intake valve rocker lever
rocker lever shafts 11. Engine brake lever
3. Flow to injector rocker lever shafts 12. Exhaust valve rocker lever
4. Flow to injector rocker levers 13. Injector rocker lever
5. Flow to injector camshaft journal bearings 14. Oil drain from overhead (front and rear).
6. Flow to fuel pump
7. Flow to valve rocker lever shaft
4
14 4
3
5 10
9 11
9
3 Cummins Inc.
8
3 1
4
15
6 1
13
Inc.
9 12
7 2
07c00302
3. Oil cooler bypass flow 11. Thermostat open - oil flows through oil cooler
4. Flow through oil cooler 12. Thermostat closed - oil flows directly to oil filter
5. Flow return to filter head 13. Flow to oil filter
6. Filter bypass valve 14. Bypass valve closed - oil flows to oil filter
7. Oil Filter 15. Bypass valve open - oil flows directly to main oil rifle.
Cooling System - Overview Signature, ISX, and QSX15 Eng [...]
Cooling System - Overview (008-999)

General Information
A single thermostat design was implemented with the introduction of the 2002 ISX engine. The thermostat opens at
82C [180F] and is the same thermostat used in previous ISX engines, which were designed with two thermostats.
The ISX 2002 engine with EGR implemented an impeller that is similar to the impeller on the QSX15 engine to
maximize the cooling capacity of the water pump. The water pump pulley drive ratio was increased to provide faster
water pump speeds to increase cooling capacity. Increased cooling capacity is required because of the flow and heat
associated with the EGR.
The functions of the cooling system are to:
Absorb heat from the engine components
Circulate the coolant in the engine
Dissipate the heat through the radiator
Control coolant temperature by the thermostat.
The coolant must be made up of the correct proportions
of water, antifreeze, and supplemental coolant additives
(SCA) to perform these functions properly.
The accompanying chart illustrates the coolant flow

through the engine. For more detail, refer to the Cooling
System Flow Diagram.
Conventionally cooled engines with automatic

transmissions typically use a oil-to-water transmission
torque converter cooler plumbed between the radiator and
the engine water pump.
A torque converter cooling system with a remote bypass
allows the torque converter to receive coolant flow when
the thermostat is closed (engine cold).
Signature, ISX, and QSX15 Eng [...] Cooling System - Overview
The following publications, available through a Cummins

Authorized Repair Location, provide cooling system
installation recommendations and specifications
approved by Cummins Inc.:
Data Sheets for specific engine models
Operation of Diesel Engines in Cold Climates, Bulletin
3379009
Heavy-Duty Coolant/SCA Maintenance Requirements,
Bulletin 3387910.
Flow Diagram, Cooling System Signature, ISX, and QSX15 Eng [...]
Flow Diagram, Cooling System (200-003)

Flow Diagram
7

3
6
Cummins Inc.
5

1
2 3 4 00c00041
1. Coolant inlet 5. Coolant flow from water pump

2. Coolant flow from coolant filter 6. Coolant flow past oil cooler
3. Coolant bypass flow from thermostat 7. Coolant flow to cylinder head.
4. Coolant flow to water pump
Signature, ISX, and QSX15 Eng [...] Flow Diagram, Cooling System

Flow Diagram
3 10 3
1 1

4 9
2 2
5
6
Cummins Inc.
7 11

8 8
08c00125
Single Thermostat
1. Coolant flow through cylinder head 7. Coolant bypass flow to water pump
2. Coolant flow from cylinder head to thermostat 8. Coolant flow to water pump
housing 9. Bypass closed
3. Thermostat 10. Coolant flow to radiator
4. Bypass open 11. Coolant flow from radiator.
5. Coolant flow through thermostat housing to bypass
passage
6. Coolant bypass passage

Flow Diagram
2 3 2
3
2Cummins Inc. Cummins Inc.

4 4
7
5
Cummins Inc.
6
1
00c00042
Dual Thermostat
1. Coolant flow from cylinder block to cylinder head 5. Coolant bypass flow to water pump
2. Coolant flow from cylinder head to thermostat 6. Coolant bypass flow to water pump
housing 7. Thermostats.
3. Coolant flow to radiator

7
13
Cummins
16
Inc.17 Cummins Inc.
15 3
14 6
Cummins Inc.
5
12 11
10
6
9
8 1
16
2 3 4 08c00124
1. Coolant inlet 10. Coolant flow around EGR valve

2. Coolant flow from coolant filter 11. EGR valve coolant return to thermostat housing
3. Coolant bypass flow from thermostat 12. EGR cooler coolant supply from cylinder block
4. Coolant flow to water pump 13. Coolant flow through EGR cooler
5. Coolant flow from water pump 14. EGR cooler coolant return to thermostat housing
6. Coolant flow past lubricating oil cooler 15. Thermostat housing
7. Coolant flow to cylinder head. 16. Coolant supply to turbocharger
8. Lubricating oil cooler housing 17. Coolant return from turbocharger.
9. Coolant supply to EGR valve body
3 10 3
1 1

4 9
2 2
5
6
Cummins Inc.
7 11

8 8
08c00125
Single Thermostat
passage

2
8
10
8 3
7
Cummins
9 Inc. 11
1
6
5 4
08c00251
1. Coolant supply to EGR cooler 7. Coolant flow to actuator valve

2. Coolant flow through EGR cooler 8. Coolant flow from actuator valve to thermostat
3. Coolant return to block housing
4. Lubricating oil cooler housing 9. Coolant flow from turbocharger bearing housing to
5. Coolant flow to turbocharger thermostat housing
6. Coolant flow to turbocharger bearing housing 10. Thermostat housing
11. EGR cooler coolant vent line

8 Inc.
7
4
Cummins Inc.
Cummins Inc.
6 Cummins Inc.
1 5
2 3 4 08c00259
1. Coolant inlet 5. Coolant flow from water pump

2. Coolant flow from coolant filter 6. Coolant flow past oil cooler
3. Coolant flow to water pump 7. Coolant flow around cylinder liners
4. Coolant bypass flow to water pump 8. Coolant flow to cylinder head.
Single Thermostat
3 10 3
1 1

4 9
2 2
5
6
Cummins Inc.
7 11

8 8
08c00125
passage
Air Intake System - Overview Signature, ISX, and QSX15 Eng [...]
Air Intake System - Overview (010-999)

General Information
Variable Geometry
To maximize the performance of the engine and also to help decrease emissions levels, a variable geometry
turbocharger is used on the ISX engine, referred to as automotive with CM870 and automotive with CM871
The variable geometry turbochargers have quicker response time, and quicker engine deceleration for quicker shifting
than fixed geometry turbochargers.
Because of the active control of the variable geometry turbocharger, intake manifold pressure and turbocharger noise
can often change. There is not a loss of power associated with the change in intake manifold pressure or turbocharger
noise; however, customer perception of engine power can be affected. Typically, when the intake manifold pressure
and turbocharger noise are changing during steady state operation, the ECM is adjusting the flow of EGR into the
engine and the engine power is not affected.
When the throttle is released, perhaps for a gear change, the variable geometry actuator closes. This prepares the
turbocharger to be ready to build intake manifold pressure quickly to provide improved turbocharger response when
the throttle is depressed after the gear change. Because of this design for improved turbocharger response, after
releasing the throttle, the engine speed of the ISX engine with a variable geometry turbocharger can decrease more
quickly than an engine without a variable geometry turbocharger. Fast deceleration in engine speed can cause drivers
to adjust their shifting styles until they become accustomed to the different deceleration speeds.
Similar to all of Cummins Inc. electronically controlled heavy duty engines, the ISX engine with a variable geometry
turbocharger incorporates a power derate to protect the turbocharger from damage while operating in high altitudes.
The ISX engine with a variable geometry turbocharger meets or exceeds the power output of the ISX engine with a
fixed geometry turbocharger at most altitudes. At and around 2.438 km [8000 ft] elevation, however, a slight power
decrease can be noticeable when operating the ISX engine with a variable geometry turbocharger, when comparing
its performance to the ISX engine with a fixed geometry turbocharger.
The ISX with CM870 variable geometry turbocharger is
pneumatically actuated with air from the OEM air tanks.
High air pressure from the turbocharger control valve
closes the variable geometry mechanism, which
increases the exhaust gas pressure and facilitates EGR
flow through the engine. A closing variable geometry
mechanism also increases turbocharger speed and intake
manifold pressure under certain engine operating
conditions. Lower air pressure from the turbocharger
control valve opens the variable geometry mechanism,
which decreases exhaust gas pressure, turbocharger
speed, and manifold pressure under certain engine
operating conditions.
Depending on the build date, the ISX with CM870 uses
either a low mount turbocharger control valve or a high
mount turbocharger control valve.
The early ISX with CM870 use the high mount

turbocharger control valve, which is located on top of the
front gear housing.
Signature, ISX, and QSX15 Eng [...] Air Intake System - Overview
The air filter is located on the air shut-off valve.
The later ISX with CM870 engines, engine serial number

first (ESN) 79031440 uses the low mount turbocharger
control valve. The low mount turbocharger control valve
does not require an air filter.
However, the vehicle must be equipped with an air dryer
to meet engine installation requirements. The vehicle air
supply will be plumbed directly to the control valve inlet
port (1). The outlet air supply port (2) to the variable
geometry turbocharger .

The ISX with CM871 variable geometry turbocharger is
electronically actuated. The electronic control module
(ECM) sends a command directly to the variable geometry
actuator mounted on the turbocharger.
Closing the variable geometry mechanism increases the
exhaust gas pressure, facilitating EGR flow through the
engine. Turbocharger speed and intake manifold pressure
will also increase when the variable geometry mechanism
closes under certain engine operating conditions. Closing
the variable geometry turbocharger will also increase
exhaust gas temperature under certain normal engine
operating conditions and during aftertreatment
regeneration events. This is used to improve
aftertreatment component efficiency. Refer to Procedure
011-999 for further information regarding variable
geometry turbocharger and aftertreatment system
interactions.
Opening the variable geometry mechanism decreases
exhaust gas pressure, turbocharger speed and intake
manifold pressure under certain engine operating
conditions.
Air Intake System - Overview Signature, ISX, and QSX15 Eng [...]
All Applications
The combustion air system consists of intake air piping,
turbocharger, charge-air cooler piping, charge air cooler,
and exhaust piping.
The turbocharger uses exhaust gas energy to turn the

turbine wheel. The turbine wheel drives the compressor
impeller that provides pressurized air to the engine for
combustion. The additional air provided by the
turbocharger allows more fuel to be injected to increase
the power output from the engine.
The correct turbocharger must be used. Providing too
much additional air will increase the cylinder pressures
and shorten the life of the engine.
The turbine and compressor wheels and the shaft are

supported by two rotating bearings in the bearing housing.
Passages in the bearing housing direct filtered,
pressurized engine oil to the shaft bearings and thrust
bearings. The oil is used to lubricate and cool the rotating
components to provide for smooth operation. The oil then
drains from the bearing housing to the engine sump
through the oil drain line.
An adequate supply of good, filtered oil is very important
to the life of the turbocharger.
As the intake air is compressed by the turbocharger, the

air temperature increases. This heated air is then passed
through the charge-air cooler, which cools the air. Cool air
is more dense, which allows more air to be compressed
into the cylinder, yielding a much greater combustion
efficiency.
Signature, ISX, and QSX15 Eng [...] Flow Diagram, Air Intake System
Flow Diagram, Air Intake System (200-004)

Flow Diagram
6 5
2
Cummins Inc.
1
3
00c00005
1. Intake air inlet to turbocharger 4. From charge air cooler to intake manifold
2. Turbocharger air to charge air cooler 5. Intake valve port
3. Charge air cooler 6. Intake valves.
Flow Diagram, Air Intake System Signature, ISX, and QSX15 Eng [...]
With CM870
7 6
8
5
9 4
5
Cummins Inc.
3
Cummins Inc.
1
Cummins Inc.
2
10c00126
1. Intake air inlet to turbocharger 6. EGR mixer

2. Turbocharger air to charge air cooler 7. Air intake connection
3. Charge air cooler 8. Intake valve port
4. From charge air cooler to intake manifold 9. Intake valves.
5. Exhaust gas to EGR mixer
Signature, ISX, and QSX15 Eng [...] Flow Diagram, Air Intake System
11
10
4
Cummins Inc. 5
Cummins Inc.
6 7
9
8
3
Cummins Inc.

1
2
10c00168
1. Intake air inlet to turbocharger 7. Exhaust to exhaust manifold

2. Turbocharger air to charge air cooler 8. Exhaust gas to EGR cooler
3. Charge air cooler 9. Exhaust cooler
4. From charge air cooler to air inlet connector 10. Exhaust gas to EGR valve
5. Intake valve port 11. Exhaust gas to mixer.
6. Intake valves
Exhaust System - Overview Signature, ISX, and QSX15 Eng [...]
Exhaust System - Overview (011-999)

General Information
Exhaust gas recirculates through the engine to reduce the amount of oxides of nitrogen (NO x) emitted from the engine.
The exhaust gas is cooled as if flows through an EGR cooler, and then is mixed with the compressed fresh air from
the turbocharger before entering the intake manifold. EGR was introduced to reduce the amount of in-cylinder oxygen
available for combustion while maintaining the same amount of flow through the engine. Exhaust gases present during
the start of combustion are very stable and have a very slow reaction rate. They absorb heat during combustion,
resulting in lower in-cylinder peak flame temperatures, and therefore, lower NO x emissions.
The EGR mixer was designed to completely mix the EGR gas with the turbocharged air from the charge air cooler.
Complete mixing is necessary to provide smooth operation and decreased emissions.
The variable geometry turbocharger is required for several important engine operating conditions. It is used to facilitate
EGR flow through the engine. Refer to Procedure 010-999 (Air Intake System - Overview) for variable geometry
turbocharger and EGR flow interactions.
The variable geometry turbocharger is also used for engine braking. The variable geometry mechanism closes in
order to increase exhaust manifold pressure. The increased exhaust pressure works against the pistons on the
exhaust stroke, retarding engine speed.
The aftertreatment system is used to reduce particulate
emissions and is composed of six main components:
1. Aftertreatment inlet
2. Aftertreatment diesel particulate filter differential
pressure sensor
3. Aftertreatment diesel oxidation catalyst
4. Aftertreatment diesel particulate filter
5. Aftertreatment outlet
6. Aftertreatment exhaust gas temperature sensors.
NOTE: In some applications, the aftertreatment diesel
oxidation catalyst can be contained within the inlet section
of the aftertreatment system.
Passive regeneration occurs when the exhaust

temperatures are naturally high enough to oxidize the soot
collected in the aftertreatment diesel particulate filter
faster than the soot is collected.
Passive regeneration typically occurs when the
temperature of the aftertreatment diesel particulate filter
is above 316C [600F]. This occurs during highway
driving or driving with heavy loads.
Since passive regeneration occurs naturally, it is
considered to be normal engine operation. No fuel is
added to the exhaust stream during passive regeneration.
Signature, ISX, and QSX15 Eng [...] Exhaust System - Overview
Active regeneration occurs when the exhaust

temperatures are not naturally high enough to oxidize the
soot collected in the aftertreatment diesel particulate filter
faster than it is collected.
Active regeneration requires assistance from the engine
in order to increase the exhaust temperature. This is
typically done by injecting a small amount of diesel fuel
into the exhaust stream (called aftertreatment injection)
which is then oxidized by the aftertreatment diesel
oxidation catalyst. The oxidation of this additional fuel
creates the heat needed to regenerate the aftertreatment
diesel particulate filter.
For active regeneration to occur, the ECM must detect
that the aftertreatment diesel particulate filter restriction
has reached a specified limit. Once this limit is reached,
the engine will alter its operation in order to create exhaust
temperatures high enough to actively regenerate the
aftertreatment diesel particulate filter.
An active regeneration event typically consists of two
parts: a warming up phase and a regenerating phase.
The purpose of the warm up phase is to increase the
exhaust temperatures to the point that aftertreatment
injection can occur.
Exhaust System - Overview Signature, ISX, and QSX15 Eng [...]
Aftertreatment injection requires that temperatures in the aftertreatment system reach approximately 288C [550F].
At this temperature and above, the small quantities of fuel injected into the exhaust will properly oxidize across the
aftertreatment diesel oxidation catalyst creating the additional heat required to actively regenerate the aftertreatment
diesel particulate filter.
Once the warm up phase is complete and the aftertreatment injection has begun, the active regeneration phase
begins.
During active regeneration, the engine ECM monitors the exhaust temperatures before and after the aftertreatment
diesel particulate filter and maintains the temperatures in a range of approximately 427 to 649C [800 to 1200F].
The quantity of fuel used for aftertreatment injection will vary as the temperature is controlled within these limits.
The temperatures achieved during active regeneration are typically higher than those achieved during passive
regeneration. The conversion of soot to carbon dioxide occurs much faster as temperatures increase.
A typical active regeneration event will take approximately 20 to 40 minutes to complete while the vehicle is operating.
The vehicle operator may notice additional turbocharger noise during this time, along with an illuminated high exhaust
temperature lamp, if equipped.
The frequency at which an engine will require an active regeneration varies greatly from application to application. In
general, vehicles with a low vehicle speed, such as urban vehicles, or a low-load duty cycle, will require more active
regeneration events than a heavily loaded vehicle or a vehicle with a high speed duty cycle.
The engine ECM also contains a time-based feature for active regenerations which is used to verify correct
aftertreatment operation when the vehicle duty cycle is typically high enough that active regeneration events are
not necessary.
Under some operating conditions, such as low speed, low load, or stop and go duty cycles, the engine may not have
enough opportunity to regenerate the aftertreatment diesel particulate filter during normal vehicle operation. When
this occurs, the engine illuminates the aftertreatment diesel particulate filter lamp to inform the vehicle operator that
assistance is required, typically in the form of a stationary (parked) regeneration.
Stationary (parked) regeneration is a form of active regeneration that is initiated by the vehicle operator when the
vehicle is not moving.
Refer to Procedure 014-013 (Aftertreatment Testing) in Section 14, for more information on Stationary (Parked)
Regeneration.
The vehicle manufacturer has the that option of installing two switches that control aftertreatment functions: the start
switch and the permit switch.
The start switch (known as the Diesel Particulate Filter Regeneration Start Switch in INSITE electronic service tool)
is used to start a stationary (parked) regeneration. The vehicle manufacturer may also reference this switch as a
stationary regeneration switch, start switch, or parked regeneration switch.
The permit switch (known as the Diesel Particulate Filter Permit Switch in INSITE electronic service tool) is used to
allow the vehicle operator to disable active regeneration, if necessary. The vehicle manufacturer may also reference
this switch as an inhibit switch, stop switch, or disable switch.
Refer to Procedure 011-056 (Exhaust System Diagnostics) in Section 11, for switch operation and troubleshooting.
Signature, ISX, and QSX15 Eng [...] Exhaust System - Overview

The Signature, ISX, and QSX15 engines utilize either a
wastegated, Holset HX55 or HX60 turbocharger. Some
lower horsepower automotive ratings and most industrial
applications utilize a non-wastegated, fixed geometry
Holset HX55 turbocharger.
The wastegated turbocharger is comprised of a
turbocharger, wastegate actuator, and wastegate valve in
the turbine housing. A wastegated turbocharger provides
improved response at low engine speeds without
sacrificing turbocharger durability at high speeds. This is
accomplished by allowing exhaust gases to bypass the
turbine wheel during certain modes of engine operation.
During low rpm operation, the turbocharger operates as a
closed-system turbocharger where the gases' energy is
transferred to the compressor wheel and use to compress
intake air. During high rpm operation, however, the
turbocharger becomes an open-system turbocharger and
allows exhaust gases to bypass the turbine wheel. Since
exhaust gas is gated around the turbine wheel, less
energy is absorbed through the turbine and transferred to
the compressor, reducing intake manifold pressures and
turbine speeds.
The wastegate controller is mounted on the air intake

connection and is controlled by the ECM. The wastegate
controller regulates the percentage of the intake manifold
pressures sent to the wastegate actuator. Two solenoids,
similar to the fuel pump shutoff valve of the CELECT
product, are used in conjunction with four orifices to
regulate this percentage.
The wastegate actuator is mounted on the turbocharger

and consists of a pressure canister, diaphragm, and rod.
As pressure changes in the canister, as dictated by the
wastegate controller, the actuator rod adjusts the
wastegate valve accordingly.
The wastegate valve is mounted inside the turbocharger
in the turbine housing. As the valve opens, exhaust gas is
allowed to bypass the turbine wheel, lowering turbine
speed to adjust intake manifold pressure.
Flow Diagram, Exhaust System Signature, ISX, and QSX15 Eng [...]
Flow Diagram, Exhaust System (200-005)

Flow Diagram
2

1
Cummins Inc. 3
00c00006
1. Exhaust valve ports 3. Turbocharger turbine.

2. Exhaust manifold
Signature, ISX, and QSX15 Eng [...] Flow Diagram, Exhaust System
Flow Diagram, Exhaust System (200-005)

Flow Diagram
Cummins Inc.
12200016
Wastegate OPEN; Wastegate CLOSED

With CM870
2
1
3
Cummins Inc. Cummins Inc.8
Cummins Inc.
4
5 7
6 11c00066
1. Exhaust gas to manifold 5. EGR valve

2. Exhaust manifold 6. Exhaust gas to EGR cooler connection
3. Exhaust gas to turbocharger 7. EGR cooler
4. Exhaust gas to EGR valve 8. Cooled exhaust gas to EGR connection tube and
EGR mixer.
With CM870
1 1
2
4 Inc.
Cummins Inc.

2 4
3
5
11c00067
Variable Geometry
1. Exhaust in 4. Sliding nozzle closed
2. Sliding nozzle Open 5. Exhaust gas high velocity flow.
3. Exhaust gas low velocity flow
1 1
2
4 Inc.
Cummins Inc.

2 4
3
5
11c00067
1. Exhaust gas in 4. Sliding nozzle - closed position

2. Sliding nozzle - open position 5. Exhaust gas high velocity flow.
3. Exhaust gas low velocity flow

9 10
6
4
5 7
8
Cummins Inc.

2 1
11c00191
1. Exhaust gas to EGR cooler 6. Front EGR connection tube

2. EGR cooler 7. EGR measurement venturi
3. Cooled exhaust gas to rear EGR connection tube 8. Cooled exhaust gas to the EGR mixer
4. EGR valve mounting bracket 9. EGR differential pressure sensing tubes
5. EGR valve 10. EGR differential pressure sensor.

1 Cummins Inc.
3 Cummins Inc.
6
5
4
Cummins
7
Inc.
8
10
13
14 Inc.
9
11 15
12 11c00095
Cummins Particulate Filter

1. Exhaust from turbocharger 9. Aftertreatment particulate trap differential pressure
2. Aftertreatment fuel injector sensor tubes (High)
3. Exhaust pipe with exhaust mixture 10. Installation alignment tab
4. Exhaust gas temperature sensor (number 1) 11. Aftertreatment particulate trap
5. Aftertreatment inlet 12. Aftertreatment particulate filter differential pressure
6. Aftertreatment particulate trap differential pressure sensor tube (Low)
sensor 13. Aftertreatment outlet
7. Aftertreatment catalyst 14. Exhaust gas temperature sensor (number 3)
8. Exhaust gas temperature sensor (number 2) 15. Exhaust flow exiting aftertreatment system.
Signature, ISX, and QSX15 Eng [...] Compressed Air System - Overview
Compressed Air System - Overview

(012-999)
General Information
The compressed air system normally consists of a gear-
driven air compressor, air governor, air tanks, and all
necessary plumbing.
Complete installation recommendations are found in
Cummins Inc. publication, Automotive and Bus
Installation Recommendations, Air Compressor Systems,
Bulletin 3884946.
Single Cylinder
The components listed below are commonly used in a
single cylinder air system.
(1) Air Governor
(2) Discharge line
(3) Air dryer
(4) Supply tank
(5) Check valve
(6) Primary tank
(7) Secondary tank
(8) Check valve
(9) Air compressor.
Flow Diagram, Compressed Air System Signature, ISX, and QSX15 Eng [...]
Flow Diagram, Compressed Air System (200-006)

Flow Diagram

1
Cummins Inc. 2
00c00007
1. Coolant 3. Lubricant.
2. Air
Signature, ISX, and QSX15 Eng [...] Flow Diagram, Compressed Air System
Flow Diagram, Compressed Air System (200-006)

Flow Diagram

2 3
5
Cummins Inc.

6
4
00c00008
WABCO - Type System with Air Dryer

1. Governor 4. Reservoir (wet tank)
2. Discharge 5. Air compressor
3. Intake 6. Air dryer.
Electrical Equipment - Overview Signature, ISX, and QSX15 Eng [...]
Electrical Equipment - Overview (013-999)

General Information
All Delco Remy America alternators are rated for inlet air temperatures of -35 to 93C [-31 to 200F], measured 25.4
mm [1 in] from the rear of the unit, except for the 26SI. The 26SI has a maximum rating of 85C [185F] because of
the sealed electronics. Avoid mounting the alternator near any heat sources, such as manifolds, turbochargers, and
so forth. Adequate clearance must also be provided at the rear of the alternator for cooling air to enter (the alternator
fan pulls air through toward the front of the unit).
The second most common cause of failure of Cummins alternators is contamination by dirt, chemicals, water, or
unknown substances. While the alternator is laboratory tested to withstand salt spray, dust, and high humidity, it is
necessary to mount the alternator to minimize environmental and application contamination. Exposure to salt spray
over an extended period of time will shorten the alternator life, as well as increase circuit resistance by causing
corrosion to terminal connections for all electrical components. Exposure to engine oil or oil mist from the engine
breather tubes can cause brush problems in brush alternators, as well as attract other debris. Any contamination of
the rear of the alternator can reduce airflow, which will eventually overheat the diodes.
If operating in extreme environments, especially off-road, the 21SI can be installed with a dust shield, which has shown
to reduce the effects of extreme environments and improve alternator life. Debris shields have been developed for
the 19SI, 22SI, and 23SI alternators. New debris shields have provisions for mounting an air duct in order to route
clean air where necessary.
Establish proper cable routing, and determine cable lengths. Avoid routing taut cables between connections. The
maximum voltage drop in the charging system at rated alternator output is 0.5 VDC for a 12 VDC system, 1.0 VDC
for a 24 VDC system, and 1.5 VDC for a 32 VDC system. The voltage drop in the charging system must be kept to a
minimum in order to make sure enough voltage exists to charge the batteries.
While all Delco Remy America alternators are negative grounds, it is suggested that a full copper return be provided
to the negative (-) terminal of the batteries. This will also make sure that as the vehicle ages, corrosion of the frame
and ground strap do not cause excessive voltage drops. Also, painted mounting brackets can prevent a complete
electrical circuit.
Be sure all electrical connections, including ground connections, are metal-to-metal connections.
CAUTION
Never use any type of toothed lock washer, internal or external tooth (also called star washers), on wiring
connections. The points of the star washer cause current to be conducted only through the points of the star
washer, rather than the larger flat surface of a standard flat washer, and lead to corrosion and a high-
resistance electrical connection.
Mounting Hardware
All capscrews must be a minimum diameter of 12.7 mm [0.5 in].
Always use a hardened steel washer under mounting capscrew heads, or use flanged-head hardware. The
washer must match the capscrew diameter.
Never use any type of lock washer, including toothed or split lock washers, on any mounting connection. Lock
washers are not recommended for mounting capscrews because their trapezoidal cross section provides less
clamping surface and higher clamping stress.
The operating range of the cranking motor and solenoid is -25 to 121C [-13 to 250F]. Military application starters
have an operating range from -54 to 121C [-65 to 250F]. Locating the motor close to the exhaust manifold or other
heat source can result in reduced motor performance with deterioration of insulation and rubber components. A
minimum 50.8 mm [2 in] clearance is recommended. Where relocation or rotation is not possible, metal shielding can
effectively be used to protect the starter from engagement in hot conditions.
Establish proper cable routing. Avoid routing a taut cable between connections. When routing battery cables from the
frame rails to the cranking motor, anchor the cables to the engine, transmission, or cranking motor, and allow for
relative movement between the engine and the frame. It is highly recommended that a copper ground return be used
and the frame not be relied upon for ground return in the starting circuit, which will prevent corrosion from creating
excessive voltage drops. Using a copper ground cable is especially critical in applications using a wet flywheel
housing, where reliance on frame grounding can create a current path through the crankshaft and main bearings.
Limit the number of cables attached to the battery terminal of the solenoid to not more than two.
When positioning the motor at the mounting location, it is desirable to place the solenoid above the centerline of the
motor (preferably a minimum of 15 degrees above the horizontal). This will prevent potential accumulation of foreign
material or moisture that can restrict operation in the tower portion of the shift lever housing. It also reduces the
possibility of road debris being thrown up and breaking the solenoid cap.
Mounting Specifications
Signature, ISX, and QSX15 Eng [...] Electrical Equipment - Overview
The flange-to-flywheel distance is the distance on the engine from the cranking motor mounting surface to the
ring gear face. This distance is 50.8 1.52 mm [2.0 0.060 in]. This dimension must include spacers or
gaskets used on the engine. The cranking motor is designed to function within this dimension. If it is altered,
pinion or ring gear damage can occur.
Delco Remy America recommends the use of 12-point, flanged head capscrews.
No lock washers, star washers, or soft washers, including copper electrical connections can be used. Lock
washers and star washers do not have a rectangular cross section and can result in a loss of clamp force on
the mounting capscrews. The yield strength of soft washers or copper connections can be exceeded with
mounting capscrews tightened. In each case, a loose starter mounting will result.
CAUTION
If the engine does not start and must be cranked again, always wait two to three seconds to allow the pinion
and ring gear to stop. If the starter is reengaged immediately, the pinion can be milled or the armature twisted.
The starter is intended only for cranking the engine and must not be used to bump the engine.
If the engine does not start within five seconds of cranking, follow the Cold Weather Starting Using Starting Fluid -
With Mechanical or Electrical Metering Equipment (Ether) in Section 1 of the Operation and Maintenance Manual
Signature and ISX Engines, Bulletin 3666311, or Procedure 101-004 (Cold Weather Starting) in Section 1 of the
Operation and Maintenance Manual Signature and ISX Engines, Bulletin 3666251, or Operation and Maintenance
Manual Industrial and Power Generation QSX15 Engines, Bulletin 3666243. Operating the cranking motor for more
than 30 seconds at a time causes stress and/or severe internal heat buildup. A minimum two minute cooling period
is necessary between extended cranking cycles.
When mounting a magnetic switch on a vehicle, the axis of the plunger must be horizontal to the ground and
perpendicular to the axis of travel of the vehicle. This is to make sure the switch is not activated by the movement of
the vehicle. Do not mount the switch on the engine or any metal that can possibly resonate as a result of road or
engine vibration. For engines with separate fuel shutoff solenoids, Cummins Inc. requires the use of two magnetic
switches: one for the fuel shutoff circuit and one for the starting circuit. The fuel shutoff solenoid must not be wired
to the S terminal of the starting motor. Wiring to the S terminal will cause the shutoff solenoid to fail.
The basic heavy-duty electrical system consists of:
(1) Batteries
(2) Starter
(3) Alternator (generator)
(4) Magnetic switch
(5) Push-button switch
(6) Keyswitch
(7) Control (or relay) circuit wiring
(8) Battery cables or cranking circuit.
Refer to the OEM service repair manual for specific

service information about the charging and starting
circuits.
Refer to the OEM service repair manual or the component
manufacturer's service bulletins for specific service
information about the starting motor and the alternator.
Engine Testing - Overview Signature, ISX, and QSX15 Eng [...]
Engine Testing - Overview (014-999)

General Information
This section outlines engine testing and engine run-in
recommendations for Signature engines. All engines
must be run in after a rebuild or a repair involving the
replacement of one or more piston ring sets, cylinder
liners, or pistons.
NOTE: Incorrect or insufficient break-in of the piston rings
will lead to early oil consumption or high-blowby
complaints. Adherence to these run-in guidelines will
allow the full durability of new pistons, liners, and rings to
be realized.
Before running the engine, make sure the engine is filled
with the proper coolant. Also, make sure the lubricating oil
system is filled and primed.
Signature, ISX, and QSX15 Eng [...] Engine Testing - Overview
In-Service Run-In:
The following in-service run-in guidelines are recommended for Signature engines after a repair involving replacement
of one or more of the piston ring sets, cylinder liners, or pistons where engine or an engine dynamometer and/or
chassis dynamometer run-in can not be performed.
The majority of heavy-duty diesel applications will provide sufficient run-in under normal loaded operations. However,
light-load/high-rpm operation must be avoided during the run-in period.
Engine Dynamometer Run-In:
This is the preferred method of run-in for engines that have been rebuilt out of chassis. It is neither practical nor
recommended that an engine be removed from the application to conduct the run in after a rebuild or cylinder repair
has been performed in-chassis. There is no requirement, nor is it recommended, for an engine that has been run-in
and tested on an engine dynamometer to be run in again after it has been reinstalled in the vehicle or equipment.
Chassis Dynamometer, Portable Dynamometer, or Load Bank Run-In:
When it is not possible to load an engine immediately after rebuild or repair (example: On-highway tractor that
must be "bobtailed" for delivery, a standby generator or fire pump that can not be operated because of customer
restrictions, a fire truck that can not be loaded with the water pump, etc.), the engine must be run in on a chassis
dynamometer, portable dynamometer, or load bank following the recommendations outlined in the attached
procedures.
Fuel Flow Measurement on Engine or
Chassis Dynamometer
Accurate fuel flow measurement is important for
evaluation of engine performance and troubleshooting on
an engine or chassis dynamometer. The only way an
accurate fuel flow measurement can be obtained is
through proper use of available equipment. Below is a
description of the fuel measuring device, available from
Cummins Engine Company, along with installation and
operation recommendations. The fuel measuring device,
Part No. 3376375, can be used with either a chassis or
engine dynamometer.
Installation:
When installing the fuel measuring device, it is important
to reduce the amount of air that can be introduced into the
system when the device is not in use. Therefore, the
plumbing used must include nonrestrictive shutoff valves,
such as ballcock valves, to contain fuel in the device after
each use. Additional installation considerations are:
The fuel measuring device, Part No. 3376375,
must be mounted vertically to maintain accuracy
and proper operation.
A separate fuel supply for use on the dynamometer
is recommended. All fuel used in the measuring
device must be clean for consistent operation.
Care must be taken to reduce fuel line restriction to
and from the engine. Minimum recommended hose
size is No. 10 for the engine fuel inlet and No. 8 for
the engine fuel drain. The length of either hose must
not exceed 15 feet.
For accurate fuel consumption or flow measurement
while testing on a chassis dynamometer, it is
recommended to use a fuel cooler to maintain inlet
temperature to the fuel gear at 49C [120F] or
below.
Engine Testing - Overview Signature, ISX, and QSX15 Eng [...]
Operation:
This is a schematic of the fuel measuring device, Part No. 3376375. The device consists of the following components:
Fuel Filter
Flowmeter
Float Tank
Fuel Rail Pressure Gauge
Fuel cooler is not a part of fuel measuring device, Part No. 3376375; however, it must be used when conducting
a test with the flowmeter.
The fuel measuring device recirculates return fuel to the engine fuel inlet by routing the return fuel to the topside of
the float tank. The fuel is deaerated as it passes through the baffling in the float tank. A ball float valve at the bottom
of the float tank maintains an adequate volume in the tank for deaeration. The fuel is then returned to the engine fuel
inlet. Refer to the sketch for fuel line connection points on the fuel measuring device.
1. Fuel supply from tank
2. Fuel flow to fuel meter
Signature, ISX, and QSX15 Eng [...] Vehicle Braking - Overview
3. Fuel flow from fuel meter

4. Fuel flow to fuel cooler
5. Injector return fuel
6. Fuel rail pressure.
NOTE: The fuel supply tank must be below the level of the fuel measuring device to prevent overflow of the float tank.
If an overhead fuel supply tank is used, a float-controlled reservoir must be installed between the fuel supply tank
and the fuel measuring device, and below the level of the device.
The fuel measuring device is installed in series between the fuel supply tank and the engine fuel inlet. The quantity
of fuel being drawn through the flowmeter is known as makeup fuel or the amount of fuel being burned by the engine.
The flowmeter is graduated to read fuel flow in pounds per hour. The flowmeter contains two floats with respective
scales on either side of the flowmeter. The small float is used to measure lower flows and must be read on the left
scale, as shown. The larger float is for measuring higher flows and must be read on the right scale.
To obtain an accurate fuel rate measurement, the flowmeter reading must be corrected based on the fuel temperature.
There is a fuel temperature gauge on the front panel of the fuel measuring device. The gauge is graduated in percent
of error by which the reading requires correction. By way of illustration, the fuel of an engine reads 125 lb/hr on the
flowmeter, and the temperature gauge reads +2 percent; the corrected fuel flow rate will be 125 plus 2 percent, or
127.5 lb/hr.
Vehicle Braking - Overview (020-999)

General Information
CAUTION
Do not exceed governed engine speed when
operating engine brakes. Engine damage can occur.
The engine brakes are designed to assist the vehicle's
service brakes in slowing down the vehicle. Never use
only the engine brakes to stop the vehicle. If other
engine brakes are used, refer to the component
manufacturer's manual.
Vehicle Braking - Overview Signature, ISX, and QSX15 Eng [...]
Signature and ISX engines are equipped with the

Intebrake system (engine brakes). The Intebrake
system is optional on QSX engines.
Engine brakes use the energy of engine compression to
provide vehicle retardation by converting the engine to an
energy-absorbing device to reduce vehicle speed. This is
accomplished by a hydraulic circuit that opens the
exhaust valves near the end of the compression stroke.
Engine brakes provide the maximum retarding power at
rated speed; therefore, gear selection is important.
The amount of braking power available on Signature, ISX,

or QSX engines is up to 600 hp. Braking power is
managed by the Intebrake system (engine brakes).
Engine brake controls consist of the following:

A six-position selector switch or a three-position
selector switch
An on/off switch
A clutch switch
A throttle sensor
A service brake pressure switch.
Other switches for cruise control that affect engine brake

operations are:
Cruise control ON/OFF and SET/RESUME switches
(if the engine brakes in cruise control feature is
turned off)
Service brake air pressure switch.
Engine brakes can operate while cruise control is turned
on. Refer to Programmable Features in this section.
The six-position selector switch is located next to the on/

off switch in the cab, and allows you to select the retarding
power from brake positions 1 to 6.
The engine brake level specifications (six-position selector

switch):
Position 1 = 17-percent engine braking power
Position 6 = 100-percent engine braking power.
NOTE: For OEMs that use a three-position selector
switch, the engine brake level specifications are:
Position 3 = 100 percent engine braking power.
Signals from the on/off switch, the clutch switch, the

throttle sensor, and the cruise/PTO switches are fed into
the electronic control module (ECM).
NOTE: Any one of these switches can deactivate the
engine brakes. If the engine brakes in cruise control
feature is turned on, the cruise control/PTO switches will
not deactivate the engine brakes.
The ECM then electronically enables or disables the

engine brakes.
NOTE: Engine brakes can not be enabled:
1. When cruise control is active and if the engine
brakes in cruise control feature is turned off
2. When engine speed drops below 850 rpm, or 30 mph
3. When an electronic fault code is active.
The throttle sensor is part of the accelerator pedal

assembly located in the cab and will deactivate the engine
brakes when depressed.
The clutch switch uses the motion of the clutch linkage

to deactivate the engine brakes when the clutch pedal is
depressed. Depressing the clutch while in cruise control
will disengage the cruise control.
The service brake pressure switch is attached to the

service brake air supply line.
Applying the service brakes while in cruise control will
disengage the cruise control and enable the engine
brakes.
If the pedal activated engine brake feature is enabled, the
service brake pedal must be tapped before the engine
brakes will be activated.
Idle the engine 3 to 5 minutes at approximately 1000 rpm

to warm the engine before activating the engine brakes.
Do not operate the engine brakes until the engine oil
temperature is above 30C [86F].
To activate the engine brakes, switch the on/off switch to

the ON position. Once activated, the operation of the
engine brakes is fully automatic.
NOTE: Refer to the appropriate pages in this section for
specific information about engine brake operation under
certain road conditions.
WARNING
Do not use the engine brakes while bobtailing or
pulling an empty trailer. With the engine brakes in
operation, wheel lockup can occur more quickly when
the service brakes are applied, especially on vehicles
with single-drive axles.
Make sure the engine brakes are switched to the OFF
position when bobtailing or pulling an empty trailer.
CAUTION
The engine brakes are designed to assist the vehicle's
service brakes in slowing the vehicle to a stop.
Remember, service brakes will be required to bring the
vehicle to a stop.
CAUTION
Do not use the engine brakes to aid clutchless
gearshifting. This can cause the engine to stall or lead
to engine damage.
The ECM will disable the engine brakes when engine rpm
is below 850 rpm or when an electronic fault code is active.
CAUTION
Do not operate the engine if the engine brakes will not
deactivate. To do so will cause severe engine
damage.
If the engine brakes will not shut off, shut off the engine
immediately.
Section TS - Troubleshooting Symptoms Page TS-a
Section TS - Troubleshooting Symptoms

Section Contents
Page
.........................................................................................................................................................................TS-1
General Information........................................................................................................................................TS-1
Troubleshooting Symptoms Charts ...............................................................................................................TS-2
General Information........................................................................................................................................TS-2
Aftertreatment Diesel Particulate Filter Excessive Ash Cleaning................................................................TS-12
Aftertreatment Diesel Particulate Filter - Excessive Automatic and/or Stationary Regeneration......................TS-90
Aftertreatment Diesel Particulate Filter Excessive Soot Loading................................................................TS-11
Air Compressor Air Pressure Rises Slowly .....................................................................................................TS-3
Air Compressor Cycles Frequently..................................................................................................................TS-4
Air Compressor Noise is Excessive.................................................................................................................TS-5
Air Compressor Pumping Excess Lubricating Oil into the Air System .............................................................TS-6
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)....................................TS-8
Air Compressor Will Not Pump Air..................................................................................................................TS-9
Air Compressor Will Not Stop Pumping.........................................................................................................TS-10
Alternator Not Charging or Insufficient Charging...........................................................................................TS-13
Coolant in the Lubricating Oil........................................................................................................................TS-26
Coolant Loss - External.................................................................................................................................TS-15
Coolant Loss - Internal..................................................................................................................................TS-17
Coolant Temperature Above Normal - Gradual Overheat...............................................................................TS-19
Coolant Temperature Above Normal - Sudden Overheat...............................................................................TS-22
Coolant Temperature Below Normal..............................................................................................................TS-24
Crankcase Coalescing Filter - Frequent Replacement...................................................................................TS-28
Crankcase Gases (Blowby) Excessive...........................................................................................................TS-27
Engine Brake - Low Retarding Power or Slow to Activate..............................................................................TS-32
Engine Brake One or More Cylinders Braking with Power Switch Off........................................................TS-35
Engine Brake Does Not Operate...................................................................................................................TS-29
Engine Decelerates Slowly............................................................................................................................TS-37
Engine Noise Excessive................................................................................................................................TS-38
Engine Noise Excessive Combustion Knocks............................................................................................TS-41
Engine Noise Excessive Connecting Rod..................................................................................................TS-42
Engine Noise Excessive Main Bearing......................................................................................................TS-43
Engine Noise Excessive Piston.................................................................................................................TS-45
Engine Noise Excessive Turbocharger......................................................................................................TS-46
Engine Shuts Off Unexpectedly or Dies During Deceleration.........................................................................TS-47
Engine Speed Surges in PTO or Cruise Control............................................................................................TS-49
Engine Starts But Will Not Keep Running......................................................................................................TS-51
Engine Will Not Crank or Cranks Slowly (Air Starter).....................................................................................TS-54
Engine Will Not Crank or Cranks Slowly (Electric Starter)..............................................................................TS-55
Engine Will Not Shut Off...............................................................................................................................TS-57
Fuel Consumption Excessive........................................................................................................................TS-58
Fuel in Coolant.............................................................................................................................................TS-63
Fuel in the Lubricating Oil.............................................................................................................................TS-64
Intake Manifold Air Temperature Above Specification....................................................................................TS-66
Intake Manifold Pressure (Boost) is Below Normal.........................................................................................TS-68
Lubricating Oil Consumption Excessive........................................................................................................ TS-71
Lubricating Oil Contaminated........................................................................................................................TS-74
Lubricating Oil Filter Plugged........................................................................................................................TS-75
Lubricating Oil in the Fuel.............................................................................................................................TS-70
Lubricating Oil Pressure High.......................................................................................................................TS-78
Lubricating Oil Pressure Low........................................................................................................................TS-79
Lubricating Oil Sludge in the Crankcase Excessive.......................................................................................TS-81
Lubricating Oil Temperature Above Specification..........................................................................................TS-83
Lubricating or Transmission Oil in the Coolant..............................................................................................TS-85
Stationary Regeneration Will Not Activate.................................................................................................TS-87
Stationary Regeneration - Will Not Complete.................................................................................................TS-91
Turbocharger Leaks Engine Oil or Fuel.........................................................................................................TS-86
Troubleshooting Overview ...........................................................................................................................TS-93
Page TS-b Section TS - Troubleshooting Symptoms
Connecting Rod Bearing Noise.....................................................................................................................TS-93

Coolant Loss Pre-Troubleshooting Guide....................................................................................................TS-102
Driver Interview Questions.......................................................................................................................TS-103
Service History Review.............................................................................................................................TS-104
ECM Data Review:...................................................................................................................................TS-104
Driveability - General Information..................................................................................................................TS-93
Driveability/Low Power - Customer Complaint Form......................................................................................TS-95
Driveability/Low Power/Excessive Fuel Consumption - Checklist...................................................................TS-96
Engine Noise Diagnostic Procedures - General Information...........................................................................TS-93
Fuel Consumption - Customer Complaint Form.............................................................................................TS-99
Fuel Consumption - General Information.......................................................................................................TS-98
Main Bearing Noise...................................................................................................................................... TS-93
Oil Consumption.........................................................................................................................................TS-101
Piston Noise.................................................................................................................................................TS-93
Section TS - Troubleshooting Symptoms Page TS-1
General Information
A thorough analysis of the customer's complaint is the key to successful troubleshooting. The more information known
about a complaint, the faster and easier the problem can be solved.
The Troubleshooting Symptom Charts are organized so that a problem can be located and corrected by doing the
easiest and most logical things first. Complete all steps in the sequence shown from top to bottom.
It is not possible to include all the solutions to problems that can occur; however, these charts are designed to
stimulate a thought process that will lead to the cause and correction of the problem.
Follow these basic troubleshooting steps:
Get all the facts concerning the complaint
Analyze the problem thoroughly
Relate the symptoms to the basic engine systems and components
Consider any recent maintenance or repair action that can relate to the complaint
Double-check before beginning any disassembly
Solve the problem by using the symptom charts and doing the easiest things first
Determine the cause of the problem and make a thorough repair
After repairs have been made, operate the engine to make sure the cause of the complaint has been corrected
Troubleshooting Symptoms Charts Signature, ISX, and QSX15 Eng [...]
Page TS-2 Section TS - Troubleshooting Symptoms
Troubleshooting Symptoms Charts

General Information
Use the charts on the following pages of this section to aid in diagnosing specific engine symptoms. Read each row
of blocks from top to bottom. Follow through the chart to identify the corrective action.
WARNING
Troubleshooting presents the risk of equipment damage, personal injury or death. Troubleshooting must be
performed by trained, experienced technicians.
Signature, ISX, and QSX15 Eng [...] Troubleshooting Symptoms Charts
Air Compressor Air Pressure Rises Slowly

This is symptom tree t004
Cause Correction
Block the vehicle wheels and check the air system
for leaks with spring brakes applied and released.
STEP 1 Check for leaks from the air compressor gaskets
............ and the air system hoses, fittings, tanks, and
Air system leaks
valves. Refer to Procedure 012-019 and the OEM
service manuals. Turn the keyswitch ON. Walk
around the engine and listen for air leaks.
OK
Go To Next Step
STEP 2 Check for carbon buildup. Replace the air

compressor discharge line and cylinder head
Carbon buildup is excessive in the air discharge ............
assembly if necessary. Refer to Procedure
line, downstream air valves, or cylinder head
012-003.
OK
Go To Next Step
STEP 3 Check the operation of air system valves, air

............ dryers, and other OEM-installed air system
Air system component is malfunctioning
components. Refer to the OEM service manual.
OK
Go To Next Step
Replace the air compressor air cleaner (if
STEP 4 installed). Check the air intake piping. Check
Air intake system restriction to air compressor is ............ engine air intake restriction if the air compressor
excessive inlet is plumbed to the vehicle or equipment intake
system. Refer to Procedure 010-031.
OK
Go To Next Step
STEP 5 Inspect the air compressor head assembly and
............
Air compressor intake or exhaust system leaks air replace if required. Refer to Procedure 012-003.
Air Compressor Cycles Frequently

Cause Correction
Air system leaks
OK
Go To Next Step
STEP 2 Check the air governor for correct operation. Refer
............
Air governor is malfunctioning or not set correctly to the OEM service manual.
OK
Go To Next Step
Check the operation of check valves, alcohol
STEP 3 evaporators, air dryers, and other OEM-installed
............
Air system component is malfunctioning air system components. Refer to the OEM service
manual.
OK
Go To Next Step
Check for carbon buildup. Replace the air
STEP 4 compressor discharge line and cylinder head
012-003. Check the turbocharger for oil leaks.
Check the intake tube for oil. Refer to Procedure
010-033.
OK
Go To Next Step
STEP 5 Lubricate or replace the air dryer outlet check valve
............
Air dryer outlet check valve is sticking assembly. Refer to the OEM service manual.
Air Compressor Noise is Excessive

Cause Correction
STEP 1
............ Check for ice in low spots of the air discharge line.
Ice buildup in the air system components
OK
Go To Next Step
STEP 2 Check for carbon buildup. Replace the air

compressor discharge line and cylinder head
012-003.
OK
Go To Next Step
STEP 3 Install a ping tank between the air dryer and the
Air compressor is sending air pulses into the air ............ wet tank and check discharge line size for the
tanks application. Refer to the OEM service manual.
OK
Go To Next Step
STEP 4 Check the air compressor timing. Refer to
............
Air compressor timing is not correct Procedure 012-014.
OK
Go To Next Step
STEP 5
Check air compressor mounting hardware. Refer
Air compressor mounting hardware is loose, worn, ............
to Procedure 012-014.
or broken
OK
Go To Next Step
STEP 6 Replace the air compressor. Replace the desiccant
Air compressor is excessively worn or internally ............ element on the air dryer (if equipped). Refer to
damaged Procedure 012-014 and the OEM service manual.
OK
Go To Next Step
STEP 7
Inspect the drive gears and gear train and repair
Air compressor drive gear or engine gear train is ............
as necessary. Refer to Procedure 012-014.
worn or damaged
Air Compressor Pumping Excess Lubricating Oil into the Air System
Cause Correction
Verify the correct lubricating oil drain interval.
Refer to Procedure 102-002 in Section 2 of the
STEP 1 Operation and Maintenance Manual Signature and
............
Lubricating oil drain interval is excessive ISX Engines, Bulletin 3666251, or the Operation
and Maintenance Manual Industrial and Power
Generation QSX15 Engines, Bulletin 3666423.
OK
Go To Next Step
OK
Go To Next Step
STEP 3 Check the air compressor duty cycle. Install larger

............ air compressor if available. Check for and repair all
Air compressor pumping time is excessive
air system leaks. Refer to the OEM service manual.
OK
Go To Next Step
Check for carbon buildup. Replace the air
STEP 4 compressor discharge line, if necessary. Check
Carbon buildup is excessive in the air discharge ............ the turbocharger for oil leaks. Check the intake
line, check valve, or cylinder head tube for oil. Refer to Procedures 012-003 and
010-033.
OK
Go To Next Step
STEP 5
Engine angularity during operation exceeds ............ Refer to the Engine Specification data sheet.
specification
OK
Go To Next Step
STEP 6 Check for excessive blowby. Refer to the

............ Crankcase Gases (Blowby) Excessive symptom
Crankcase pressure is excessive
tree.
OK
Go To Next Step
STEP 7 If coolant temperature is above normal, refer to the

Air compressor runs hot
tree.
OK
Go To Next Step
Air Compressor Pumping Excess Lubricating Oil into the Air System
Cause Correction
Air compressor is excessively worn or internally ............ element on the air dryer (if equipped). Refer to the
damaged OEM service manual.
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)
Cause Correction
Air system leaks
OK
Go To Next Step
............
OK
Go To Next Step
STEP 3
Inspect the air compressor head assembly and
Air compressor intake or exhaust valve system ............
replace if required. Refer to Procedure 012-019.
leaks air
Air Compressor Will Not Pump Air

Cause Correction
OK
Go To Next Step
STEP 2 Check the unloader system and head assembly

............ system. Replace the head assembly if required.
Unloader system is malfunctioning
Refer to Procedure 012-013.
OK
Go To Next Step
STEP 3
Inspect the air compressor cylinder head and
Air compressor cylinder head is cracked or porous, ............
gasket. Refer to Procedure 012-013.
or has a leaking gasket
OK
Go To Next Step
Air compressor is excessively worn or internally ............ element on the air dryer (if equipped). Refer to
damaged Procedure 012-014 and the OEM service manual.
Air Compressor Will Not Stop Pumping

Cause Correction
Air system leaks
OK
Go To Next Step
Check the operation of check valves, alcohol
STEP 2 evaporators, air dryers, and other OEM-installed
............
Air system component is malfunctioning air system components. Refer to the OEM service
manual.
OK
Go To Next Step
STEP 3 Inspect the air compressor head assembly and
............
Air compressor intake or exhaust system leaks air replace if required. Refer to Procedure 012-003.
OK
Go To Next Step
............
Aftertreatment Diesel Particulate Filter Excessive Soot Loading

Cause Correction
STEP 1 Refer to Section TF in the ISX CM871 and ISM

CM876 Electronic Control Systems,
Electronic fault codes active or high counts of ............
Troubleshooting and Repair Manual, Bulletin
inactive fault codes
4021560.
OK
Go To Next Step
STEP 2 Review the repair history of the engine to

determine aftertreatment diesel particulate filter
Progressive damage from excessive black smoke ............
was replaced or needs replacement. Refer to
caused from an earlier or current failure event.
Procedure 014-013 for test procedure.
OK
Go To Next Step
STEP 3 Perform stationary regeneration with the INSITE
Extended operation of engine in low duty cycle, ............ electronic service tool. Refer to Procedure
extended idling and/or low ambient temperatures 014-013.
OK
Go To Next Step
STEP 4
............ Use lower gear.
Engine is being lugged down
OK
Go To Next Step
STEP 5 Check the air intake system for restriction. Refer to
............
Intake air restriction is high Procedure 010-031.
OK
Go To Next Step
STEP 6 Refer to the Oil Consumption - Excessive
............
Excessive internal oil consumption Troubleshooting Symptom Tree.
OK
Go To Next Step
STEP 7 Refer to the Black Smoke - Excessive
............
Excessive black smoke is observed. Troubleshooting Symptom Tree.
Aftertreatment Diesel Particulate Filter Excessive Ash Cleaning

Cause Correction
STEP 1 Refer to Section TF in the ISX CM871 and ISM
Electronic fault codes active or high counts of ............ CM876 Electronic Control System Troubleshooting
inactive fault codes and Repair Manual, Bulletin 4021560.
OK
Go To Next Step
STEP 2 Perform stationary regeneration with the INSITE
Extended operation of engine in low duty cycle, ............ electronic service tool. Refer to Procedure
extended idling and/or low ambient temperatures 014-013.
OK
Go To Next Step
STEP 3 Use an engine lubricating oil that meets CES

............ 20081. Refer to the appropriate Operation and
Lubricating oil being used has high ash content.
Maintenance.
OK
Go To Next Step
Confirm oil blending into fuel. Drain fuel and
STEP 4 replace with clean fuel. Discontinue practice of
............
Blending of engine lubricating oil into fuel. blending oil with fuel. Refer to the appropriate
Operation and Maintenance Manual.
OK
Go To Next Step
STEP 5 Discontinue use of the fuel supplement/additive
Fuel supplement/additive used has high ash ............ being used. Refer to Cummins Fuel
content. Recommendation Bulletin 3379001.
OK
Go To Next Step
STEP 6
Review the air intake filtration system for
Intake air filtration system malfunctioned allowing ............
malfunction. Refer to Procedure 010-024.
dust contamination.
OK
Go To Next Step
Measure the engine blowby. If blowby is above
specification, refer to the Crankcase Gases
STEP 7 (Blowby). Excessive symptom tree. Replace the
............
Crankcase pressure is excessive blowby sensor if there were not any sensor fault
codes. Refer to Crankcase Gases (Blowby)
Excessive Troubleshooting Symptom Tree.
OK
Go To Next Step
STEP 8 Refer to the Oil Consumption - Excessive
............
Excessive internal oil consumption Troubleshooting Symptom Tree.
Alternator Not Charging or Insufficient Charging

Cause Correction
STEP 1
Check the battery cables and connections. Refer
Battery cables or connections are loose, broken, or ............
corroded (excessive resistance)
OK
Go To Next Step
STEP 2 Check the condition of the batteries, replace if

............ necessary. Refer to Procedure 013-007 and the
Batteries have failed
OEM service manual.
OK
Go To Next Step
STEP 3 Check the battery heater. Refer to the OEM service
............
Batteries are cold manual.
OK
Go To Next Step
STEP 4 Check the fuses, wires, and connections. Refer to
Electrical system is "open" (blown fuses, broken ............ the OEM service manual and the manufacturer's
wires, or loose connections) wiring diagrams.
OK
Go To Next Step
STEP 5 Check the alternator belt tension. Refer to
............
Alternator belt is loose Procedure 008-080 or 013-021.
OK
Go To Next Step
STEP 6 Check the vehicle gauge. Refer to the OEM service
............
Vehicle gauge is malfunctioning manual.
OK
Go To Next Step
STEP 7 Tighten the pulley. Refer to the manufacturer's
............
Alternator pulley is loose on the shaft instructions.
OK
Go To Next Step
STEP 8 Test the alternator output. Replace the alternator

............ or voltage regulator if necessary. Refer to
Alternator or voltage regulator is malfunctioning
Procedure 013-001 and the OEM service manual.
OK
Go To Next Step
STEP 9
Install an alternator with a higher capacity. Refer to
Alternator is overloaded, or alternator capacity is ............
Procedure 013-001 and the OEM service manual.
below specification
OK
Go To Next Step
Alternator Not Charging or Insufficient Charging

Cause Correction
STEP 10 Position the batteries away from heat sources.
............
Battery temperature is above specification Refer to the OEM service manual.
Coolant Loss - External

Cause Correction
Before troubleshooting, it is important to determine
STEP 1 the exact complaint by interviewing the driver,
............ looking at the service history, and looking at the
Excessive internal or external engine coolant loss
ECM information. Refer to the Coolant Loss Pre-
Troubleshooting Guide at the end of Section TS.
OK
Go To Next Step
STEP 2 Check the coolant level. Refer to the OEM service
............
Coolant level is above specification manual.
OK
Go To Next Step
Inspect the engine for coolant leaking from hoses,
draincocks, water manifold, expansion and pipe
plugs, fittings, radiator core, exhaust heat shield,
STEP 3 heat exchanger, air compressor and cylinder head
............ gaskets, lubricating oil cooler, water pump seal,
External coolant leak
and OEM-mounted components that have coolant
flow. If necessary, pressure-test the cooling
system, exhaust heat shield, or heat exchanger.
OK
Go To Next Step
STEP 4
Check the radiator pressure cap. Refer to
Radiator cap is not correct, is malfunctioning, or ............
Procedure 008-047.
has low-pressure rating
OK
Go To Next Step
STEP 5 Check the vent lines and the fill line for correct
Fill line or vent lines are restricted, obstructed, or ............ routing and for restriction. Refer to the OEM
not routed correctly service manual.
OK
Go To Next Step
STEP 6
Cooling system hose is collapsed, restricted, or ............ Inspect the hoses. Refer to Procedure 008-045.
leaking
OK
Go To Next Step
STEP 7
Check for air or combustion gases in the cooling
Air or combustion gases are entering the cooling ............
system
OK
Go To Next Step
Coolant Loss - External

Cause Correction
STEP 8 Refer to the Coolant Temperature Above Normal -

............ Gradual Overheat and Coolant Temperature
Engine is overheating
Above Normal - Sudden Overheat symptom trees.
OK
Go To Next Step
STEP 9 Check the turbocharger bearing housing. Refer to
............
Turbocharger leaking coolant Procedure 010-033.
OK
Go To Next Step
STEP 10 Check the EGR valve assembly. Refer to
............
EGR valve leaking coolant Procedure 011-022.
OK
Go To Next Step
STEP 11 Check the EGR cooler for leaks. Refer to
............
EGR cooler leaking coolant Procedure 011-019.
Coolant Loss - Internal

Cause Correction
Before troubleshooting, it is important to determine
the exact complaint by interviewing the driver,
STEP 1 looking at the service history, and looking at the
............ ECM information. Refer to the Coolant Loss Pre-
Excessive internal or external engine coolant loss
Troubleshooting Guide at the end of Section TS. If
the truck is equipped with an Auxiliary Power Unit,
make sure the unit is not leaking.
OK
Go To Next Step
STEP 2
Procedure 008-047 in Section 8.
OK
Go To Next Step
STEP 3 Check the EGR cooler core for leaks. Refer to
............
EGR cooler core is leaking Procedure 011-019 in Section 11.
OK
Go To Next Step
STEP 4 Check the aftertreatment fuel injector for coolant
............
Aftertreatment fuel injector is leaking coolant leaks. Refer to Procedure 011-061 in Section 11.
OK
Go To Next Step
STEP 5 Replace the injector o-rings and install and tighten

the injectors again to reseat the injector cups.
Injector Sleeve is leaking - even with no noticeable ............
Return the engine to operation. Refer to Procedure
defect to the injector o-rings
006-026 in Section 6.
OK
Go To Next Step
For the first investigated instance of internal
coolant loss, perform the corrections in the steps
STEP 6 above and then stop here. Return the engine to
............
First investigated instance of internal coolant loss operation and check for continuing leaks. If the
leaks continue, complete the remaining steps of
this tree.
OK
Go To Next Step
STEP 7 Check the lubricating oil cooler for coolant leaks.
............
Lubricating oil cooler is leaking Refer to Procedure 007-003 in Section 7.
OK
Go To Next Step
STEP 8 Inspect the air compressor air inlet and outlet tubes
Air compressor cylinder head is cracked or porous, ............ for signs of coolant. Refer to Procedure 012-007 in
or has a leaking gasket Section 12.
OK
Go To Next Step
Coolant Loss - Internal

Cause Correction
STEP 9
gasket. Refer to Procedure 012-003 in Section 12.
OK
Go To Next Step
STEP 10 If the unit is equipped with a water cooled

............ turbocharger, refer to Procedure 010-033 in
Turbocharger leaking coolant
Section 10.
OK
Go To Next Step
STEP 11 Check the fuel heater for coolant leaks. Refer to
............
Fuel heater is leaking coolant the OEM service manual.
OK
Go To Next Step
STEP 12 Check the transmission oil cooler and torque
Transmission oil cooler or torque converter cooler ............ converter cooler for coolant leaks. Refer to the
is leaking OEM service manual.
OK
Go To Next Step
STEP 13 Check the cylinder head gasket. Refer to
............
Cylinder head gasket is leaking Procedure 002-004 in Section 2.
OK
Go To Next Step
STEP 14 Pressure test the cylinder head. Refer to
............
Cylinder head is cracked or porous Procedure 002-004 in Section 2.
OK
Go To Next Step
STEP 15 Refer to Cummins Inc. and request additional
............
Base engine problem technical assistance.
Coolant Temperature Above Normal - Gradual Overheat

Cause Correction
Refer to Section TF in the Troubleshooting and
Repair Manual, CM870 Electronic Control System,
Signature and ISX Engines, Bulletin 4021334, or
the Troubleshooting and Repair Manual,
STEP 1 Electronic Control System, Signature, ISX and
Electronic fault codes active or high counts of ............ QSX Engines, Bulletin 3666259, or the
inactive fault codes Troubleshooting and Repair Manual, Power
Generation Control Systems QSX15, QSK23,
QSK45, QSK60, QSK78, and QST30 Series
Engines, Bulletin 4021419 for fault code
troubleshooting.
OK
Go To Next Step
STEP 2 Inspect the engine and cooling system for external

............ coolant leaks. Repair if necessary. Add coolant.
Coolant level is below specification
OK
Go To Next Step
Open the cold weather radiator cover or the
winterfront. Maintain a minimum of 784 cm2 [122
in2] or approximately 28 x 28 cm [11 x 11 in] of
opening at all times. Refer to the Cold Weather
STEP 3
............ Starting Aids, Procedure 101-005 in Section 7 of
Cold weather radiator cover or winterfront is closed the Operation and Maintenance Manual Signature
and ISX Engines, Bulletin 3666257 or Winterfronts
in Section 1 of the Operation and Maintenance
Manual Signature and ISX Engines, Bulletin
3666311.
OK
Go To Next Step
STEP 4 Check the automatic belt tensioner. Refer to
............
Fan drive belt is loose Procedure 008-002 and 008-080.
OK
Go To Next Step
STEP 5 Inspect the charge air cooler, air conditioner
Charge air cooler fins, radiator fins, or air condenser, and radiator fins. Clean, if necessary.
............
conditioner condenser fins are damaged or Refer to Procedures 010-027, 008-042 and the
obstructed with debris OEM service manual.
OK
Go To Next Step
STEP 6 Check the fan drive and controls. Refer to
............
Fan drive or fan controls are malfunctioning Procedure 008-027.
OK
Go To Next Step

Cause Correction
STEP 7
Procedure 008-047.
OK
Go To Next Step
STEP 8 Inspect the radiator shutters. Repair or replace if
Radiator shutters are not opening completely, or ............ necessary. Check the shutterstat setting. Refer to
the shutterstat setting is wrong the OEM service manual.
OK
Go To Next Step
STEP 9 Test the temperature gauge. Repair or replace the

............ gauge, if necessary. Refer to Procedure 008-049
Coolant temperature gauge is malfunctioning
and the OEM service manual.
OK
Go To Next Step
STEP 10
leaking
OK
Go To Next Step
STEP 11 Inspect the shroud and the recirculation baffles.
Fan shroud is damaged or missing or the air ............ Repair, replace, or install, if necessary. Refer to
recirculation baffles are damaged or missing Procedure 008-038 and the OEM service manual.
OK
Go To Next Step
STEP 12 Check the vent lines and the fill line for correct
Fill line or vent lines are restricted, obstructed, or ............ routing and for restriction. Refer to Procedure
not routed correctly 008-017 and the OEM service manual.
OK
Go To Next Step
STEP 13 Check the thermostat for the correct part number

............ and for correct operation. Refer to Procedure
Thermostat is not correct or is malfunctioning
008-013.
OK
Go To Next Step
STEP 14
Refer to the Intake Manifold Air Temperature
Intake manifold air temperature is above ............
Above Specification symptom tree.
specification
OK
Go To Next Step

Cause Correction
STEP 15 Check the oil level. Add or drain oil, if necessary.

............ Refer to Procedure 007-037. Check the dipstick
Lubricating oil level is above or below specification
calibration. Refer to Procedure 007-009.
OK
Go To Next Step
STEP 16
Check the swing check valve for correct operation.
Radiator swing check valve is malfunctioning (if ............
Refer to the OEM service manual.
equipped)
OK
Go To Next Step
STEP 17 Check the water pump for correct operation.

............ Replace the water pump if necessary. Refer to
Water pump is malfunctioning
Procedure 008-062.
OK
Go To Next Step
STEP 18
Inspect the radiator and clean if necessary. Refer
Radiator core is internally obstructed or damaged, ............
or the check valve or J-tube is malfunctioning
OK
Go To Next Step
STEP 19
Inspect the check valve. Replace if necessary.
Check valve is damaged (with remote-mounted ............
engine coolant heater)
OK
Go To Next Step
STEP 20
system
OK
Go To Next Step
STEP 21 Check the torque converter. Refer to the OEM
............
Torque converter is malfunctioning service manual.
OK
Go To Next Step
STEP 22 Verify that the engine and vehicle cooling systems

............ are using the correct components. Refer to the
Vehicle cooling system is not adequate
OEM service manual.
Coolant Temperature Above Normal - Sudden Overheat

Cause Correction
STEP 1 Inspect the engine and cooling system for external

............ coolant leaks. Repair if necessary. Add coolant.
Coolant level is below specification
OK
Go To Next Step
STEP 2 Troubleshooting and Repair Manual, Electronic
Control System, Signature, ISX and QSX15
Engines, Bulletin 3666259, or the Troubleshooting
and Repair Manual, Power Generation Control
Systems QSX15, QSK23, QSK45, QSK60, QSK78,
and QST30 Series Engines, Bulletin 4021419 for
fault code troubleshooting.
OK
Go To Next Step
STEP 3 Check the fan drive belt. Replace the belt, if
............
Fan drive belt is broken necessary. Refer to Procedure 008-002 or 008-003.
OK
Go To Next Step
............
OK
Go To Next Step
the shutterstat setting is wrong Procedure 008-049.
OK
Go To Next Step
STEP 6
leaking
OK
Go To Next Step
STEP 7
Procedure 008-047.
OK
Go To Next Step

008-013.
OK
Go To Next Step
Coolant Temperature Above Normal - Sudden Overheat

Cause Correction
STEP 9 Check the water pump for correct operation.

............ Replace the water pump if necessary. Refer to
Water pump is malfunctioning
Procedure 008-062.
OK
Go To Next Step
STEP 10
equipped)
OK
Go To Next Step
STEP 11
system
OK
Go To Next Step
STEP 12
Check the disc for correct installation. Refer to
Torque converter cooler disc is not installed ............
Procedure 008-062.
correctly
Coolant Temperature Below Normal

Cause Correction
Electronic fault codes active or high counts of ............ QSX15 Engines, Bulletin 3666259, or the
troubleshooting.
OK
Go To Next Step
Use an electronic service tool to check the coolant
temperature sensor circuit. Refer to Procedure
019-019 in the Troubleshooting and Repair
Manual, CM870 Electronic Control System,
Procedure 019-019 in the Troubleshooting and
Repair Manual, Electronic Control System,
STEP 2 Signature, ISX and QSX15 Engines, Bulletin
............ 3666259, or Procedure 019-019 in the
Coolant temperature sensor is malfunctioning
Troubleshooting and Repair Manual,
PowerCommand Control Version 3200 QSX15,
QSK45 and QSK60 Generator Sets, Bulletin
3666394, or Procedure 019-019 in the
Troubleshooting and Repair Manual, Power
Engines, Bulletin 4021419.
OK
Go To Next Step
STEP 3 Test the temperature gauge. Repair or replace the

............ gauge, if necessary. Refer to in the OEM service
Coolant temperature gauge is malfunctioning
manual.
OK
Go To Next Step
Check the winterfront, shutters, and under-the-
STEP 4 hood air. Use under-the-hood intake air in cold
............ weather. Refer to Cold Weather Operation, Bulletin
Engine is operating at low ambient temperature
3387266 and the correct Operation and
Maintenance manual.
OK
Go To Next Step
............
OK
Go To Next Step
Coolant Temperature Below Normal

Cause Correction
STEP 6 Check the routing of the coolant fill line. Refer to
............
Coolant fill line is not routed correctly the OEM service manual.
OK
Go To Next Step
STEP 7 Check the shutter operation. Repair or replace the

............ shutters if necessary. Refer to the OEM service
Radiator shutters are stuck open or opening early
manual and Procedure 008-049.
OK
Go To Next Step
STEP 8
equipped)
OK
Go To Next Step
STEP 9 Check the thermostat seal. Check the thermostat
Thermostat seal is damaged, missing, or not ............ for correct seating. Refer to Procedure 008-013 or
installed correctly 008-016.
OK
Go To Next Step

008-013.
OK
Go To Next Step
STEP 11 Check for correct coolant flow through the radiator.
............
Coolant flow through the radiator is not correct Refer to Procedure 008-042.
Coolant in the Lubricating Oil

Cause Correction
STEP 1 Check the EGR cooler for leaks. Refer to
............
EGR cooler leaking coolant Procedure 011-019 in Section 11.
OK
Go To Next Step
STEP 2 Replace the injector o-rings and install and torque

the injectors again to reseat the injector cups.
Injector Sleeve is leaking - even with no noticeable ............
Return the engine to operation. Refer to Procedure
defect to the injector o-rings
OK
Go To Next Step
For the first investigated instance of internal
STEP 3 coolant loss, perform the appropriate corrections
in the steps above and STOP. Return the engine
First investigated instance of coolant in the ............
to operation. For repeat instances, verify the
lubricating oil
completion of the steps above and continue to the
next steps.
OK
Go To Next Step
STEP 4 Check the lubricating oil cooler for coolant leaks.
............
Lubricating oil cooler is leaking Refer to Procedure 007-003 in Section 7.
OK
Go To Next Step
STEP 5
gasket. Refer to Procedure 012-003 in Section 12.
OK
Go To Next Step
............
Cylinder head gasket is leaking Procedure 002-004 in Section 2.
OK
Go To Next Step
STEP 7 Pressure test the cylinder head. Refer to
............
Cylinder head is cracked or porous Procedure 002-004 in Section 2.
OK
Go To Next Step
STEP 8 Refer to Cummins Inc. and request additional
............
Base engine problem technical assistance.
Crankcase Gases (Blowby) Excessive

Cause Correction
STEP 1 Check the turbocharger compressor and turbine
............
Turbocharger oil seal is leaking seals. Refer to Procedure 010-033.
OK
Go To Next Step
STEP 2 Isolate the air compressor by disconnecting the air

............ inlet and outlet lines. Refer to the OEM service
Air compressor is malfunctioning
manual.
OK
Go To Next Step
STEP 3 Check the valve guides for wear. Replace the

............ cylinder head if necessary. Refer to Procedure
Cylinder head valve guides are excessively worn
002-004.
OK
Go To Next Step
STEP 4 Check the rocker lever housing gasket. Refer to
............
Rocker lever housing gasket is leaking Procedure 003-011.
OK
Go To Next Step
STEP 5 Check for air intake system leaks. Refer to

Procedure 010-024. Check the pistons, piston
Piston, cylinder liner, or piston rings are worn or ............
rings, and liners for wear or damage. Refer to
damaged
Procedures 001-043, 001-047, or 001-028.
Crankcase Coalescing Filter - Frequent Replacement

Cause Correction
Review the engine's maintenance records to
STEP 1 determine if the crankcase breather filter
Filter miles or hours is at expected maintenance ............ replacement is at expected interval, based on
interval for replacement crankcase blowby. Replace the filter if it is
acceptable per the records.
OK
Go To Next Step
STEP 2 Check the oil level. Verify the dipstick calibration

............ and oil pan capacity. Fill the system to the specified
Lubricating oil level is above specification
level. Refer to Procedure 007-009 in Section 7.
OK
Go To Next Step
STEP 3 Check and clean the crankcase breather and vent
............
Crankcase ventilation system is plugged tube. Refer to Procedure 003-001 in Section 3.
OK
Go To Next Step
STEP 4 Analyze an oil sample for fuel dilution percentage,

............ coolant in oil, and foreign contamination. Repair
Lubricating oil is contaminated
the source of contamination.
OK
Go To Next Step
STEP 5 Refer to Crankcase Gases (Blowby) Excessive
............
Engine Crankcase Gases (Blowby) excessive. Troubleshooting Symptom Tree.
Engine Brake Does Not Operate

Cause Correction
STEP 1
............ Turn on the switch.
Engine brake on/off switch is off
OK
Go To Next Step
Check the programmable parameters and the
STEP 2 selected features with an electronic service tool.
Programmable parameters or selected features ............ Set the parameters and features again, if
are not correct necessary. Refer to the electronic service tool
manual.
OK
Go To Next Step
Signature and ISX Engines, Bulletin 4021334.
Refer to the Troubleshooting and Repair Manual
STEP 3 Electronic Control System Signature, ISX and
Electronic fault codes active or high counts of ............ QSX15 Engines, Bulletin 3666259, for fault code
inactive fault codes troubleshooting. Refer to the Troubleshooting and
Repair Manual, Power Generation Control
and QST30 Series Engines, Bulletin 4021419, for
OK
Go To Next Step
Check the engine brake on/off switch and circuit.
Refer to Procedures 019-034 and 019-035 in
Section 19 in the Troubleshooting and Repair
STEP 4 Signature and ISX Engines, Bulletin 4021334.
Engine brake on/off switch or circuit is ............ Refer to Procedures 019-034 and 019-035 in
malfunctioning Section 19 in the Troubleshooting and Repair
Manual Electronic Control System Signature, ISX
and QSX15 Engines, Bulletin 3666259. Refer to
Procedure 020-012 in Section 20. Refer to
OK
Go To Next Step
Check the engine brake circuit, solenoid, and
harness connectors. Check the engine brake
harness, solenoids, and grounding for continuity.
STEP 5 Refer to Procedure 019-136 in Section 19 in the
Engine brake solenoid, harness or connectors are ............ ISX and ISM CM871 and CM876 Electronic Control
loose, broken or have an open circuit Systems Troubleshooting and Repair Manual,
Bulletin 4021560. Refer to Procedure 020-004 in
Section 20. Refer to Procedure 020-012 in Section
20. Refer to Procedure 020-015 in Section 20..
OK
Go To Next Step

Cause Correction
Check the clutch switch adjustment, switch, and
circuit. Refer to Procedures 019-009 or 019-010 in
STEP 6 Manual, CM870 Electronic Control System,
............ Signature and ISX Engines, Bulletin 4021334.
Clutch switch or circuit is malfunctioning
Refer to Procedures 019-009 or 019-010 in Section
19 in the Troubleshooting and Repair Manual
Electronic Control System Signature, ISX and
QSX15 Engines, Bulletin 3666259.
OK
Go To Next Step
Check for foot pedal restriction. Check the
accelerator pedal or lever position sensor and
circuit. Refer to Procedures 019-085 and 019-086
STEP 7 in Section 19 in the Troubleshooting and Repair
Accelerator pedal or lever position sensor or circuit ............ Manual, CM870 Electronic Control System,
is malfunctioning Signature and ISX Engines, Bulletin 4021334.
Refer to Procedures 019-085 and 019-086 in
Section 19 in the ISX Fuel System Troubleshooting
and Repair Manual, Bulletin 3666259.
OK
Go To Next Step
STEP 8
Check the service brake pressure switch and
Service brake pressure switch or circuit is ............
circuit. Refer to the OEM service manual.
malfunctioning
OK
Go To Next Step
Check for poor battery and chassis grounds.
Check ground wires or cables for loose
connections. Check the following grounds, make
STEP 9 sure they are secure, clean, and on a non-painted
............
Engine electrical ground is malfunctioning surface: engine block ground, chassis (or frame
rail) grounds, ECM grounds, alternator and starter
negative posts. Disconnect and clean battery cable
connections.
OK
Go To Next Step
Check the engine brake control valve and the
STEP 10 engine brake piston. Refer to Procedure 020-017
............
Lubricating oil leak (internal) in Section 20. Refer to Procedure 020-019 in
Section 20.
OK
Go To Next Step
STEP 11 Check the engine brake assembly for restriction.
............
Engine brake lubricating oil passage is restricted Refer to Procedure 020-004 in Section 20.
OK
Go To Next Step

Cause Correction
STEP 12 Adjust the engine brakes. Refer to Procedure
............
Engine brake adjustment is not correct 020-004 in Section 20.
Engine Brake - Low Retarding Power or Slow to Activate

Cause Correction
Refer to Driveability-General Information, the
STEP 1 Driveability/Low-Power Customer Complaint Form,
............ and the Driveability Checklist at the end of Section
Interview the operator to verify the complaint
TS. Follow the instructions on the forms before
continuing with this tree.
OK
Go To Next Step
Control System Signature, ISX, and QSX15
Engines Bulletin 3666259, or Troubleshooting and
and QST30 Engines, Bulletin 4021419 for fault
code troubleshooting.
OK
Go To Next Step
Programmable parameters or selected features ............ Set the parameters and features again, if
manual.
OK
Go To Next Step
Allow the engine to warm to operating temperature.
STEP 4 If the engine will not reach operating temperature,
............
Engine is cold refer to the Coolant Temperature Below Normal
symptom tree in Section TS.
OK
Go To Next Step
............
Engine brake adjustment is not correct 020-004 in Section 20.
OK
Go To Next Step

Cause Correction
Refer to Procedure 019-034 in Section 19.
Procedure 019-035 in Section 19. These
procedures are found in the Signature and ISX
CM870 Electronic Control System,
STEP 6 Troubleshooting and Repair Manual, Bulletin
Engine brake on/off switch or circuit is ............ 4021334. Procedure 019-034 in Section 19.
malfunctioning Procedure 019-035 in Section 19. These
procedures are found in the Signature, ISX and
QSX15 Electronic Control System,
3666259. Procedure 020-012 in Section 20.
OK
Go To Next Step
Check the engine brake circuit, solenoid, and
harness connectors. Check the engine brake
harness, solenoids, and grounding for continuity.
STEP 7 Refer to Procedure 019-136 in Section 19. This
procedure is found in the ISX and ISM CM871 and
Engine brake solenoid, harness or connectors are ............
CM876 Electronic Control Systems
loose, broken or have an open circuit
Troubleshooting and Repair Manual Bulletin
Procedure 020-012 in Section 20. Procedure
OK
Go To Next Step
Check for poor battery and chassis grounds.
Check ground wires or cables for loose
connections. Check the following grounds, make
STEP 8 sure they are secure, clean, and on a non-painted
............
Engine electrical ground is malfunctioning surface: engine block ground, chassis (or frame
rail) grounds, ECM grounds, alternator and starter
negative posts. Disconnect and clean battery cable
connections.
OK
Go To Next Step
STEP 9 Check the oil level. If the level is high, contact a
............
Air in the lubricating oil system Cummins Authorized Repair Location.
OK
Go To Next Step
STEP 10 Check the engine brake control valve and the

............ engine brake piston. Refer to Procedure 020-017
Lubricating oil leak (internal)
in Section 20 and Procedure 020-019 in Section 20.
OK
Go To Next Step

Cause Correction
STEP 11
............ Refer to Procedure 020-012 in Section 20.
Engine brake solenoid(s) is malfunctioning
OK
Go To Next Step
STEP 12 Check the engine brake control valve(s). Replace

............ the engine brake control valve(s) if necessary.
Engine brake control valve(s) is malfunctioning
OK
Go To Next Step
STEP 13 Check the engine brake assembly for restriction.
............
Engine brake lubricating oil passage is restricted Refer to Procedure 020-004 in Section 20.
OK
Go To Next Step
Perform diagnostics to determine if the
turbocharger has failed. Replace the turbocharger
STEP 14 as necessary. Refer to Bulletin 4021334, for ISX
............
Turbocharger is malfunctioning CM870, Section TT, 70-t02-1001, Guided Step 6.
For ISX CM871 refer to Bulletin 4021560, Section
TT, 16-t02-1001a, Guided Step 6.
Engine Brake One or More Cylinders Braking with Power Switch Off
Cause Correction
Troubleshooting and Repair Manual, Electronic
STEP 1 Control System, Signature, ISX and QSX15
Electronic fault codes active or high counts of ............ Engines, Bulletin 3666259, or Section TF in the
troubleshooting.
OK
Go To Next Step
Check the engine brake enable circuit. Refer to
STEP 2 Signature and ISX Engines, Bulletin 4021334, or
............
Engine brake enable circuit is malfunctioning Procedure 019-034 in the Troubleshooting and
Signature, ISX and QSX15 Engines, Bulletin
3666259.
OK
Go To Next Step
Refer to Procedures 019-034 and 019-035 in the
STEP 3 Troubleshooting and Repair Manual, CM870
Electronic Control System, Signature and ISX
Engine brake on/off switch or circuit is ............
Engines, Bulletin 4021334, or Procedures 019-034
malfunctioning
and 019-035 in the Troubleshooting and Repair
Manual, Electronic Control System, Signature, ISX
and QSX15 Engines, Bulletin 3666259.
OK
Go To Next Step
............
Engine brake adjustment is not correct 020-004.
OK
Go To Next Step
STEP 5 Remove the solenoid valve and inspect the top and
............ bottom o-rings. Replace the o-rings if necessary.
Solenoid valve o-ring seals are leaking
Procedure 020-004
OK
Go To Next Step
STEP 6 Check for voltage at the solenoid valve. Refer to
............
Solenoid valve is malfunctioning Procedure 020-012.
OK
Go To Next Step
Engine Brake One or More Cylinders Braking with Power Switch Off
Cause Correction
STEP 7 Replace the solenoid valve. Refer to Procedure
............
Solenoid valve is stuck in the on position 020-012.
Engine Decelerates Slowly

Cause Correction
Bulletin 4021334, or Troubleshooting and Repair
STEP 1 Manual, Electronic Control System, Signature, ISX
and QSX15 Engines, Bulletin 3666259, or Section
TF in the Troubleshooting and Repair Manual,
Power Generation Control Systems QSX15,
QSK23, QSK45, QSK60, QSK78, and QST30
Series Engines, Bulletin 4021419 for fault code
troubleshooting.
OK
Go To Next Step
Check the percent accelerator pedal or lever
reading on an electronic service tool. Verify that it
STEP 2 reads 100 percent with the accelerator pedal
Accelerator pedal or lever is restricted or ............ depressed and 0 percent when released. Calibrate
malfunctioning the accelerator if possible. Replace the accelerator
pedal if necessary. Refer to the OEM service
manual.
OK
Go To Next Step
STEP 3 Check for air in the fuel system. Refer to Procedure
............
Air in the fuel system 006-003.
OK
Go To Next Step
STEP 4 Remove and check the injectors. Replace the
............
Injector o-rings are damaged or missing injector o-rings. Refer to Procedure 006-026.
OK
Go To Next Step
STEP 5 Perform the automated cylinder performance test.

............ Replace injectors as necessary. Refer to
Injector is malfunctioning
Procedure 006-026 or 014-008.
OK
Go To Next Step
............
Engine Noise Excessive

When troubleshooting engine noise complaints, make sure the engine accessories (air compressor, fan clutch,
refrigerant compressor, or hydraulic pump) are not the cause of the noise. Refer to Engine Noise Diagnostic
Procedures - General Information at the end of Section TS before using this symptom tree.
Cause Correction
OK
Go To Next Step
STEP 2 Inspect the air intake and exhaust systems for air
............
Air intake or exhaust leaks leaks. Refer to Procedure 010-024 in Section 10.
OK
Go To Next Step
Signature and ISX Engines, Bulletin 4021334,or
Electronic fault codes active or high counts of ............ QSX15 Engines, Bulletin 3666259,or
Generation Control Systems, QSX15, QSK23,
QSK45, QSK60, QSK78 and QST30 Series
troubleshooting.
OK
Go To Next Step
Check the oil level. Verify the dipstick calibration
STEP 4 and the oil pan capacity. Fill the system to the
............
Lubricating oil level is below specification specified level. Refer to Procedures 007-009 and
OK
Go To Next Step
STEP 5
Isolate each component and check for noise. Refer
Fan clutch, hydraulic pump, or refrigerant ............
to the OEM service manual.
compressor noise is excessive
OK
Go To Next Step
STEP 6 Check the fan. Refer to Procedure 008-040 in
............
Fan is loose, damaged, or not balanced Section 8.
OK
Go To Next Step
STEP 7 Inspect the air piping, chassis, and cab for contact
Air intake or exhaust piping is contacting the ............ points. Refer to Procedure 010-031 in Section 10
chassis or cab or Procedure 010-080 in Section 10.
OK
Go To Next Step

Cause Correction
STEP 8 Verify the condition of the mounts. Refer to
Engine mounts are worn, damaged, loose, or not ............ Procedure 016-010 in Section 16. Refer to the OEM
correct service manual.
OK
Go To Next Step
STEP 9 Refer to the Engine Noise Excessive -
............
Turbocharger noise Turbocharger symptom tree.
OK
Go To Next Step
Remove the vibration damper and operate the
STEP 10 engine at the rpm where the noise normally occurs.
............ If the noise is still present, proceed to the next step.
Vibration damper has failed
If the noise is eliminated, replace the vibration
damper. Refer to Procedure 001-052 in Section 1.
OK
Go To Next Step
STEP 11 Disconnect the drivetrain. Check for engine noise.
............
Drivetrain noise is excessive Refer to the OEM service manual.
OK
Go To Next Step
STEP 12 Refer to the Air Compressor Noise Is Excessive
............
Air compressor noise is excessive symptom tree.
OK
Go To Next Step
STEP 13 Measure and adjust the overhead settings. Refer
............
Overhead adjustments are not correct to Procedure 003-004 in Section 3.
OK
Go To Next Step
STEP 14 Inspect the rocker levers, rocker shafts, and valves

............ for damage or excessive wear. Refer to Procedure
Overhead components are damaged
OK
Go To Next Step
STEP 15 Perform the single-cylinder cutout test. Replace

............ the injectors as necessary. Refer to Procedure
OK
Go To Next Step

Cause Correction
STEP 16 Check the flywheel. Refer to Procedure 016-005 in
............
Flywheel is loose or damaged Section 16.
OK
Go To Next Step
STEP 17 Check the gear backlash and the gear teeth for
Gear train backlash is excessive or the gear teeth ............ excessive wear. Refer to Procedure 001-088 in
are damaged Section 1 and Procedure 007-031 in Section 7.
OK
Go To Next Step
STEP 18 Refer to the Engine Noise Excessive - Main

............ Bearing or Engine Noise Excessive - Connecting
Main bearing or connecting rod bearing noise
Rod symptom trees.
OK
Go To Next Step
STEP 19
Refer to the Engine Noise Excessive - Piston
Piston, piston rings, or cylinder liner is worn or ............
symptom tree.
damaged
OK
Go To Next Step
STEP 20
Disassemble and repair the REPTO as necessary.
Rear engine power take-off (REPTO) noise is ............
excessive
OK
Go To Next Step
STEP 21 Refer to the Engine Noise Excessive - Combustion
............
Combustion knocks Knocks symptom tree.
OK
Go To Next Step
STEP 22 Analyze the oil and inspect the filters to locate an

............ area of probable damage. Refer to Procedure
Internal engine damage
Engine Noise Excessive Combustion Knocks

Cause Correction
Check the winterfront, shutters, and under-the-
STEP 1 hood air. Use under-the-hood intake air in cold
............
Engine is operating at low ambient temperature weather. Refer to Cold Weather Operation, Bulletin
3387266.
OK
Go To Next Step
STEP 2 Repair or replace the ether starting aids. Refer to
............
Ether starting aid is malfunctioning the OEM service manual.
OK
Go To Next Step
Operate the engine from a tank of high-quality fuel.
Refer to Procedure 018-002 (Fuel
STEP 3 Recommendations and Specifications) in Section
V of the Operation and Maintenance Manual,
Fuel grade is not correct for the application or the ............
Signature and ISX, Bulletin 3666251 or the
fuel quality is poor
Operation and Maintenance Manual, Industrial and
Power Generation, QSX15 Engines, Bulletin
3666423.
OK
Go To Next Step
STEP 4 Check for air in the fuel system. Refer to Procedure
............
Air in the fuel system 006-003 (Air in Fuel) in Section 6.
OK
Go To Next Step
Remove the vibration damper and operate the
engine at the rpm where the noise normally occurs.
STEP 5 If noise is still present, proceed to the next step. If
............
Vibration damper has failed the noise is eliminated, replace the vibration
damper. Refer to Procedure 001-052 (Vibration
Damper, Viscous) in Section 1.
OK
Go To Next Step
STEP 6 Refer to the Coolant Temperature Below Normal
............
Coolant temperature is below specification symptom tree.
OK
Go To Next Step

006-026 (Injector) in Section 6.
OK
Go To Next Step
............
Overhead adjustments are not correct to Procedure 003-004 (Overhead Set) in Section 3.
Engine Noise Excessive Connecting Rod

Refer to Engine Noise Diagnostic Procedures General Information at the end of this section before using this
symptom tree.
Cause Correction
OK
Go To Next Step
Control System, Signature, ISX and QSX Engines,
Bulletin 3666259, or Troubleshooting and Repair
Manual, Power Generation Control Systems
QSX15, QSK23, QSK45, QSK60, QSK78, and
QST30 Series Engines, Bulletin 4021419 for fault
OK
Go To Next Step
............
Lubricating oil level is below specification specified level. Refer to Procedures 007-009 and
007-037.
OK
Go To Next Step
STEP 4 Check the oil pressure. If the pressure is low, refer
............
Lubricating oil pressure is below specification toProcedure 007-028.
OK
Go To Next Step

007-083.
OK
Go To Next Step
STEP 6
Check the torque on the connecting rod
Connecting rod capscrews are loose or not ............
capscrews. Refer to Procedure 001-014.
tightened correctly
OK
Go To Next Step
STEP 7
Inspect the connecting rod bearings. Refer to
Connecting rod bearings are damaged or worn, are ............
Procedure 001-005.
not assembled correctly, or are the wrong bearings
Engine Noise Excessive Main Bearing

symptom tree.
Cause Correction
OK
Go To Next Step
Refer to Section TF Section TF in the
Troubleshooting and Repair Manual, CM870
STEP 2 and Repair Manual Electronic Control System
Electronic fault codes active or high counts of ............ Signature ISX and QSX15 Engines, Bulletin
inactive fault codes 3666259, or the Troubleshooting and Repair
QST30 Series Engines, Bulletin 4021419 for fault
OK
Go To Next Step
............
Lubricating oil level is below specification specified level. Refer to Procedure 007-009 and
007-037.
OK
Go To Next Step
STEP 4 Check the oil pressure. If the pressure is low, refer
............
Lubricating oil pressure is below specification to Procedure 007-028.
OK
Go To Next Step
STEP 5
............ Check the flywheel. Refer to Procedure 016-005.
Flywheel is loose or damaged
OK
Go To Next Step
STEP 6 Check the torque converter. Refer to the OEM
............
Torque converter is loose service manual.
OK
Go To Next Step
STEP 7 Check the torque on the main bearing capscrews.
Main bearing capscrews are loose, worn or not ............ Inspect the capscrews for wear. Refer to
tightened correctly Procedure 001-006.
OK
Go To Next Step
Engine Noise Excessive Main Bearing

symptom tree.
Cause Correction
STEP 8 Inspect the main bearings for damage, excessive
Main bearings are damaged or worn, or the wrong ............ wear, and the correct part number. Refer to
bearings are installed Procedure 001-006.
OK
Go To Next Step
STEP 9 Inspect the thrust bearing for damage. Refer to
............
Thrust bearings are damaged Procedure 001-007.
OK
Go To Next Step

007-013.
Engine Noise Excessive Piston

symptom tree.
Cause Correction
STEP 1 Refer to Procedure 018-002 in the Operation and
Maintenance Manual, Signature and ISX Engines,
Bulletin 3666251, and the Operation and
Maintenance Manual, Industrial and Power
Generation, QSX15 Engines, Bulletin 3666423.
OK
Go To Next Step

006-026.
OK
Go To Next Step
STEP 3 Remove the pistons and inspect the piston pin and
Piston pin or bushing is loose, worn, or not ............ bushing for damage, wear, and correct installation.
installed correctly Refer to Procedure 001-043.
OK
Go To Next Step
STEP 4 Check the pistons, piston rings, and cylinder liner.
Cylinder liner, pistons, or piston rings are worn or ............ Refer to Procedures 001-043, 001-047, and
damaged 001-028.
Engine Noise Excessive Turbocharger

symptom tree.
Cause Correction
Inspect the air piping, chassis, and cab for contact
points. Refer to Procedure 010-058 in the
STEP 1 Operation and Maintenance Manual, Signature
Air intake or exhaust piping is contacting the ............ and ISX Engines, Bulletin 3666251 and the
chassis or cab Operation and Maintenance Manual, Industrial and
3666423.
OK
Go To Next Step
............
Air intake or exhaust leaks leaks. Refer to Procedure 010-024.
OK
Go To Next Step
STEP 3 Inspect the air intake system for restriction. Clean

............ or replace filter and inlet piping as necessary.
Air intake system restriction is above specification
OK
Go To Next Step
STEP 4 Check the exhaust system for any restrictions.
............
Exhaust system restriction Refer to Procedure 011-009.
OK
Go To Next Step
Check the turbocharger for damage. Measure the
STEP 5 turbine and compressor wheel clearances. Refer
............ to Procedure 010-033. Perform the EGR/VGT
Turbocharger is worn or damaged
Operation Test. Perform the Turbocharger
Actuator Test.
OK
Go To Next Step
Check the turbocharger part number and compare
STEP 6 it to the Control Parts List (CPL), Bulletin 3379133
............
Turbocharger is not correct or 4021327. Replace the turbocharger if
necessary. Refer to Procedure 010-033.
Engine Shuts Off Unexpectedly or Dies During Deceleration

Cause Correction
STEP 1 the Troubleshooting and Repair Manual Electronic
Electronic fault codes active or high counts of ............ Control System Signature, ISX and QSX15
inactive fault codes Engines, Bulletin 3666259, or the Troubleshooting
and QST30 Series Engines, Bulletin 4021419.
OK
Go To Next Step
STEP 2 Check the time limit on idle and PTO shutdowns
Idle shutdown or PTO shutdown features are ............ with an electronic service tool. Refer to the
activated electronic service tool manual.
OK
Go To Next Step
STEP 3 Refer to the Engine Performance TT tree in this
............
Engine will not restart manual.
OK
Go To Next Step
View the fault codes and the engine protection data
with an electronic service tool. Refer to the
appropriate electronic service tool manual. Refer
to the corresponding fault code in Section TF
Section TF in the Troubleshooting and Repair
............ Signature and ISX Engines, Bulletin 4021334, or
Engine protection fault code(s) inactive
the Troubleshooting and Repair Manual Electronic
Control System Signature, ISX and QSX15
OK
Go To Next Step
Check the vehicle keyswitch circuit. Refer to
............
Keyswitch circuit is malfunctioning Procedure 019-064in the Troubleshooting and
Repair Manual Electronic Control System,
3666259.
OK
Go To Next Step
STEP 6 Check for fuel inlet restriction. Refer to Procedure
............
Fuel inlet restriction 006-020.
OK
Go To Next Step
Engine Shuts Off Unexpectedly or Dies During Deceleration

Cause Correction
STEP 7 Bleed the fuel system and correct source of the
............
Air in fuel system leak. Refer to Procedure 006-003.
OK
Go To Next Step
STEP 8 Check the engine brake operation, adjustment,

............ and solenoid resistance. Repair or adjust as
Engine brakes are malfunctioning
OK
Go To Next Step
............
Injector o-rings are damaged or missing injector o-rings. Refer to Procedure 006-026.
Engine Speed Surges in PTO or Cruise Control

Cause Correction
STEP 1 the Troubleshooting and Repair Manual Electronic
Electronic fault codes active or high counts of ............ Control System Signature, ISX and QSX15
inactive fault codes Engines, Bulletin 3666259, or Troubleshooting and
OK
Go To Next Step
Check the cruise control/PTO on/off switch and the
circuit. Refer to Procedures 019-021 and 019-022
in Section 19 in the Troubleshooting and Repair
Cruise control/PTO on/off switch or circuit is ............ Signature and ISX Engines, Bulletin 4021334, or
malfunctioning Procedures 019-021 and 019-022 in Section 19 in
the Troubleshooting and Repair Manual Electronic
Control System Signature, ISX and QSX15
OK
Go To Next Step
Verify the ECM calibration is correct. Check the
calibration revision history for applicable fixes to
the calibration stored in the ECM. Refer to the
calibration history spreadsheet
ecm_calibration_rev_history.xlson QuickServe
Online or the INCAL CD-ROM. Compare the
calibration stored in the ECM with the engine rating
and Control Parts List (CPL), Bulletin 4021326 or
STEP 3 4021327. If necessary, calibrate the ECM. Refer to
Electronic control module (ECM) calibration is ............ Procedure 019-032 in Section 19 in the
malfunctioning Troubleshooting and Repair Manual, CM870
Engines, Bulletin 4021334, or ISX Fuel System
3666259, or Procedure 019-032 in Section 19 in
OK
Go To Next Step
Engine Speed Surges in PTO or Cruise Control

Cause Correction
Check the Performance Options of the calibration
stored in the electronic control module (ECM). Use
INSITE electronic service tool and INCAL
STEP 4 Calibration DVD_ROM to check the Performance
Options section for the specific calibration under
Engine is operating in a unique application with a ............
Calibration Selection. If the Performance Option
specific calibration
reads Vacuum Truck, the condition may be
normal. A slight oscillation/surging of the engine
speed during unloaded PTO is a normal
consequence of these unique calibrations.
OK
Go To Next Step
Check the engine position sensor and circuit. Refer
to Procedure 019-363 in Section 19 in the
Engines, Bulletin 4021334, or Procedure 019-038
Engine position sensor (EPS) or circuit is ............ Manual Electronic Control System Signature, ISX
malfunctioning and QSX15 Engines Bulletin 3666259, or
Procedure 019-038 in Section 19 in the
OK
Go To Next Step
STEP 6
Refer to the Engine Performance Troubleshooting
Engine speed surges while in the normal operating ............
Tree in Section TT.
range and not in PTO or cruise control
OK
Go To Next Step
STEP 7 Dry the connectors with Cummins electronic
............
Moisture in the wiring harness connectors cleaner, Part Number 3824510.
OK
Go To Next Step
STEP 8 Refer to the Engine Performance Troubleshooting
............
Engine speed also surges at idle Tree in Section TT.
Engine Starts But Will Not Keep Running

Cause Correction
Also, refer to Section TF in the Troubleshooting
STEP 1 and Repair Manual, Electronic Control System,
Signature, ISX and QSX Engines, Bulletin
3666259. Also, refer to Section TF in the
Engines, Bulletin 4021419, for fault code
troubleshooting.
OK
Go To Next Step
STEP 2 Turn OFF the keyswitch for 5 seconds. Turn ON

the keyswitch and check fault lamp operation. Use
Idle shutdown or PTO shutdown features are ............
INSITE electronic service tool to check Idle
activated
Shutdown and PTO parameters.
OK
Go To Next Step
STEP 3 Fill the supply tank. Refer to the OEM service
............
Fuel level is low in the tank manual.
OK
Go To Next Step
Check the batteries and the unswitched battery
supply circuit. Refer to Procedure 019-087
(Unswitched Battery Supply Circuit) in Section 19
in the Troubleshooting and Repair Manual, CM870
Engines, Bulletin 4021334. Also, refer to
Procedure 019-087 (Unswitched Battery Supply
STEP 4 Circuit) in Section 19 in the Troubleshooting and
............
Battery voltage is low Repair Manual, Electronic Control System,
Signature, ISX and QSX Engines, Bulletin
3666259. Also, refer to Procedure 019-087
(Unswitched Battery Supply Circuit) in Section 19
in the Troubleshooting and Repair Manual, Power
OK
Go To Next Step
STEP 5 Check for fuel inlet restriction. Refer to Procedure
............
Fuel inlet restriction 006-020 (Fuel Inlet Restriction) in Section 6.
OK
Go To Next Step

Cause Correction
STEP 6 Bleed the fuel system and correct source of the

............ leak. Refer to Procedure 006-003 (Air in Fuel) in
Air in fuel system
Section 6.
OK
Go To Next Step
Check the vehicle keyswitch circuit. Refer to
Procedure 019-064 (Key Switch Battery Supply
Circuit) in Section 19 in the Troubleshooting and
STEP 7 Signature and ISX Engines, Bulletin 4021334.
............
Keyswitch circuit is malfunctioning Also, refer to Procedure 019-064 (Key Switch
Battery Supply Circuit) in Section 19 in the
Control System, Signature, ISX and QSX Engines,
Bulletin 3666259, for fault code troubleshooting.
OK
Go To Next Step
Check the fuel shutoff valve and circuit. Refer to
Procedures 019-049 (Fuel Shutoff Valve Circuit) in
Section 19 and 019-050 (Fuel Shutoff Valve
Solenoid) in Section 19 in the Troubleshooting and
Also, refer to Procedure 019-049 (Fuel Shutoff
Valve Circuit) in Section 19. Also, refer to
Procedure 019-050 (Fuel Shutoff Valve Solenoid)
Fuel shutoff valve(s) closed (electronically ............
and QSX Engines, Bulletin 3666259. Also, refer to
controlled injection)
and QST30 Series Engines, Bulletin 4021419, for
fault code troubleshooting. Also, refer to Procedure
QST30 Series Engines, Bulletin 4021419, for fault
OK
Go To Next Step
Refer to Fuel Recommendations and
STEP 9 Specifications in the Operation and Maintenance
Manual, Signature and ISX Engines, Bulletin
3666251. Also, refer to Fuel Recommendations
and Specifications in the Operation and
OK
Go To Next Step

Cause Correction
STEP 10 Check for transmission malfunctioning, cooling fan

............ operation cycle time, and engine-driven units.
Vehicle parasitics are excessive
Engine Will Not Crank or Cranks Slowly (Air Starter)

Cause Correction
STEP 1 Increase air pressure with an external air source.
............
Air pressure is low in the air tanks Refer to the OEM service manual.
OK
Go To Next Step
STEP 2
............ Disengage engine-driven units.
Engine-driven units are engaged
OK
Go To Next Step
Change the oil and filters. Refer to Procedure
018-003 in the Operation and Maintenance
STEP 3 Manual, Signature and ISX Engines, Bulletin
3666251 and 018-003 in the Operation and
Lubricating oil does not meet specifications for ............
operating conditions
Use the oil type recommended in Section V of the
engine operation and maintenance manual.
OK
Go To Next Step
STEP 4 Check the starting motor operation. Compare the
Starting motor is malfunctioning or starting motor ............ starting motor with the engine and vehicle
is not correct specifications. Refer to the OEM service manual.
OK
Go To Next Step
STEP 5 Remove the starting motor, and inspect the gear.

............ Refer to Procedure 013-020, 016-005, and the
Starting motor pinion or ring gear is damaged
OEM service manual.
OK
Go To Next Step
STEP 6 Check the crankshaft for ease of rotation. Refer to
............
Crankshaft rotation is impaired Procedure 001-016.
OK
Go To Next Step
STEP 7 Remove the injectors and rotate the crankshaft.

............ Look for the source of fluid in the cylinder. Refer to
Hydraulic lock in a cylinder
Procedures 006-026 and Procedure 001-016.
OK
Go To Next Step
Analyze the oil and inspect the filters to locate an
area of probable damage. Refer to Procedure
STEP 8 018-003 in the in the Operation and Maintenance
............ Manual, Signature and ISX Engines, Bulletin
3666251 and 018-003 in the Operation and
Engine Will Not Crank or Cranks Slowly (Electric Starter)

Cause Correction
Check the batteries and the unswitched battery
supply circuit. Refer to Procedure 013-009 in this
manual and Procedure 019-087 in the
STEP 1 Engines, Bulletin 4021334, or Procedure 019-087
............ in the Troubleshooting and Repair Manual,
Battery voltage is low
Electronic Control System, Signature, ISX and
QSX15 Engines, Bulletin 3666259, or Procedure
019-087 Troubleshooting and Repair Manual,
Series Engines, Bulletin 4021419.
OK
Go To Next Step
STEP 2
Check the battery cables and connections. Refer
Battery cables or connections are loose, broken, or ............
corroded (excessive resistance)
OK
Go To Next Step
STEP 3
............ Disengage engine-driven units.
Engine-driven units are engaged
OK
Go To Next Step
STEP 4 Manual, Industrial and Power Generation, QSX15
Engines, Bulletin 3666423 or 018-003 in the
Operation and Maintenance Manual, Signature
and ISX Engines, Bulletin 3666251. Use the oil
type recommended in Section V of the operation
and maintenance manual.
OK
Go To Next Step
STEP 5 Refer to Procedure 018-021. Replace the batteries
............
Battery capacity is below specification if necessary.
OK
Go To Next Step
STEP 6 Check the battery heater. Refer to the
............
Batteries are cold manufacturer's instructions.
OK
Go To Next Step
STEP 7 Check the starting circuit components. Refer to the
............
Starting circuit component is malfunctioning OEM service manual.
OK
Go To Next Step
Engine Will Not Crank or Cranks Slowly (Electric Starter)

Cause Correction
STEP 8 Remove the starting motor, and inspect the gear.

............ Refer to Procedure 013-020, 016-005, and the
Starting motor pinion or ring gear is damaged
OEM service manual.
OK
Go To Next Step
STEP 9 Check the crankshaft for ease of rotation. Refer to
............
Crankshaft rotation is impaired Procedure 001-016.
OK
Go To Next Step
STEP 10 Remove the injectors and rotate the crankshaft.

............ Look for the source of fluid in the cylinder. Refer to
Hydraulic lock in a cylinder
Procedures 006-026 and 001-016.
OK
Go To Next Step
Analyze the oil and inspect the filters to locate an
area of probable damage. Refer to Procedure
Manual, Industrial and Power Generation, QSX15
STEP 11 Engines, Bulletin 3666423 or 018-003 in the
............
Internal engine damage Operation and Maintenance Manual, Signature
and ISX Engines, Bulletin 3666251. Remove the oil
pan and inspect for damaged camshaft, cam
followers, push rods, pistons and liners. Refer to
Procedure 007-025.
Engine Will Not Shut Off

Cause Correction
STEP 1 the Troubleshooting and Repair Manual,
QSX Engines, Bulletin 3666259, or the
OK
Go To Next Step
Check the vehicle, equipment, or vessel keyswitch
circuit. Refer to Procedure 019-064 in the
STEP 2 Electronic Control System, Signature and ISX
............
Keyswitch circuit is malfunctioning Engines, Bulletin 4021334, or Procedure 019-064
in the Troubleshooting and Repair Manual,
QSX Engines, Bulletin 3666259.
OK
Go To Next Step
STEP 3
Fuel shutoff valve (FSOV) solenoid or circuit is
............ Check the fuel shutoff valve solenoid and circuit.
malfunctioning (electronically controlled fuel
systems)
OK
Go To Next Step
STEP 4 Perform the automated cylinder performance test.

............ Replace injectors as necessary. Refer to
Procedure 006-026.
OK
Go To Next Step
STEP 5 Check the air intake ducts. Locate and isolate the
Engine is running on fumes drawn into the air ............ source of the fumes. Repair as necessary. Refer to
intake the OEM service manual.
OK
Go To Next Step
............
Fuel Consumption Excessive

Cause Correction
Refer to Fuel Consumption General Information
STEP 1 and Customer Complaint Form in Procedure
............ t00-004 (Troubleshooting Overview) at the end of
this section. Follow the instructions on the form
before continuing with this tree.
OK
Go To Next Step
Explain correct engine operation to the operator.
Refer to Procedure 101-015 the Operation and
STEP 2 Maintenance Manual, Signature and ISX Engines,
............
Operator technique is not correct Bulletin 3666251 or 101-015 Operation and
OK
Go To Next Step
Review the VE/VMS data and compare to the
STEP 3 vehicle and engine specifications. Do not use
............
VE/VMS analysis uses incorrect data more than 20 percent for the Aero value. Refer to
the VE/VMS User's Manual.
OK
Go To Next Step
STEP 4 Consider ambient temperatures, wind, tire size,
Equipment and environmental factors are affecting ............ axle alignment, routes, and use of aerodynamic
fuel consumption aids when evaluating fuel consumption.
OK
Go To Next Step
STEP 5 Check for correct gearing and drivetrain
............
Drivetrain is not correctly matched to the engine components. Refer to the OEM service manual.
OK
Go To Next Step
Refer to Section TF or the Troubleshooting and
STEP 6 Signature, ISX and QSX Engines, Bulletin
Electronic fault codes active or high counts of ............ 3666259, or the Troubleshooting and Repair
inactive fault codes Manual, Power Generation Control Systems
QST30 Series Engines, Bulletin 4021419.
OK
Go To Next Step
Programmable parameters or selected features ............ Set the parameters and features again if
manual.
OK
Go To Next Step

Cause Correction
............ or 4021327. Replace the turbocharger if
Turbocharger is not correct
necessary. Refer to Procedure 010-033
(Turbocharger) in Section 10.
OK
Go To Next Step
STEP 9 Check the fuel lines, fuel connections, and fuel

............ filters for leaks. Check the fuel lines to the supply
Fuel leak
tanks. Refer to the OEM service manual.
OK
Go To Next Step
Check the hubometer and odometer calibrations.
STEP 10 Calibrate or replace the hubometer or odometer, if
............
Hubometer or odometer is miscalibrated necessary. Calculate fuel consumption with new
mileage figures.
OK
Go To Next Step
STEP 11 Refer to Procedures 018-002 in the Operation and
Bulletin 3666251 or 018-002 Operation and
OK
Go To Next Step
STEP 12 and oil pan capacity. Fill the system to the specified
............ level. Refer to Procedures 007-009 (Lubricating Oil
Dipstick) in Section 7 and 007-037 (Lubricating Oil
System) in Section 7.
OK
Go To Next Step

Cause Correction
Verify the electronic control module (ECM)
calibration is correct. Check the calibration
revision history for applicable fixes to the
calibration stored in the ECM. Refer to the
Online Internet Website or the INCAL calibration
CD. Compare the calibration stored in the ECM
with the engine rating and the Control Parts List
STEP 13 (CPL), Bulletin 4021326 or 4021327. If necessary,
recalibrate the ECM. Refer to the appropriate
Electronic control module (ECM) calibration is ............
electronic service tool manual and Procedure
malfunctioning
Signature and ISX Engines, Bulletin 4021334, and
Engines, Bulletin 3666259, or 019-032 in the
OK
Go To Next Step
Use an electronic service tool to monitor the
vehicle speed while the vehicle is not moving.
Refer to the appropriate electronic service tool
manual. If necessary, install the correct VSS. Refer
STEP 14 to Procedure 019-091 in the Troubleshooting and
............ Repair Manual, CM870 Electronic Control System,
Vehicle speed sensor (VSS) is not correct
3666259.
OK
Go To Next Step
Check the vehicle speed sensor and circuit. Refer
to Procedures 019-090 and 019-091 in the
STEP 15 Troubleshooting and Repair Manual, CM870
Vehicle speed sensor (VSS) or circuit is ............
malfunctioning
and QSX15 Engines, Bulletin 3666259.
OK
Go To Next Step

Cause Correction
Check the vehicle speed sensor and circuit for
tampering. Check for Fault Code 242. Repair the
circuit as necessary. Refer to Procedures 019-090
Vehicle speed sensor (VSS) tampering has ............ Procedure 019-090 and 019-091 in the
occurred Troubleshooting and Repair Manual, Electronic
OK
Go To Next Step
STEP 17 Check the air intake system for restriction. Clean

............ or replace the air filter and inlet piping as
OK
Go To Next Step
STEP 18
Check the exhaust system for restrictions. Refer to
Exhaust system restriction is not within ............
Procedure 011-009.
specification
OK
Go To Next Step

006-026 or 014-008.
OK
Go To Next Step
STEP 20
Check the wastegate for correct operation. Refer
Turbocharger wastegate is malfunctioning (if ............
equipped)
OK
Go To Next Step
Monitor the turbocharger boost pressure with an
STEP 21 electronic service tool. Refer to Engine
............ Performance Troubleshooting in Section TT.
Turbocharger is malfunctioning
Check the turbocharger variable geometry
operation (if applicable).
OK
Go To Next Step
............
Overhead adjustments are not correct to Procedure 003-004.
OK
Go To Next Step

Cause Correction

007-083.
Fuel in Coolant
Cause Correction
Check the bulk coolant supply. Drain the coolant
and replace with noncontaminated coolant.
Replace the coolant filters. Refer to Procedure
STEP 1 018-003 in the Operation and Maintenance
............
Bulk coolant supply is contaminated Manual, Signature and ISX Engines, Bulletin
3666251 or 018-003 in the Operation and
OK
Go To Next Step
STEP 2 Check the fuel heater and replace, if necessary.
............
Fuel heater is malfunctioning (if equipped) Refer to the manufacturer's instructions.
OK
Go To Next Step
STEP 3
Remove and check the injectors. Check o-rings
Injector o-rings and sleeves are damaged. Injector ............
and injector sleeves. Refer to Procedure 006-026.
o-rings are missing
OK
Go To Next Step
Remove intake and exhaust manifolds. Check for
STEP 4 evidence of coolant leak. If necessary, operate
............
Cylinder head is cracked or porous engine at low idle. Pressure-test the cylinder head.
Fuel in the Lubricating Oil

Cause Correction
Check the bulk oil supply. Drain the oil and replace
STEP 1 with non-contaminated oil. Replace the oil filters.
............
Bulk oil supply is contaminated Refer to Procedure 007-083 in Section 7 and
OK
Go To Next Step
Low oil and coolant temperatures can be caused
by long idle times (greater than 10 minutes). Shut
STEP 2 off the engine rather than idle for long periods. If
............
Engine idle time is excessive idle time is necessary, raise the idle speed. Refer
to Bulletin 4021334 for ISX CM870 engines and
Bulletin 4021560 for ISX CM871 engines.
OK
Go To Next Step
STEP 3 Inspect the fuel drain lines for restrictions. Remove

............ any restrictions found. Refer to Procedure 006-012
Fuel drain line is restricted
in Section 6.
OK
Go To Next Step
STEP 4 Perform the fluorescent dye tracer test to confirm

............ the fuel leak. Replace the fuel pump if necessary.
Fuel pump seal is leaking
OK
Go To Next Step
Perform diagnostics to find the damaged injector
(s). Replace the injector(s) as necessary. Refer to
Bulletin 4021334, Section TT, 70-t02-1001, Guided
STEP 5 Step 5, for ISX CM870 engines. Refer to Procedure
............
Injector(s) are malfunctioning 014-008 for ISX CM870 and ISX CM871 engines.
Refer to Bulletin 4021560, Section TT, Procedure
16-t02-1001a, Guided Step 5, for ISX CM871
engines..
OK
Go To Next Step
STEP 6 Perform the fluorescent dye tracer test to find the
Top injector o-ring or injector timing plunger is ............ damaged injector. Replace the injector or o-ring.
damaged Refer to Procedure 006-026 in Section 6.
OK
Go To Next Step
STEP 7 Inspect the injectors for blown or missing plug
............
Injector has blown or missing plug ball balls. Refer to Procedure 006-026 in Section 6.
OK
Go To Next Step
Fuel in the Lubricating Oil

Cause Correction
STEP 8 Perform the fuel passage leak test in the cylinder
............
Cylinder head is cracked or porous head. Refer to Procedure 002-004 in Section 2.
OK
Go To Next Step
Check the engine for high crankcase pressure, low
STEP 9 compression, static injection timing, damaged
............
Base engine problem pistons, camshaft, and other parts. Refer to
Intake Manifold Air Temperature Above Specification

Cause Correction
Electronic fault codes active or high counts of ............ Control System, Signature, ISX and QSX15
inactive fault codes Engines, Bulletin 3666259, or Troubleshooting and
OK
Go To Next Step
Check the intake manifold temperature sensor.
Refer to Procedure 019-159 in the Troubleshooting
and Repair Manual, Electronic Control System,
STEP 2 3666259, or Procedure 019-059 in Troubleshooting
Intake manifold temperature sensor is ............ and Repair Manual, Power Generation Control
malfunctioning Systems QSX15, QSK23, QSK45, QSK60, QSK78,
and QST30 Series Engines, Bulletin 4021419 or
Procedure 019-059 in Troubleshooting and Repair
OK
Go To Next Step
Open the cold weather radiator cover or the
winterfront. Maintain a minimum of 784 cm2 [122
in2] or approximately 28 x 28 cm [11 x 11 in] of
STEP 3 opening at all times. Refer to Procedure 101-015 in
............ the Operation and Maintenance Manual, Signature
Cold weather radiator cover or winterfront is closed
and ISX Engines, Bulletin 3666251 or Procedure
101-015 Operation and Maintenance Manual,
Industrial and Power Generation, QSX15 Engines,
Bulletin 3666423.
OK
Go To Next Step
STEP 4 Inspect the charge air cooler, air conditioner
Charge air cooler fins, radiator fins, or air condenser, and radiator fins. Clean, if necessary.
............
conditioner condenser fins are damaged or Refer to Procedures 010-027, 008-042 and the
obstructed with debris OEM service manual.
OK
Go To Next Step
STEP 5 Check the belt tension and tighten if necessary.
............
Fan drive belt is loose Refer to Procedure 008-003.
OK
Go To Next Step
............
OK
Go To Next Step
Intake Manifold Air Temperature Above Specification

Cause Correction
STEP 7 Inspect the shroud and the recirculation baffles.
Fan shroud is damaged or missing or the air ............ Repair, replace, or install, if necessary. Refer to
recirculation baffles are damaged or missing Procedure 008-038 and the OEM service manual.
OK
Go To Next Step
the shutterstat setting is wrong Procedure 008-049.
OK
Go To Next Step
STEP 9 Verify that the fan is the correct size. Refer to the
............
Fan is not an adequate size for the application OEM service manual.
OK
Go To Next Step
STEP 10 Check the EGR cooler. Refer to Procedure
............
EGR cooler malfunctioning 011-019.
OK
Go To Next Step
STEP 11 Refer to Procedures 010-024, 010-057, or the

............ Engine Performance Troubleshooting in Section
Intake air or exhaust leaks
TT.
OK
Go To Next Step
Check the EGR differential pressure sensor
mounting for leaks. Refer to Procedure 011-028,
STEP 12 Engine Performance Troubleshooting in Section
............
EGR differential pressure sensor leaking TT, and Procedure 019-370 in Troubleshooting and
OK
Go To Next Step
STEP 13 Check the tubes for leaks. Refer to Procedure

............ 011-026 and Engine Performance Troubleshooting
EGR differential pressure sensor tubes leaking
in Section TT.
Intake Manifold Pressure (Boost) is Below Normal

Cause Correction
Engines, Bulletin 3666259, or Troubleshooting and
OK
Go To Next Step
Check the intake manifold pressure sensor. Refer
to Procedure 019-061 in the Troubleshooting and
............
Intake manifold pressure sensor is malfunctioning Procedure 019-061 in Troubleshooting and Repair
QST30 Series Engines, Bulletin 4021419.
OK
Go To Next Step
............
Air intake or exhaust leaks leaks. Refer to Procedure 010-024.
OK
Go To Next Step
STEP 4 Inspect the charge air cooler for air restrictions or
............
Charge air cooler is restricted or leaking leaks. Refer to Procedure 010-027.
OK
Go To Next Step
STEP 5 Check the air intake system for restriction. Clean

............ or replace the air filter and inlet piping as
OK
Go To Next Step
STEP 6 Check the wastegate for freedom of movement.
Turbocharger wastegate is damaged or is stuck ............ Inspect the wastegate for damage. Refer to
open Procedure 010-050.
OK
Go To Next Step
STEP 7 Check the turbocharger for damage. Measure the

............ turbine and compressor wheel clearances. Refer
Turbocharger is worn or damaged
OK
Go To Next Step
Intake Manifold Pressure (Boost) is Below Normal

Cause Correction
STEP 8 Check the connection between the manifold and
............
Air compressor connection is loose or damaged the air compressor. Repair or replace if necessary.
OK
Go To Next Step
............
Turbocharger is not correct or 4021327. Replace the turbocharger if
OK
Go To Next Step
STEP 10 Check the exhaust system for any restrictions.
............
Exhaust system restriction Refer to Procedure 011-009.
OK
Go To Next Step
STEP 11 Refer to Engine Performance Troubleshooting in
............
Engine power output is low Section TT.
Lubricating Oil in the Fuel

Cause Correction
STEP 1 Refer to the Centinel Master Repair Manual,
............
Engine equipped with Centinel Bulletin 3666231.
OK
Go To Next Step
Perform oil dye test. Refer to Procedure 007-024 in
Section 7. Add dye to oil. Inspect for dye in fuel
STEP 2 tank with black light. If no dye was found in the fuel
............
Check for lubricating oil in fuel Asphaltines are the likely cause of the dark fuel. To
verify, take a fuel sample and perform an analysis
to check for Asphaltines.
OK
Go To Next Step

............ injector o-rings. Refer to Procedure 006-026 in
Injector o-rings are damaged or missing
Section 6.
OK
Go To Next Step
STEP 4 Inspect the cylinder head for Injector bore damage.
............
Cylinder head has damaged injector bore Refer to Procedure 002-004 in Section 2.
OK
Go To Next Step
STEP 5 Replace the upper plunger seal in the fuel injector.
............
Damaged injector upper plunger seal Refer to Procedure 006-026 in Section 6.
OK
Go To Next Step
STEP 6
Inspect the IFSM mounting gasket and sealing
Integrated Fuel System Module (IFSM) mounting ............
surfaces. Refer to Procedure 005-073 in Section 5.
gasket leaking
OK
Go To Next Step
Inspect the cylinder head for cracked or porous fuel
passages per the Fuel Passage Leak Test. Refer
STEP 7 to Procedure 002-004 in Section 2. Note: It is not
............
Cylinder head is cracked or porous necessary to remove the cylinder head to perform
this procedure unless the tools will not fit on the
cylinder head in chassis.
OK
Go To Next Step
STEP 8 Replace the malfunctioning injector. Refer to
............
Injector is malfunctioning Procedure 006-026 in Section 6.
Lubricating Oil Consumption Excessive

Cause Correction
Check the amount of oil added versus the mileage.
STEP 1 Refer to Procedure 502-016 in Section 2. This
............
Verify the oil consumption rate procedure is in the Warranty Administration
Manual, Bulletin 4021290.
OK
Go To Next Step
Inspect the engine for external oil leaks. Tighten
STEP 2 the capscrews, pipe plugs, and fittings. Replace
............
Lubricating oil leak (external) gaskets, if necessary. Refer to Procedure 007-024
in Section 7.
OK
Go To Next Step
STEP 3 Check and clean the crankcase breather and vent
............
Crankcase ventilation system is plugged tube. Refer to Procedure 003-001 in Section 3.
OK
Go To Next Step
STEP 4 Check the air lines for carbon buildup and

lubricating oil. Refer to the Air Compressor is
Air compressor is pumping lubricating oil into the ............
Pumping Excessive Lubricating Oil into the Air
air system
System symptom tree.
OK
Go To Next Step
STEP 5 Check the dipstick calibration. Refer to Procedure
............
Lubricating oil dipstick calibration is not correct 007-009 in Section 7.
OK
Go To Next Step
Refer to Procedure 102-002 in Section 2 in the
............ and ISX Engines, Bulletin 3666251. Refer to
Lubricating oil drain interval is excessive
Procedure 102-002 in Section 2 in the Operation
and Maintenance Manual, Industrial and Power
OK
Go To Next Step

Cause Correction
Change the oil and filters. Refer to Service Bulletin
3810340. The following can be found in the
and ISX Engines, Bulletin 3666251. Refer to
Procedure 018-003 in Section V. The following can
STEP 7 be found in the Operation and Maintenance
Manual, Industrial and Power Generation, QSX15
Engines, Bulletin 3666423. Refer to Procedure
018-003 in Section V. The following can be found
in the Operation and Maintenance Manual,
Industrial and Power Generation, QSX15 Engines,
Section 4. Use the oil type recommended in
Section V.
OK
Go To Next Step
............
Turbocharger oil seal is leaking seals. Refer to Procedure 010-033 in Section 10.
OK
Go To Next Step
STEP 9 Refer to the Centinel Master Repair Manual,
............
Engine equipped with Centinel Bulletin 3666231.
OK
Go To Next Step
STEP 10 Check for lubricating oil in the coolant. Refer to the

............ Lubricating or Transmission Oil in the Coolant
Lubricating oil cooler is leaking
symptom tree.
OK
Go To Next Step
STEP 11 Refer to the Lubricating Oil Contaminated
............
Lubricating oil is contaminated with coolant or fuel symptom tree.
OK
Go To Next Step
STEP 12 Check blowby. Refer to Section 14. If blowby is

excessive, check the piston rings for correct
Piston rings are not seated correctly (after an ............
seating. Refer to Procedure 001-043 and
engine rebuild or piston installation)
OK
Go To Next Step
STEP 13 Check for air intake system leaks. Refer to
Piston, cylinder liner, or piston rings are worn or ............ Procedure 001-043, Procedure 001-047, and
damaged Procedure 001-028 in Section 1.
OK
Go To Next Step

Cause Correction
Perform oil dye test. Refer to Procedure 007-024 in
Section 7. Add dye to oil. Inspect for dye in fuel
STEP 14 tank with black light. If no dye was found in the fuel
............
Check for lubricating oil in fuel Asphaltines are the likely cause of the dark fuel. To
verify, take a fuel sample and perform an analysis
to check for Asphaltines.
OK
Go To Next Step

............ injector o-rings. Refer to Procedure 006-026 in
Injector o-rings are damaged or missing
Section 6..
OK
Go To Next Step
STEP 16 Replace the fuel injector upper seals. Refer to
............
upper seal is worn or damaged Procedure 006-026 in Section 6.
OK
Go To Next Step
............
Injector is malfunctioning Procedure 006-026 in Section 6.
Lubricating Oil Contaminated

Cause Correction
STEP 1 Perform an oil analysis to determine the
............
Identify lubricating oil contamination contaminants.
OK
Go To Next Step
STEP 2 Check the bulk oil supply. Drain the oil and replace
............ with non-contaminated oil. Replace the oil filters.
Bulk oil supply is contaminated
OK
Go To Next Step
STEP 3
............ Refer to the Coolant Loss - Internal symptom tree.
Internal coolant leaks
OK
Go To Next Step
STEP 4 Change the oil and filters. Refer to the Lubricating

............ Oil Sludge in the Crankcase is Excessive symptom
Lubricating oil sludge is excessive
tree.
OK
Go To Next Step
STEP 5 Refer to the Fuel in the Lubricating Oil symptom
............
Fuel in the lubricating oil tree.
OK
Go To Next Step
STEP 6
Transmission or hydraulic fluid is in the lubricating ............ Refer to the OEM service manual.
oil
Lubricating Oil Filter Plugged

This is symptom tree t103-56
Cause Correction
STEP 1 Measure the differential pressure drop across the

............ lubricating oil filter. Refer to Procedure 007-013 in
Verify the plugged lubricating oil filter complaint
Section 7 .
OK
Go To Next Step
007-037 and Procedure 007-013 in Section 7. For
STEP 2 oil type recommendations, refer to Procedure
018-003 in Section V, in the Signature and ISX
Operation and Maintenance Manual, Bulletin
3666251, or Procedure 018-003 in Section V, in the
QSX15 Operation and Maintenance Manual,
Bulletin 3666423.
OK
Go To Next Step
007-037 and Procedure 007-013 in Section 7. Use
INSITE electronic service tool to verify the
STEP 3 average kilometers per liter (km/liter) [miles per
The present lubricating oil drain interval was gallon (mpg)]. For the correct oil drain intervals,
............
missed or is exceeded based on duty cycle, or oil refer to Procedure 102-002 in Section 2 of the
and filter combination Signature and ISX Operation and Maintenance
Manual, Bulletin 3666251, or Procedure 102-002 in
Section 2 in the QSX15 Operation and
Maintenance Manual, Bulletin 3666423.
OK
Go To Next Step
Change the oil and filter. Refer to Procedure
007-037 and Procedure 007-013 in Section 7. For
oil type recommendations, refer to Procedure
018-003 in Section V, in the Signature and ISX
STEP 4 Operation and Maintenance Manual, Bulletin
Engine has history of missed or excessive oil drain ............ 3666251, or Procedure 018-003 in Section V, in the
intervals QSX15 Operation and Maintenance Manual,
Bulletin 3666423. Clean any contaminated
residual engine oil from the oil pan and cylinder
head. Return the engine to operation. Repeat, if
necessary, to reach a full oil drain interval.
OK
Go To Next Step
Lubricating oil is visually contaminated with ............ symptom tree, if a visual inspection reveals
coolant or fuel contamination.
OK
Go To Next Step

Cause Correction
Review the customer oil analysis records if
available. If recent customer oil analysis results are
not available and the results of an oil analysis can
be obtained within a reasonable time frame,
STEP 6 perform an oil analysis. If the results of an oil
analysis can not be obtained within a reasonable
The filter plugging interval is less than 16,093 ............
time frame, proceed with the next step in this
kilometers [10,000 miles]
troubleshooting procedure. Refer to Cummins
Engine Oil and Oil Analysis Recommendations,
Bulletin 3810340. Refer to the appropriate
troubleshooting symptom tree if lubricating oil
contamination is identified.
OK
Go To Next Step
For the correct fuel recommendations, refer to
STEP 7 Procedure 018-002 in Section V in the Operation
An inspection or customer interview reveals that and Maintenance Manual, Signature and ISX
............
the fuel grade may not be correct for the Engines, Bulletin 3666251, or Procedure 018-002
application or the fuel quality is poor in Section V of the Operation and Maintenance
Manual, QSX15 Engines, Bulletin 3666423.
OK
Go To Next Step
Check for excessive engine blowby. Refer to
STEP 8 Procedure 014-002 in Section 14 . If crankcase
............
Combustion gas contamination gases are excessive, refer to the Crankcase Gases
(Blowby) Excessive symptom tree.
OK
Go To Next Step
STEP 9 Check or replace the fuel lines, check valves, or

............ tank vents as needed. Refer to Procedure 006-012
Fuel drain line restriction
in Section 6.
OK
Go To Next Step
Perform diagnostics to find the damaged injector
(s). Replace the injector(s) as necessary. Refer to
Guided Step 5 in Troubleshooting Tree t02-1001 in
STEP 10 Section TT of the Signature, ISX, and QSX15
............ Service Manual, Bulletin 4021334, or Guided Step
Injector(s) are malfunctioning
5 in Troubleshooting Tree t02-1001a in Section TT
of the CM871 and CM876 Electronic Control
Systems, ISX and ISM Engines, Bulletin 4021560.
Return the engine to operation.
OK
Go To Next Step

Cause Correction
If no documentation of repeat occurrences of
premature oil and filter changes is available in
engine warranty history, or from the customer,
STEP 11 perform the appropriate corrections in the steps
First investigated instance of premature filter ............ above and STOP. Return the engine to operation.
plugging For repeat instances without improvement,
measure and record the pressure drop across the
filter. Verify the completion of the steps above and
continue to the next steps.
OK
Go To Next Step
Review the customer oil analysis records, if
available. If recent customer oil analysis records
STEP 12 are not available, perform an oil analysis to identify
Lubricating oil is contaminated with coolant or fuel ............ potential contamination. For used oil
with no clear visual indication contamination guidelines refer to Cummins
Engine Oil and Oil Analysis Recommendations,
Bulletin 3810340.
OK
Go To Next Step
STEP 13 Inspect the injectors for missing or damaged o-

rings and plug balls. Replace the o-rings or
Injector has a blown plug ball or a cut o-ring not ............
injector, as necessary. Refer to Procedure 006-026
detected by diagnostics
in Section 6 .
OK
Go To Next Step
Check the engine base timing and adjust the
overhead. Refer to Procedure 001-088 in Section
STEP 14 1 and Procedure 003-004 in Section 3. Return the
............
Engine timing incorrect engine to operation. If no improvement, request
additional Cummins Inc. technical assistance
before continuing to the next step.
OK
Go To Next Step
Check the engine for damaged pistons, rings,
STEP 15 liners, and other parts. Refer to Procedure 002-004
............
Base engine problem in Section 2. Request additional Cummins Inc.
technical assistance.
Lubricating Oil Pressure High

Cause Correction
Electronic fault codes active or high counts of ............ Control System, Signature, ISX and QSX15
inactive fault codes Engines, Bulletin 3666259, Troubleshooting and
OK
Go To Next Step
STEP 2 Check the oil pressure switch, gauge, or sensor for
Lubricating oil pressure switch, gauge, or sensor is ............ correct operation and location. Refer to Procedure
malfunctioning or is not in the correct location 007-028 or the OEM service manual.
OK
Go To Next Step
STEP 3 Change the oil and filters. Refer to Service Bulletin
Lubricating oil does not meet specifications for ............ 3810340. Use the oil type recommended in Section
operating conditions V of the operation and maintenance manual.
OK
Go To Next Step
STEP 4 Remove and inspect the high pressure relief
Lubricating oil high pressure relief valve or ............ valve or lubricating oil pump. Refer to Procedures
lubricating oil pump is malfunctioning 007-021 and 007-031.
Lubricating Oil Pressure Low

Cause Correction
Check the lubricating oil pressure sensor and
circuit. Refer to Procedures 019-155 or 019-066 in
STEP 1 QST30 Series Engines, Bulletin 4021419, or
Lubricating oil pressure sensor or circuit is ............ Procedure 019-155 in Section 19 in
malfunctioning (electronic controlled fuel system) Troubleshooting and Repair Manual, Electronic
Control System, Signature, ISX and QSX
in Section 19 in Troubleshooting and Repair
OK
Go To Next Step
Change the oil and filters. Refer to Service Bulletin
3810340 or Procedure 018-003 in Section V in the
STEP 2 and ISX Engines, Bulletin 3666251 or Procedure
Lubricating oil does not meet specifications for ............ 018-003 in Section V in the Operation and
operating conditions Maintenance Manual, Industrial and Power
Use the oil type recommended in Section V of the
operation and maintenance manual.
OK
Go To Next Step
............
Lubricating oil level is above or below specification Refer to Procedure 007-037 in Section 7.
OK
Go To Next Step
STEP 4
Engine angularity during operation exceeds ............ Refer to the Engine Specification data sheet.
specification
OK
Go To Next Step
Measure the differential pressure drop across the
lubricating oil filter. Refer to Procedure 007-013 in
STEP 5 Section 7 or the Lubricating Oil Pressure Low
............
Lubricating oil filter is plugged symptom tree. If lubricating oil filter is plugged,
refer to the Lubricating Oil Filter Plugged symptom
tree.
OK
Go To Next Step
............
OK
Go To Next Step
Lubricating Oil Pressure Low

Cause Correction
STEP 7
Inspect the lubricating oil pump and o-rings. Refer
Lubricating oil pump is malfunctioning or the o- ............
to Procedure 007-031 in Section 7.
rings are damaged
OK
Go To Next Step
STEP 8 Remove and inspect the high-pressure relief valve
Lubricating oil high-pressure relief valve or ............ or lubricating oil pump. Refer to Procedures
lubricating oil pump is malfunctioning 007-021 and 007-031 in Section 7.
OK
Go To Next Step
STEP 9 Refer to the Lubricating Oil Temperature Above
............
Lubricating oil temperature is above specification Specification symptom tree.
OK
Go To Next Step
STEP 10
Remove and inspect the oil pan or suction tube.
Lubricating oil suction or transfer tube is loose or ............
broken, or the gasket or o-rings are leaking
OK
Go To Next Step
STEP 11 Check the piston cooling nozzles for damage and
Piston cooling nozzles are damaged or are not ............ correct installation. Refer to Procedure 001-046 in
installed correctly Section 1.
OK
Go To Next Step
STEP 12 Check the oil cooler. Refer to Procedure 007-003
............
Lubricating oil cooler is plugged in Section 7.
OK
Go To Next Step
STEP 13 Analyze the oil and inspect the filters, pistons,

............ camshaft, and other parts to locate an area of
probable damage.
Lubricating Oil Sludge in the Crankcase Excessive

Cause Correction
STEP 1 Check the bulk oil supply. Drain the oil and replace
............ with noncontaminated oil. Replace the oil filters.
Bulk oil supply is contaminated
OK
Go To Next Step
Change the oil and filters. Refer to 007-083. Use
the oil type recommended in 018-003 of the
Lubricating oil does not meet specifications for ............ and ISX Engines, Bulletin 3666251 or 018-003
operating conditions Operation and Maintenance Manual, Industrial and
3666423.
OK
Go To Next Step
Refer to Section 2 in 102-002 of the Operation and
STEP 3 Maintenance Manual, Signature and ISX Engines,
............
Lubricating oil drain interval is excessive Bulletin 3666251 or 102-002 Operation and
OK
Go To Next Step
STEP 4 Refer to Procedure 018-002 in the Operation and
Bulletin 3666251 or 018-002 Operation and
OK
Go To Next Step
STEP 5 Refer to the Coolant Temperature Below Normal
............
Coolant temperature is below specification symptom tree.
OK
Go To Next Step
............
OK
Go To Next Step
STEP 7 Check for excessive blowby. Refer to the

Crankcase pressure is excessive
tree.
OK
Go To Next Step
Lubricating Oil Sludge in the Crankcase Excessive

Cause Correction
STEP 8 Check the injector cups for damage and for correct
............
Injector cup is damaged or is not correct part numbers. Refer to Procedure 006-026.
OK
Go To Next Step
............
Injector is malfunctioning Procedure 006-026.
OK
Go To Next Step
Replace the timing or fueling actuator Procedure
019-110 and 019-111 in the Troubleshooting and
STEP 10 019-110 and 019-111 Troubleshooting and Repair
............ Manual, Electronic Control System, Signature, ISX
Timing or fueling actuator malfunctioning
and QSX Engines, Bulletin 3666259, 019-110 and
019-111 Troubleshooting and Repair Manual,
Series Engines, Bulletin 4021419.
OK
Go To Next Step
Check the engine position sensor or circuit. Refer
to Section TF and or Procedure 019-038 in the
STEP 11 Electronic Control System, Signature and ISX
Engines, Bulletin 4021334, or ISX Fuel System
Engine position sensor (EPS) or circuit is ............
malfunctioning or wiring is not correct
3666259, or Troubleshooting and Repair Manual,
Series Engines, Bulletin 4021419 .
OK
Go To Next Step
STEP 12 Check base engine timing. Refer to Procedure
............
Engine is out of time 001-088.
Lubricating Oil Temperature Above Specification

Cause Correction
STEP 1 ISX Fuel System Troubleshooting and Repair
Electronic fault codes active or high counts of ............ Manual, Bulletin 3666259, or Troubleshooting and
inactive fault codes Repair Manual, Power Generation Control
OK
Go To Next Step
Check the oil temperature switch, gauge, or sensor
for correct operation and location. Refer to
Lubricating oil temperature switch, gauge, or ............ 019-155 ISX Fuel System Troubleshooting and
sensor malfunctioning or not in the correct location Repair Manual, Bulletin 3666259, or 019-155
OK
Go To Next Step
Check the lubricating oil temperature sensor and
circuit. Refer to Procedure 019-067 in the
STEP 3 Engines, Bulletin 4021334, or 019-155
Lubricating oil temperature sensor or circuit is ............ Troubleshooting and Repair Manual, Power
malfunctioning (electronic controlled fuel system) Generation Control Systems QSX15, QSK23,
Engines, Bulletin 4021419 or 019-155 ISX Fuel
System Troubleshooting and Repair Manual,
Bulletin 3666259.
OK
Go To Next Step
............
Lubricating oil level is above or below specification Refer to Procedure 007-037.
OK
Go To Next Step
STEP 5 Refer to the Coolant Temperature is Above Normal

............ - Sudden Overheat or the Coolant Temperature is
Coolant temperature is above specification
Above Normal - Gradual Overheat symptom tree.
OK
Go To Next Step
Lubricating Oil Temperature Above Specification

Cause Correction
STEP 6 Check the oil thermostat. Refer to Procedure
............
Lubricating oil thermostat is malfunctioning 007-039.
OK
Go To Next Step
STEP 7
............ Check the oil cooler. Refer to Procedure 007-003.
Lubricating oil cooler is malfunctioning
Lubricating or Transmission Oil in the Coolant

Cause Correction
Check the bulk coolant supply. Drain the coolant
STEP 1 and replace with noncontaminated coolant.
............
Bulk coolant supply is contaminated Replace the coolant filters. Refer to Procedure
008-018.
OK
Go To Next Step
STEP 2
Check the oil cooler transfer housing and the
Lubricating oil cooler transfer housing or ............
support. Refer to Procedure 007-003.
lubricating oil cooler support is cracked or porous
OK
Go To Next Step
STEP 3
............ Check the oil cooler. Refer to Procedure 007-003.
Lubricating oil cooler is malfunctioning
OK
Go To Next Step
STEP 4
Remove and inspect the cooler cores and o-rings.
Torque converter cooler or hydraulic oil cooler is ............
malfunctioning
OK
Go To Next Step
............
Cylinder head gasket is leaking Procedure 002-004 or 002-021.
OK
Go To Next Step
Remove intake and exhaust manifolds. Check for
STEP 6 evidence of coolant leak. If necessary, operate
............
Cylinder head is cracked or porous engine at low idle. Pressure-test the cylinder head.
OK
Go To Next Step
STEP 7 Check the cylinder liners for corrosion or cracks.
............
Cylinder liner is corroded or cracked Refer to Procedure 001-028.
OK
Go To Next Step
STEP 8 Inspect the cylinder block. Refer to Procedure
............
Cylinder block is cracked or porous 001-026.
Turbocharger Leaks Engine Oil or Fuel

Cause Correction
Review the engine operating instructions in
Section 1 Procedure 101-015 (Operating the
Engine) in Section 1 in the Operation and
STEP 1 Maintenance Manual, Signature and ISX
Engine is operating for extended periods under ............ Engines, Bulletin 3666251 or Procedure 101-015
light- or no-load conditions (slobbering) (Operating the Engine) in Section 1 in the
Operation and Maintenance Manual, Industrial and
3666423.
OK
Go To Next Step
STEP 2 Remove the intake and exhaust piping, and check
............
Lubricating oil or fuel is entering the turbocharger for oil or fuel.
OK
Go To Next Step
Remove the turbocharger oil drain line and check
STEP 3 for restriction. Clean or replace the oil drain line.
............
Turbocharger oil drain line is restricted Refer to Procedure 010-033 (Turbocharger) in
Section 10.
OK
Go To Next Step
Check for excessive blowby. Refer to Procedures
014-001 (Dynamometer Worksheet) in Section 14,
014-002 (Engine Testing (Chassis Dynamometer))
in Section 14, 014-003 (Engine Run-In (Chassis
Dynamometer)) in Section 14, 014-004 (Engine
STEP 4 Run-In (Without Dynamometer)) in Section 14,
............
Crankcase pressure is excessive 014-005 (Engine Testing (Engine Dynamometer))
in Section 14, 014-006 (Engine Run-In (Engine
Dynamometer)) in Section 14, 014-008 (Engine
Testing (In Chassis) in Section 14, and 014-009
(Engine Testing (Portable Dynamometer or Load
Bank)) in Section 14.
OK
Go To Next Step
Check the turbocharger compressor and turbine
STEP 5 seals. Refer to Procedure 010-033 (Turbocharger)
............
Turbocharger oil seal is leaking in Section 10 and 010-040 (Turbocharger
Compressor Seal Leaks) in Section 10.
OK
Go To Next Step
STEP 6 Check the actuator cross shaft oil seal for leakage.
Turbocharger actuator cross shaft oil seal is ............ Refer to Procedure 010-137 (Variable Geometry
leaking Turbocharger Cross Shaft) in Section 10.
Stationary Regeneration Will Not Activate

The steps in this tree are intended to cover vehicles equipped with an on vehicle method of activating a stationary
regeneration. This troubleshooting tree can also be used if INSITE electronic service tool Aftertreatment Diesel
Particulate Filter Regeneration Test will not operate.
Cause Correction
View and troubleshoot the fault codes with
INSITE electronic service tool. Refer to Section
STEP 1 TF for active fault code troubleshooting or
Electronic fault codes active or high counts of ............ Procedure 019-362 for inactive fault code
inactive fault codes troubleshooting in the Troubleshooting and Repair
Manual, CM871 and CM876 Electronic Control
OK
Go To Next Step
STEP 2 A stationary regeneration can not be performed

while the soot load is in the normal range. Refer to
Soot load of the Aftertreatment Diesel Particulate ............
the Aftertreatment Diesel Particulate Filter
Filter is too low
Regeneration Test section of Procedure 014-013.
OK
Go To Next Step
Refer to the OEM instructions on how to perform a
STEP 3 stationary regeneration via the drive/vehicle
interface or refer to the Aftertreatment Diesel
The correct Stationary Regeneration procedure is ............
Particulate Filter Regeneration Test in Procedure
not being followed
014-013 for the INSITE electronic service tool
procedure
OK
Go To Next Step
STEP 4
Refer to the OEM instructions on Regeneration
OEM or customer-selected inhibit feature is ............
inhibit features.
preventing a stationary regeneration
OK
Go To Next Step
selected features with an electronic service tool.
Set the parameters and features again if
STEP 5 necessary. Refer to Procedure 019-078 in the
Programmable parameters or selected features ............ Troubleshooting and Repair Manual, CM871 and
are not correct CM876 Electronic Control System, ISX and ISM
Engines, Bulletin 4021560 and to Multiplexing
Troubleshooting, Service Manual, Bulletin
4021378.
OK
Go To Next Step
Check the vehicle brake switch and circuit. Refer
STEP 6 to Refer to Procedures 019-088 and 019-089 in the
............ Troubleshooting and Repair Manual, CM871 and
Vehicle brake switch or circuit is malfunctioning
CM876 Electronic Control Systems, ISX and ISM
OK
Go To Next Step

Cause Correction
Use an electronic service tool to monitor the
vehicle speed while the vehicle is not moving.
STEP 7 Refer to the appropriate electronic service tool
manual. If the monitor shows speed, check the
Vehicle speed sensor (VSS) or circuit is ............
sensor and circuit. Refer to Procedures, 019-091,
malfunctioning
and 019-093 the Troubleshooting and Repair
Manual, CM871 and CM876 Electronic Control
OK
Go To Next Step
Check the clutch switch adjustment, switch, and
circuit. Refer to Procedure 019-009 or 019-010 the
STEP 8 Troubleshooting and Repair Manual, CM871 and
............ CM876 Electronic Control Systems, ISX and ISM
Clutch switch or circuit is malfunctioning
Engines, Bulletin 4021560. If available, use an
electronic service tool to monitor the clutch switch
status.
OK
Go To Next Step
Check for foot pedal restriction. Check the
STEP 9 accelerator pedal or lever position sensor and
circuit. Refer to Procedure 019-085 the
Accelerator pedal or lever position sensor or circuit ............
Troubleshooting and Repair Manual, CM871 and
is malfunctioning
CM876 Electronic Control Systems, ISX and ISM
OK
Go To Next Step
Check the cruise control/PTO selector switch and
STEP 10 circuit. Refer to Procedures 019-021 and 019-022
Cruise control/PTO selector switch or circuit is ............ the Troubleshooting and Repair Manual, CM871
malfunctioning and CM876 Electronic Control Systems, ISX and
ISM Engines, Bulletin 4021560.
OK
Go To Next Step
STEP 11 Verify the parking brake is set. Refer to the OEM
............
Vehicle parking brake is not set instructions.
OK
Go To Next Step
STEP 12 Verify the transmission is in Park, if provided,
Transmission is not in Park, if provided, otherwise ............ otherwise in Neutral. Refer to the OEM
in Neutral instructions.
OK
Go To Next Step

Cause Correction
Verify the electronic control module (ECM)
STEP 13 Online Internet Website or the INCAL calibration
Electronic control module (ECM) calibration is ............ CD. Compare the calibration stored in the ECM
malfunctioning with the engine rating and the Control Parts List
(CPL), Bulletin 4021326 or 4021327. If necessary,
recalibrate the ECM. Refer to the appropriate
electronic service tool manual and Procedure
019-032 the Troubleshooting and Repair Manual,
CM871 and CM876 Electronic Control Systems,
ISX and ISM Engines, Bulletin 4021560.
Aftertreatment Diesel Particulate Filter - Excessive Automatic and/or Stationary

Regeneration
For vehicles that have the diesel particulate lamp illuminating frequently, high exhaust temperature lamp (if equipped)
illuminating frequently, and/or requires frequent stationary regenerations.
Cause Correction
STEP 1 INSITE electronic service tool. Refer to the
Electronic fault codes active or high counts of ............ Troubleshooting and Repair Manual, CM871 and
inactive fault codes CM876 Electronic Control System, ISX and ISM
OK
Go To Next Step
Check the aftertreatment system inhibit feature
STEP 2 with INSITE electronic service tool. Change the
OEM or customer selected inhibit feature is vehicle route and/or duty cycle so the inhibit
............
preventing active regeneration during vehicle feature does not prevent active regeneration or
operation contact OEM/customer about changing inhibit
features.
OK
Go To Next Step
Check the aftertreatment system trip information
with INSITE electronic service tool. Low duty
STEP 3 cycle applications can possibly require more active
regeneration time to keep the aftertreatment
Extended operation of engine in low duty cycle, ............
system functioning correctly. Change the vehicle
extended idling and/or low ambient temperatures
route and/or duty cycle to increase the load on the
engine in order to decrease the amount of active
regeneration time.
OK
Go To Next Step
Maintenance interval for ash cleaning has been
reached. See the corresponding Owners or
STEP 4 Operation and Maintenance manual for the engine
............
Aftertreatment Diesel Particulate Filter is full of ash being serviced. Refer to the Aftertreatment Diesel
Particulate Filter - Excessive Ash Cleaning
Troubleshooting Symptom Tree.
OK
Go To Next Step
STEP 5 Refer to the Troubleshooting Performance
............
Engine produces excessive black smoke Symptom Tree.
Stationary Regeneration - Will Not Complete

This tree is to be used when the engine speed changes after the stationary (parked) regeneration has been started
and either stops after a short period of time, or continues for an excessive period of time. If the engine speed does
not increase when the stationary (parked) regeneration is started, refer to the Stationary Regeneration - Will Not
Activate TS tree (t146).
Cause Correction
INSITE electronic service tool. Refer to Section
STEP 1 TF for active and inactive fault code
Electronic fault codes active or high counts of ............ troubleshooting, Procedure 019-362 in Section 19
inactive fault codes of the ISX and ISM CM871 and CM876 Electronic
Control System, Troubleshooting and Repair
Manual, Bulletin 4021560.
OK
Go To Next Step
STEP 2 Verify that all of the conditions that allow a

stationary (parked) regeneration to activate are still
Stationary (Parked) Regeneration stops after a ............
valid. Refer to Stationary Regeneration - Will Not
short period of time
Activate symptom tree.
OK
Go To Next Step
Allow the stationary (parked) regeneration to run
until completion, which can take up to 2.5 hours.
Refer to Procedure 014-013 in Section 14. NOTE:
STEP 3 The 2.5 hours is the maximum time that a
Stationary (Parked) Regeneration not allowed to ............ regeneration will take to complete. If the Diesel
run to completion Oxidation Catalyst temperature is not at or above
316C [600F] and the aftertreatment injector has
not turned on within 1 hour, abort the regeneration
and continue through this tree.
OK
Go To Next Step
STEP 4
Inspect the OEM exhaust piping and the
Exhaust leaks in the OEM exhaust piping leading
............ aftertreatment system for exhaust leaks. Refer to
to the aftertreatment system or leaks in the
aftertreatment system
OK
Go To Next Step
STEP 5 Monitor the aftertreatment gas temperature sensor

values with INSITE electronic service tool during
Aftertreatment Gas Temperature Sensors are not ............
the stationary (parked) regeneration. Refer to
functioning properly
OK
Go To Next Step
Stationary Regeneration - Will Not Complete

This tree is to be used when the engine speed changes after the stationary (parked) regeneration has been started
and either stops after a short period of time, or continues for an excessive period of time. If the engine speed does
not increase when the stationary (parked) regeneration is started, refer to the Stationary Regeneration - Will Not
Activate TS tree (t146).
Cause Correction
Monitor the engine percent load value with
INSITE electronic service tool during the
stationary (parked) regeneration. If this value stays
STEP 6 consistently above 8% the metering actuators are
Fuel metering actuators are not functioning ............ over fueling and need to be replaced. Refer to
properly Procedure 019-110 in Section 19 of the ISX and
ISM CM871 and CM876 Electronic Control
System, Troubleshooting and Repair Manual,
Bulletin 4021560.
OK
Go To Next Step
STEP 7 Verify that the EGR valve is closed during the

............ stationary (parked) regeneration. Refer to
EGR valve is not functioning properly
OK
Go To Next Step
Use INSITE electronic service tool to verify that
the turbocharger actuator position is maintained at
89 percent closed or higher during the stationary
STEP 8 (parked) regeneration. If the turbocharger actuator
............
Turbocharger is not functioning properly position does not maintain 89 percent closed or
higher, verify that the turbocharger sector gear has
full travel. Refer to Procedure 010-134 in Section
10.
OK
Go To Next Step
STEP 9 Check for progressive damage to the

............ aftertreatment system. Refer to Procedure 014-013
Aftertreatment System is damaged
in Section 14.
OK
Go To Next Step
Verify that the electronic control module (ECM)
STEP 10 ecm_calibration_rev_history.xlson QuickServe
Online Internet Website or the INCAL calibration
Electronic control module (ECM) calibration is ............
CD. Compare the calibration stored in the ECM
malfunctioning
with the engine rating and the Control Parts List
(CPL), Bulletin 4021326 or 4021327. If necessary,
calibrate the ECM. Refer to Procedure 019-032 in
Section 19 of the ISX and ISM CM871 and CM876
Electronic Control System, Troubleshooting and
Repair Manual, Bulletin 4021560.
Signature, ISX, and QSX15 Eng [...] Troubleshooting Overview
Troubleshooting Overview
Engine Noise Diagnostic Procedures - General Information
NOTE: When diagnosing engine noise problems, make sure that noises caused by accessories, such as the air
compressor and power takeoff, are not mistaken for engine noises. Remove the accessory drive belts to eliminate
noise caused by these units. Noise will also travel to other metal parts not related to the problem. The use of a
stethoscope can help locate an engine noise.
Engine noises heard at the crankshaft speed, engine rpm, are noises related to the crankshaft, rods, pistons, and
piston pins. Noises heard at the camshaft speed, one-half of the engine rpm, are related to the valve train. A handheld
digital tachometer can help to determine if the noise is related to components operating at the crankshaft or camshaft
speed.
Engine noise can sometimes be isolated by performing a cylinder cutout test. Refer to the Electronic Service Tool
Manual. If the volume of the noise decreases or the noise disappears, it is related to that particular engine cylinder.
There is not a definite rule or test that will positively determine the source of a noise complaint.
Engine driven components and accessories, such as gear-driven fan clutches, hydraulic pumps, belt-driven
alternators, air-conditioning compressors, and turbochargers can contribute to engine noise. Use the following
information as a guide to diagnosing engine noise.
Main Bearing Noise
(Refer to Engine Noise Excessive - Main Bearing symptom tree)
The noise caused by a loose main bearing is a loud dull knock heard when the engine is pulling a load. If all main
bearings are loose, a loud clatter will be heard. The knock is heard regularly every other revolution. The noise is the
loudest when the engine is lugging or under heavy load. The knock is duller than a connecting rod noise. Low oil
pressure can also accompany this condition.
If the bearing is not loose enough to produce a knock by itself, the bearing can knock if the oil is too thin, or if there
is no oil at the bearing.
An irregular noise can indicate worn crankshaft thrust bearings.
An intermittent sharp knock indicates excessive crankshaft end clearance. Repeated clutch disengagements can
cause a change in the noise.
Connecting Rod Bearing Noise
(Refer to Engine Noise Excessive - Connecting Rod symptom tree)
Connecting rods with excessive clearance knock at all engine speeds, and under both idle and load conditions. When
the bearings begin to become loose, the noise can be confused with piston slap or loose piston pins. The noise
increases in volume with engine speed. Low oil pressure can also accompany this condition.
Piston Noise
(Refer to Engine Noise Excessive - Piston symptom tree)
It is difficult to tell the difference between piston pin, connecting rod, and piston noise. A loose piston pin causes a
loud double knock which is usually heard when the engine is idling. When the injector to this cylinder is cut out, a
noticeable change will be heard in the sound of the knocking noise. However, on some engines the knock becomes
more noticeable when the vehicle is operated on the road at steady speed condition.
Driveability - General Information
Driveability is a term which in general describes vehicle performance on the road. Driveability problems for an engine
can be caused by several different factors. Some of the factors are engine related and some are not.
Before troubleshooting, it is important to determine the exact complaint and whether the engine has a real driveability
problem or if it simply does not meet driver expectations. The Driveability-Low Power Customer Complaint Form is a
valuable list of questions that must be used to assist the service technician in determining what type of driveability
problem the vehicle is experiencing. Complete the checklist before troubleshooting the problem. The form can be
found at the end of this section. If an engine is performing to factory specifications but does not meet the customer's
expectations, it must be explained to the customer that nothing is wrong with the vehicle and why.
The troubleshooting symptom charts have been set up to divide driveability problems into two different symptoms:
Engine Power Output Low and Engine Acceleration or Response Poor.
Troubleshooting Overview Signature, ISX, and QSX15 Eng [...]
Low power is a term that is used in the field to describe many different performance problems. However, in this manual
low power is defined as the inability of the engine to produce the power necessary to move the vehicle at a speed that
can be reasonably expected under the given conditions of load, grade, wind, and so on. Low power is usually caused
by the lack of fuel flow which can be caused by any of the following factors:
- Lack of full travel of the throttle pedal
- Failed boost sensor
- Excessive fuel inlet, intake, exhaust, or drainline restriction
- Loose fuel pump suction lines
Low power is not the inability of the vehicle to accelerate satisfactorily from a stop or the bottom of a grade. Refer to
the symptom tree Engine Power Output Low for the proper procedures to locate and correct a low power problem.
The chart starts off with basic items which can cause lower power. It then breaks off into application specific items
that can cause lower power. All of the application specific trees end with a step called Fuel or air delivery problem.
This step leads to an engine performance check which requires engine measurements. The last section of this chart
is titled Performance Measurement. This leads the mechanic through the causes and corrections based on the
outcome of the performance check.
Poor acceleration or response is described in this manual as the inability of the vehicle to accelerate satisfactorily
from a stop or from the bottom of a grade. It can also be the lag in acceleration during an attempt to pass or overtake
another vehicle at conditions less than rated speed and load. Poor acceleration or response is difficult to troubleshoot
since it can be caused by factors such as:
- Engine or pump related factors
- Driver technique
- Improper gearing
- Improper engine application
- Worn clutch or clutch linkage
Engine related poor acceleration or response can be caused by several different factors such as:
- Failed boost sensor
- Excessive drainline restriction
- Throttle deadband
Refer to the symptom tree Engine Acceleration or Response Poor for the proper procedures to locate and correct a
poor acceleration or response complaint. For additional information, see Troubleshooting Driveability Complaints,
Bulletin 3387245.
Driveability/Low Power - Customer Complaint Form

Customer Name/Company __________________________________________________________ Date ________________
1. How did the problem occur? .... Suddenly ________ Gradually ________
2. Does the vehicle also experience poor fuel economy? .... Yes ____ No ____
3. At what hour/mileage did the problem begin? .... Hours ________ Miles ________ Since New ________
i. After engine repair? .... Yes ____ No ____
ii. After equipment repair? .... Yes _____ No ____
iii. After change in equipment use? .... Yes ____ No ____
iv. After change in selectable programmable parameters? .... Yes ____ No ____
v. If so, what was repaired and when? ........................................................................................
Answer questions 4 through 8 using selections (A through F) listed below. Circle the letter or letters that best describes
the complaint.
A. Compared to fleet D. Personal expectation
B. Compared to competition E. Won't pull on hill
C. Compared to previous engine F. Won't pull on flat
4. A B C D E F Can the vehicle obtain the expected road speed? .... Yes ____ No ____ What is desired speed? ....
rpm/mph ________ What is achieved speed? .... rpm/mph ________ GVW ________________
5. A B C D Is the vehicle able to pull the load? .... Yes ____ No ____ When? In the hills ________ With a loaded
trailer ________ On the flat ________ Other_______
IF QUESTION 4 OR 5 WAS ANSWERED NO, FILL OUT THE DRIVEABILITY/LOW POWER/EXCESSIVE
FUEL CONSUMPTION CHECKLIST AND GO TO THE LOW POWER SYMPTOM TREE.
6. A B C D E F Is the vehicle slow to accelerate or respond? .... Yes ____ No ____ From a stop? .... Yes ____ No
____ After a shift? .... Yes ____ No ____ rpm ________ Before a shift? .... Yes ____ No ____ rpm ________ No
shift? .... Yes ____ No ____ rpm ________
7. A B C D Does the vehicle hesitate after periods of long deceleration or coasting? .... Yes ____ No ____ rpm
________
IF QUESTION 6 OR 7 WAS ANSWERED YES, FILL OUT THE DRIVEABILITY/LOW POWER/EXCESSIVE
FUEL CONSUMPTION CHECKLIST AND GO TO THE POOR ACCELERATION/RESPONSE SYMPTOM
TREE.
8. A B C D E F Additional Comments: .... ....
This Page Can Be Copied For Your Convenience.
Driveability/Low Power/Excessive Fuel Consumption - Checklist

Vehicle/Equipment Specifications
Year/Type/Model: _____________________________________________________________________________________
Wheel Base: ____________________ Vehicle Configuration (ex. 6 X 4 - 2S):___________________________
Transmission Mfg: ________________________ Transmission Model: ___________________
Rear Axle Model: ________________ Rear Axle Ratio: _______________________
Application: On Highway _______ Off Highway _______ Genset _______ Marine _______
Typical GVW: _________________________lbs/kg
Trailer Type (Van, round smooth, etc.): ____________________ Height __________ Width __________
Gap between Tractor and Trailer: _________________
Description of Vehicle aerodynamic aids: ________________________________________________________________
______________________________________________________________________________________________________
General Engine Information
ESN: ___________ CPL: ___________ EPA Certification Year: ___________
ECM Code: ___________ Engine Model: ___________
Engine Rating: ___________ Rated Speed: ___________
Date in Service: ___________ Mpg (average if multiple units): ___________
Engine Brake: Yes ___________ No ___________
Throttle Type: Variable Speed ___________ Automotive ___________
Tires
Steer: Tire Mfg __________ Tire Model __________ Rev/Mile __________
Drive: Tire Mfg __________ Tire Model __________ Rev/Mile __________
Trailer: Tire Mfg __________ Tire Model __________ Rev/Mile __________
Fan Type: Direct Drive _____ Viscous ________ Clutch ________ Est. HP ________
Auxiliary Devices
Power Steering: Yes ___________ No ___________
Air Conditioner: None _____ Standard _____ Bus _____ High Capacity _____
Alternator: Amps@Volts ___________
Road Speeds
Maximum Cruise Control Speed: ___________
Maximum Accelerator Vehicle Speed: ___________
Shift Technique: Progressive Shift _________ Governed Speed Shift ___________
Electronic Features
Gear Down Protection - Heavy Load: ___________mph
Gear Down Protection - Light Load: ___________mph
Cruise Control Upper Droop: ___________mph
Cruise Control Lower Droop: ___________mph
Road Speed Governor Upper Droop: ___________mph
Road Speed Governor Lower Droop: ___________mph
Typical Routes
Route:
Interstate ____ Dump ____ Rural ____ Urban ____ Bus ____
Grades:
Level 1-2% _______ Short 1-5% _______ Long 1-5% _______
Additional Comments:
______________________________________________________________________________________________________
______________________________________________________________________________________________________
______________________________________________________________________________________________________
Vehicle/Equipment Specifications
Recommended Literature:
Troubleshooting Driveability Complaints, Bulletin 3387137
Fuel Consumption - General Information

The cause of excessive fuel consumption is hard to diagnose and correct because of the potential number of factors
involved. Actual fuel consumption problems can be caused by any of the following factors:
- Engine factors
- Vehicle factors and specifications
- Environmental factors
- Driver technique and operating practices
- Fuel system factors
- Low power/driveability problems
Before troubleshooting, it is important to determine the exact complaint. Is the complaint based on whether the
problem is real or perceived, or does not meet driver expectations? The Fuel Consumption - Customer Complaint
Form (on the next page) is a valuable list of questions that can be used to assist the service technician in determining
the cause of the problem. Complete the form before troubleshooting the complaint. The following are some of the
factors that must be considered when troubleshooting fuel consumption complaints.
1. Result of a Low Power/Driveability Problem: An operator will change his driving style to compensate for a
low power/driveability problem. Some things the driver is likely to do are, (a) shift to a higher engine rpm or (b)
run on the droop curve in a lower gear instead of upshifting to drive at part throttle conditions. These changes
in driving style will increase the amount of fuel used.
2. Driver Technique and Operating Practices: As a general rule, a 1 mph increase in road speed equals a 0.1
mpg increase in fuel consumption. This means that increasing road speed from 50 to 60 mph will result in a loss
of fuel mileage of 1 mpg.
3. Environmental and Seasonal Weather Changes: As a general rule, there can be as much as a 1 to 1.5 mpg
difference in fuel consumption depending on the season and the weather conditions.
4. Excessive Idling Time: Idling the engine can use from 0.5 to 1.5 gallons per hour depending on the engine idle
speed.
5. Truck Route and Terrain: East/west routes experience almost continual crosswinds and head winds. Less fuel
can be used on north/south routes where parts of the trip are not only warmer, but see less wind resistance.
6. Vehicle Aerodynamics: The largest single power requirement for a truce is the power needed to overcome air
resistance. As a general rule, each 10 percent reduction in air resistance results in a 5 percent increase in mpg.
7. Rolling Resistance: Rolling resistance is the second largest consumer of power on a truck. The type of tire and
tread design have a sizeable effect on fuel economy and performance. Changing from a bias ply to a low profile
radial tire can reduce rolling resistance by about 36 percent.
Additional vehicle factors, vehicle specifications, and axle alignment can also affect fuel consumption. For additional
information on troubleshooting fuel consumption complaints, refer to Troubleshooting Excessive Fuel Consumption,
Bulletin 3387245.
Fuel Consumption - Customer Complaint Form

Customer Name/Company __________________________________________________________ Date ________________
Customer Contact _________________________________________________Customer Phone Number ________________
Describe the issue/complaint in detail, including current fuel economy being achieved:
______________________________________________________________________________________________________
______________________________________________________________________________________________________
Answer the following questions. Some questions require making an X next to the appropriate answer.
1. What is the expected fuel mileage? _______________
2. What is the average GVW? _______________
3. What are the expectations based on?
Original mileage ________ Other units in fleet ________ Competitive engines ________
Previous engine ________ Expectations only ________ VE/VMS report ________
NOTE: If the answer to number 3 is based on comparison (i.e. Other units in fleet, Competitive engines, Previous
engine), the Customer Complaint Form and the Driveability/Low Power/Excessive Fuel Consumption - Checklist
must be filled out for the comparison unit(s) in order to properly troubleshoot the complaint.
4. When did the problem occur?
Since New ________ Suddenly ________ Gradually ________
5. Did the problem start after a repair? Yes ________ No ________
If so, what was repaired and why? ____________________________________________________________
6. Is the vehicle also experiencing a Driveability problem (Low Power or
Poor Acceleration/Response)? Yes ________ No ________
If number 6 is answered Yes, fill out the Driveability/Low Power/Excessive Fuel Consumption Checklist.
7. Is the problem seasonal? Yes ________ No ________
8. Weather conditions during fuel consumption check?
Rain _____ Snow _____ Windy _____ Hot Temperatures _____ Cold Temperatures _____
9. How is the fuel usage measured?
Tank _____ Trip _____ Month _____ Year _____
Road Relay _____ ECM _____ Inspec _____
10. If number 9 is answered Road Relay, ECM, or Inspec, how do these fuel numbers compare to actual?
Percent Difference ________
11. If tractor pulls a refrigerated trailer, are fuel tickets kept separate for tractor and trailer fuel?
Yes ________ No ________
12. How is the distance measured?
Hub _____ Odometer _____ Road Relay _____ ECM _____ Inspec _____ Map Miles _____ Dispatch/Paid Miles
_____
13. If number 12 is answered Road Relay, ECM, Inspec, Map, or Dispatch/Paid, how do these distance numbers
compare to actual?
Percent Difference ___________
14. Are accurate records kept of fuel added on the road? Yes ________ No ________
15. Do routes vary between compared vehicles? Yes ________ No ________
16. Have routes changed for the engine being checked? Yes ________ No ________
17. Has driver changed for the engine being checked? Yes ________ No ________
18. Has typical load changed for the engine being checked? Yes ________ No ________
19. Has the fuel source changed? Yes ________ No ________
20. What are the loads hauled, compared to comparison unit? GVW _______________
Heavier ________ Lighter ________
21. At what altitude is the truck operating?
Below 10,000 feet ________ Above 10,000 feet ________
22. According to the driver, how many hours per day is the truck idling? Hours/day __________
The Service Location should fill out the remaining section
Distributor Name __________________________________________ Date __________________
Distributor Contact _________________________________________ Distributor Phone Number
__________________
23. Record the following parameters from Trip Information in INSITE:
Version of INSITE used ______________
Percent Time in Top Gear ______________%
Percent Time One Gear Down ______________%
Percent Time in Cruise Control ______________%
Percent Time at Idle ______________%
PTO Time ______________hrs
Trip Distance ______________mi/km

Trip Fuel Used ______________gal/L
Trip Gear Down Distance ______________mi/km
Trip Top Gear Distance ______________mi/km
Cruise Control Distance ______________mi/km
Vehicle Overspeed 1 Distance ______________mi/km
Vehicle Overspeed 1 Threshold ______________mph/kph
Vehicle Overspeed 1 Time ______________hrs
Vehicle Overspeed 2 Distance ______________mi/km
Vehicle Overspeed 2 Threshold ______________mph/kph
Vehicle Overspeed 2 Time ______________hrs
24. Is the driver technique or operating practices affecting fuel economy?
Incorrect shift rpm? Yes ________ No ________
Rpm at cruise control speed? Yes ________ No ________
Is customer compensating for low power? Yes ________ No ________
25. Have fuel tank vents been verified to be working properly? Yes ________ No ________
26. Has vehicle been checked for brake drag? Yes ________ No ________
27. Has vehicle been checked for tractor and trailer alignment? Yes ________ No ________
28. Has vehicle been checked for fuel leaks? Yes ________ No ________
29. Does vehicle have either a fuel heater or cooler? Yes ________ No ________
30. Is customer using proper fuel for ambient conditions? Yes ________ No ________
31. Are all charge air cooler clamps present and tight? Yes ________ No ________
IF AFTER FILLING OUT THIS FORM IT APPEARS THAT THE PROBLEM IS NOT CAUSED BY VEHICLE
FACTORS, ENVIRONMENTAL FACTORS, OR DRIVER TECHNIQUE, FILL OUT THE DRIVEABILITY/LOW
POWER/EXCESSIVE FUEL CONSUMPTION CHECKLIST.
Oil Consumption
In addition to the information that follows, a service publication is available titled Technical Overview of Oil
Consumption, Bulletin 3379214.
Engine Lubricating Oil Consumption Report

Owner's Name Date of Delivery Engine Serial Number
Month Day Year Engine Model and Horsepower
Address Equipment Manufacturer
City State/Province Equipment Serial Number Fuel Pump Serial Number
Engine Application (describe) Oil and Filter Change Interval Complaint Originally Registered
Oil Filters Date Miles/Hours/Kilometers
Lubricating Oil Added
Date Added Oil Engine Operation Miles/ Quarts/Liters Oil Brand and Viscosity of Oil Used
Hours/Kilometers Added
Start Test
Last Mileage/Hours/Kilometers _________________________ Minus Start Mileage/Hours/Kilometers

___________________________________
Equals Test Mileage/Hours/Kilometers ____________________________ Divided by Oil Added
__________________________________________
Equals ___________________________________________ Usage
Rate________________________________________________________________
Customer Signature Cummins Dealer Cummins Distributor
Cummins Inc. Form 4755
Coolant Loss Pre-Troubleshooting Guide

Before troubleshooting, it is critical to know where the coolant is being lost. It is not always obvious where the missing
coolant has gone.
Before troubleshooting, it is important to determine the exact complaint by interviewing the driver, looking at the
service history and looking at the ECM information.
Driver Interview Questions

Driver's Name:....
ESN:....
What is your complaint?....
How is this engine used?....
What sort of load factors?....
Where is the vehicle driven?....
1. How often do you add coolant?....
2. How do you fill the radiator?....
3. Do you fill to the High or Low mark when the engine is cold (less than 60C [140F])?....
4. What type of coolant do you add?....
5. Have you seen any coolant on the ground under your truck?....
6. Have you seen green or white streaks on the engine or near the coolant overflow hose?....
7. Is there any specific condition when you get indications of coolant loss (weather, altitude or load)?....
8. Does the engine ever overheat?....
9. Does the warning light flash?....
10. Under what condition?....
11. What temperature does the coolant run at normally?....
12. Does the cooling fan operate correctly (fan on at 99C [210F])?....
13. Have you seen any white smoke at operating temperature, or has anyone told you that white smoke is coming
out of the exhaust?....
14. Do you have oil analysis performed as part of your maintenance?....
15. Are there elevated levels of sodium or potassium?....
16. Have you noticed any increase in moisture condensation on the dipstick or oil fill cap, or moisture in the blowby?
....
17. Have you noticed a milky appearance in your lube oil that might indicate coolant is present?....
18. What other comments do you have that might help us make the right repair?....
Service History Review

Repeat cylinder head or cylinder head gasket repairs can indicate the problem is likely not the cylinder head or cylinder
head gasket. Repeat problems can indicate a deeper problem in the engine. Keep this information in mind while going
through the troubleshooting procedure.
Look at this engine's warranty claims history: who worked on the engine last and what did they do? How many miles/
kilometers are on this engine? Has a cylinder head or cylinder head gasket been replaced before? At how many miles
were the repairs made?
ECM Data Review:
Print out an INSITE Image Report from the ECM. Look for high temperature alarms or low coolant level alarms. Either
indication confirms a complaint of loosing coolant.
Are any fault codes logged in the Engine Protection Fault History?
ECM Fault Code 235 - Low Coolant (how many times)?
ECM Fault Code 151 - High Coolant Temperature (how many times)?
At this point, do you know where the coolant is going? If not and the coolant loss is not severe, suggest mounting a
catch bottle on the radiator overflow tube to catch any overflow that can possibly be blowing out and becoming lost
while at speed. Send the vehicle out to collect more data about where the coolant is or is not going. If the catch bottle
has some coolant in it, refer back to the Coolant Loss External (out the overflow) interview questions.
Section TT - Troubleshooting Symptoms (New Format) Page TT-a
Section TT - Troubleshooting Symptoms (New Format)

Section Contents
Page
Engine Performance Troubleshooting Tree - ISX with CM871 ....................................................................TT-61
Engine Performance Troubleshooting Tree - Signature and ISX CM870 ....................................................TT-1
Fuel Economy Troubleshooting Tree .........................................................................................................TT-110
Fuel Economy Troubleshooting Tree .........................................................................................................TT-141
Vibration Excessive .....................................................................................................................................TT-146
Page TT-b Section TT - Troubleshooting Symptoms (New Format)

Signature, ISX, and QSX15 Eng [...] Engine Performance Troubleshooting Tree - Signature an [...]
Section TT - Troubleshooting Symptoms (New Format) Page TT-1
Engine Performance Troubleshooting Tree - Signature and ISX CM870

This troubleshooting procedure should be followed for the following symptoms:
Engine Acceleration or Response Poor
Cranking Fuel Pressure is Low
Engine Operating Fuel Pressure is Low
Engine Difficult to Start or Will Not Start (Exhaust Smoke)
Engine Difficult to Start or Will Not Start (No Exhaust Smoke)
Engine Run On
Engine Power Output Low
Engine Runs Rough at Idle
Engine Runs Rough or Misfires
Engine Speed Surges at Low or High Idle
Engine Speed Surges Under Load or in Operating Range
Smoke, Black - Excessive
Smoke, White - Excessive
Engine Shuts Off or Dies Unexpectedly or Dies During Deceleration
Engine Starts But Will Not Keep operating
Engine Will Not Reach Rated Speed (rpm).
How to Use This Troubleshooting Procedure:

This symptom tree can be used to troubleshoot all performance based symptoms listed above. Start by performing
Step 1 troubleshooting. Step 2 asks a series of questions and will provide a list of troubleshooting steps to perform
depending on the symptom. Perform the list of troubleshooting in the sequence shown in the Specifications/Repair
section of the tree.
Shop Talk:
Prior to operating INSITE electronic service tool EGR Valve and EGR Valve/Turbocharger Operational Test, the ECM
Calibration Software Phase can possibly need to be updated to the latest Software Phase. The ECM Calibration Phase
Software can be checked in INSITE electronic service tool, under 'Features and Parameters'. Expand the selection
for 'System ID and Dataplate' and go to 'Calibration Information'. If the Software Phase is earlier than shown below,
calibrate the ECM, use the January 2006 INCAL CD-ROM, or later. Engines with the Software Phase listed below
or later do not require a calibration.
ISX engines with CM870 (engines built after January 2004) require Software Phase 06050302.
ISX engines with CM870 (engines built before January 2004) require no changes at this time.
This is a warrantable calibration change.
Engine Performance Troubleshooting Tree - Signature an [...] Signature, ISX, and QSX15 Eng [...]
Page TT-2 Section TT - Troubleshooting Symptoms (New Format)
TROUBLESHOOTING SUMMARY
CAUTION
To reduce the possibility of pin and harness damage, use the following test leads when taking a measurement:
Part Number 3822758 - 20 AWG male Deutsch/AMP/Metri-Pack test lead and Part Number 3824811 - 12
AWG male Deutsch/AMP/Metri-Pack test lead.
STEPS SPECIFICATIONS SRT CODE

STEP 1: Perform basic troubleshooting procedures.
STEP 1A: Check for active fault codes or Active fault codes or high counts
high counts of inactive fault of inactive fault codes?
codes.
STEP 1B: Perform basic troubleshooting All steps have been verified to
checks. be correct?
STEP 2: Determination of engine symptom.
STEP 2A: Low power, poor acceleration, Is the engine symptom low
or poor response. power, poor acceleration, or
poor response?
STEP 2B: Engine misfire. Is the engine symptom Engine
Runs Rough or Misfires?
STEP 2C: Excessive black smoke. Is the engine symptom
Excessive Black Smoke?
STEP 2D: Excessive white smoke. Is the engine symptom
Excessive White Smoke and the
engine is using coolant?
STEP 2D-1: Excessive white smoke. Is the engine symptom
engine is not using coolant?
STEP 2E: Engine speed surge or engine Is the engine symptom Engine
speed unstable. Speed Surge or Engine Speed
Unstable?
STEP 2F: Engine will not start or difficult Is the symptom Engine Difficult
to start. to Start or Will Not Start?
STEP 2G: Engine stalls or shuts off Is the symptom Engine Stalls or
unexpectedly. Shuts Off Unexpectedly?
STEP 2H: Engine run on or will not shut Is the engine symptom Engine
down. Run On or Slow to Shut Down
after operated at high idle for 1
minute then keyed off?
STEP 3: No-start troubleshooting procedures.
STEP 3A: Verify the fuel system has been Has the fuel system properly
primed. primed?
STEP 3B: Check fuel shutoff valve voltage. Is the fuel shutoff valve voltage
greater than 11-VDC?
STEP 3B-1: Check ECM keyswitch Is the keyswitch voltage equal to
voltage. battery voltage?
STEP 3B-2: Check the fuel shutoff valve Less than 10 ohms?
wire.
STEP 3B-3: Check the ECM power and Is the ECM battery supply
ground. voltage equal to the battery
voltage?
STEP 3C: Check fuel shutoff valve Is the fuel shutoff solenoid
resistance. resistance 1 to 5 ohms for 6-VDC
solenoids, 6 to 15 ohms for 12-
VDC solenoids, 24 to 50 ohms
for 24-VDC solenoids, 42 to 80
ohms for 32-VDC solenoids, 46
to 87 ohms for 36-VDC
solenoids, 92 to 145 ohms for 48-
VDC solenoids, 315 to 375 ohms
for 74-VDC solenoids, 645 to 735
ohms for 115-VAC solenoids?
STEP 3D: Check fuel shutoff valve Debris or damage found on the
actuator. valve disc, valve seat, or
actuator disc?
STEP 3E: Check for correct priming pump Does the lift pump operate after
operation, if equipped. turning the keyswitch ON?
STEP 3E-1: Check priming pump Does pump pressure meet the 69
pressure. kPa [10 psi] specification?
STEP 3F: Check for coolant in the EGR Is coolant present in the
transfer tube. crossover tube?
STEP 4: Fuel system checks.
STEP 4A: Verify the fuel system has been Has the fuel system been
primed. properly primed?
STEP 4B: Check for air in the fuel. Are air bubbles visible in the coil
of clear tubing?
STEP 4C: Check fuel inlet restriction. Is fuel inlet restriction less than
the specifications?
STEP 4D: Check drain line restriction. Is fuel drain line restriction less
than 229 mm-Hg [9 in-Hg]?
STEP 4E: Check rail fuel pressure. Does the rail fuel pressure meet
the specification?
STEP 4E-1: Check the pressure side fuel Is the pressure side fuel filter
filter restriction. pressure drop less than 517 kPa
[75 psi]?
STEP 4E-2: Check 1724 kPa [250 psi] Is the 1724 kPa [250 psi]
pressure regulator. pressure regulator free of debris
or damage?
STEP 4E-3: Check 2206 kPa [320 psi] or Is the pressure regulator free of
2620 kPa [380 psi] pressure debris or damage?
regulator.
STEP 5: Injector and Actuator Diagnostics.
STEP 5A: Perform the injector check valve Did the injector leak test detect
leak test. a leaking injector?
STEP 5B: Perform INSITE electronic Does performing INSITE
service tool Cylinder electronic service tool Cylinder
Performance Test. Performance Test isolate to a
single malfunctioning injector?
STEP 5B-1: Perform INSITE electronic Does performing INSITE
Performance Test at 600 Performance Test isolate to a
rpm. single malfunctioning injector?

STEP 5C: Perform INSITE electronic Do all cylinders pass the cylinder
service tool Cylinder Cutout cutout test?
Test.
STEP 5C-1: Perform INSITE electronic Can a malfunctioning bank of
service tool Cylinder Cutout injectors be isolated by
Test on both injector banks. operating the engine on either
bank of injectors?
STEP 5C-2: Perform INSITE electronic Can a malfunctioning injector be
service tool Cylinder Cutout isolated by operating the engine
Test. on a single injector?
STEP 5C-3: Verify overhead Are the overhead settings within
adjustments are correct for the reset limits outlines in
the suspected Procedure 003-004 in Section 3?
malfunctioning injector.
STEP 5D: Swap the front and rear Does the malfunctioning bank
metering actuators. follow the metering actuator?
STEP 5E: Swap the front and rear timing Does the malfunctioning bank
actuators. follow the timing actuator?
STEP 6: Air handling diagnostic checks.
STEP 6A: Start the engine and read the Active fault codes?
fault codes.
STEP 6B: Inspect the turbocharger blades Damage found on turbocharger
for damage. blades?
STEP 6C: Determine turbocharger type. Is the turbocharger a variable
geometry turbocharger?
STEP 6D: Check the variable geometry Does the turbocharger actuator
actuator rod for correct travel. rod extend between 10 and 12
mm [0.394 and 0.472 in]?
STEP 6D-1: Check for air leaks and Air leaks found in the system?
inspect air lines.
STEP 6D-2: Check the engine and Connections tight and corrosion-
vehicle grounds. free?
STEP 6D-3: Check for air pressure at the Is vehicle air tank pressure
turbocharger control valve present at the turbocharger
outlet. control valve outlet?
STEP 6D-4: Check for air pressure at the Does the pressure gauge read
turbocharger control valve more than 103 kPa [15 psi] after
outlet. 5 minutes?
STEP 6D-5: Check for correct Does the turbocharger actuator
turbocharger actuator rod travel at least 12 mm [0.472
travel. in]?
STEP 6D-6: Check for air pressure at the Can air be heard escaping from
turbocharger control shutoff the turbocharger control shutoff
valve outlet. valve outlet?
STEP 6D-7: Check for air pressure at the Can air be heard escaping from
turbocharger control shutoff the turbocharger control shutoff
valve inlet. valve inlet?
STEP 6D-8: Check for plugged Is an air leak present at the

turbocharger control shutoff turbocharger control shutoff
valve filter. valve filter head?
STEP 6E: Perform INSITE electronic Does the Turbocharger
service tool EGR Valve/ Operational Test pass?
Turbocharger Operational Test.
STEP 6E-1: Check the engine and Connections tight and corrosion-
vehicle grounds. free?
STEP 6F: Inspect the wastegate actuator Holes or cracks found in the
hose. wastegate actuator hose?
STEP 6G: Inspect the wastegate actuator Does the wastegate actuator rod
rod for travel. move?
STEP 6G-1: Inspect wastegate actuator Does the wastegate actuator rod
rod for travel. move?
STEP 6H: Measure resistance of the four- Are the wastegate controller
stage wastegate controllers, if solenoid resistances between
equipped. 7.0 and 8.0 ohms?
STEP 6I: Inspect four-stage wastegate Damage or debris found on the
controller, if equipped. valve disc, valve seat, or
actuator disc?
STEP 7: Check EGR valve for proper operation.
STEP 7A: Check for air leaks in the EGR Air leaks found in the EGR
system. connection tubing?
STEP 7B: Check the repair history. Is there a record of the poppet
head missing?
STEP 7C: Perform EGR Valve Test. Does the EGR Valve Test pass?
STEP 8: Verify electronic features are operating correctly.
STEP 8A: Verify accelerator pedal travel. Does the Accelerator Pedal read
0 when the accelerator is
released and 100 percent when
the accelerator is depressed?
STEP 8B: Monitor vehicle speed. Does the vehicle speed read 0
when the vehicle is not moving?
STEP 8C: Verify electronic feature settings Are the electronic features set
are correct. correctly?
STEP 8D: Check the barometric pressure Is the barometric pressure
sensor reading. sensor reading in INSITE
electronic service tool within 5
percent of the present local
barometric pressure reading?
STEP 9: Perform base engine mechanical checks.
STEP 9A: Verify overhead adjustments are Are the overhead settings within
correct. the reuse limits?
STEP 9B: Check air intake restriction. Is air intake restriction greater
than 635 mm-H 2O [25 in-H 2O]
for a used air filter or 254 mm-H
2O [10 in-H 2O] for a new filter?
STEP 9C: Check exhaust restriction. Is exhaust restriction between

518 mm-H 2O [20.4 in-H 2O] or 38
mm-Hg [1.5 in-Hg] and 1036 mm-
H 2O [40.8 in-H 2O] or 76 mm-Hg

[3.0 in-Hg]?
STEP 9D: Pressure test the charge air Is the pressure drop 34 kPa [5
cooler. psi] or less in 15 seconds?
STEP 9E: Verify engine brake adjustment. Are the engine brake settings
within the reuse limits?
STEP 9F: Measure turbocharger axial and Are the axial and radial
radial clearance. clearances within specification?
STEP 9G: Verify engine blowby is within Are the engine blowby
specification. measurements within
specification?
STEP 9G-1: Verify turbocharger Did the total engine blowby drop
contribution to engine more than 30 percent?
blowby.
STEP 9H: Verify base engine timing is Is the base engine timing within
correct. specification?
STEP 9I: Check for a damaged vibration Is the vibration damper damaged
damper. or out of specification?
STEP 10: Check the EGR differential pressure sensor and exhaust gas pressure sensor
tubes.
STEP 10A: Check the EGR differential Are cracks, restrictions, or leaks
pressure tubes for cracks, present?
restrictions, or leaks.
STEP 10B: Check the exhaust gas pressure Are cracks, restrictions, or leaks
sensor tubes for cracks, present?
restrictions, or leaks.
TROUBLESHOOTING STEP

STEP 1A: Check for active fault codes or high counts of inactive fault codes.
Condition:
Connect INSITE electronic service tool.
Turn keyswitch ON.
Action Specification/Repair Next Step
Check for active fault codes or high counts of Active fault codes or high counts of inactive Go to
inactive fault codes. fault codes? appropriate
Use INSITE electronic service tool to read the YES fault code
fault codes. troubleshooti
ng tree
Active fault codes or high counts of inactive 1B

fault codes?
NO
STEP 1B: Perform basic troubleshooting checks.

Condition:
The following items must be checked or verified All steps have been verified to be correct? 2A
before continuing: YES
Verify the fuel level in the tanks
Verify there have not been any changes to
CPL components on the engine All steps have been verified to be correct? Repair
Verify ECM calibration is correct NO complete
Verify fuel grade is correct for the application
Repair:
Verify the engine is operating within the
recommended altitude Correct the condition and verify complaint is
Verify engine oil is at the correct level no longer present after repair.
Verify engine parasitics have not changed
Verify engine duty cycle has not changed
Verify engine cranking speed is greater than
150 rpm.

STEP 2A: Low power, poor acceleration, or poor response.
Condition:
Interview the driver and verify the complaint. Is the engine symptom low power, poor Perform the
acceleration, or poor response? troubleshooti
YES ng steps
suggested in
Repair: the repair
Perform the troubleshooting steps in the procedure
recommended order listed below:
Step 4 - Fuel System Checks
Step 6 - Air Handling Checks
With EGR - Step 7 - EGR Checks
Step 8 - Electronic Checks
Step 5 - Injector Checks
Step 9 - Base Engine Checks
With EGR - Step 10 - EGR Differential
Pressure and Exhaust Gas Pressure
Checks.
Is the engine symptom low power, poor 2B

acceleration, or poor response?
NO
STEP 2B: Engine misfire.

Condition:
Interview the driver and verify the complaint. Is the engine symptom Engine Runs Rough Perform the
or Misfires? troubleshooti
YES ng steps
suggested in
Repair: the repair
Checks.
Is the engine symptom Engine Runs Rough 2C

or Misfires?
NO
STEP 2C: Excessive black smoke.

Condition:
Interview the driver and verify the complaint. Is the engine symptom Excessive Black Perform the
Smoke? troubleshooti
YES ng steps
suggested in
Repair: the repair
With EGR - Step 7 - EGR Checks
Checks
Step 9 - Base Engine Checks.
Is the engine symptom Excessive Black 2D

Smoke?
NO
STEP 2D: Excessive white smoke.

Condition:
Interview the driver and verify the complaint. Is the engine symptom Excessive White Perform the
Smoke and the engine is using coolant? troubleshooti
YES ng steps
suggested in
Repair: the repair
See the Coolant Loss - Internal symptom
tree.
Is the engine symptom Excessive White 2D-1

Smoke and the engine is using coolant?
NO
STEP 2D-1: Excessive white smoke.

Condition:
Smoke and the engine is not using coolant? troubleshooti
YES ng steps
suggested in
Repair: the repair
Is the engine symptom Excessive White 2E

Smoke and the engine is not using coolant?
NO
STEP 2E: Engine speed surge or engine speed unstable.

Condition:
Interview the driver and verify the complaint. Is the engine symptom Engine Speed Surge Perform the
or Engine Speed Unstable? troubleshooti
YES ng steps
suggested in
Repair: the repair
Checks
Step 8 - Electronics Checks
Is the engine symptom Engine Speed Surge 2F

or Engine Speed Unstable?
NO
STEP 2F: Engine will not start or difficult to start.

Condition:
None
Interview the driver to verify the complaint. Is the symptom Engine Difficult to Start or Perform the
Will Not Start? troubleshooti
YES ng steps
suggested in
Repair: the repair
Perform the steps that pertain to difficult to procedure
start or will not start concerns per the
troubleshooting steps in the recommended
order listed below:
Step 3 - No Start Checks
Check the engine base timing. Use the
following procedure in the Signature,
ISX, and QSX15 Service Manual, Bulletin
3666239. Refer to Procedure 001-088 in
Section 1.
Is the symptom Engine Difficult to Start or 2G

Will Not Start?
NO
STEP 2G: Engine stalls or shuts off unexpectedly.

Condition:
None
Interview the driver to verify the complaint. Is the symptom Engine Stalls or Shuts Off Perform the
Unexpectedly? troubleshooti
YES ng steps
suggested in
Repair: the repair
Perform the steps that pertain to stalls or procedure
shuts off unexpectedly per the
troubleshooting steps in the recommended
order listed below:
Is the symptom Engine Stalls or Shuts Off 2H

Unexpectedly?
NO
STEP 2H: Engine run on, or will not shut down

Condition:
None
Interview the driver and verify the complaint. Is the engine symptom Engine Run On or Perform the
Slow to Shut Down after operated at high idle troubleshooti
for 1 minute then keyed off? ng steps
YES suggested in
the repair
Repair: procedure
Perform the troubleshooting steps in the
Is the engine symptom Engine Run On or Return to the

Slow to Shut Down after operated at high idle appropriate
for 1 minute then keyed off? symptom
NO tree

STEP 3A: Verify the fuel system has been primed.
Condition:
Turn keyswitch OFF.
If entering this tree after a component has been Has the fuel system been properly primed? 3B
replaced in the fuel system, or after the engine YES
was run out of fuel, verify the fuel system has
been properly primed before proceeding.
Verify the fuel system has been properly Has the fuel system been properly primed? Repair
primed. NO complete
Use the following procedure for fuel system
Repair:
priming information found in the Signature,
ISX, and QSX15, Service Manual, Bulletin Prime the fuel system.
3666239. Refer to Procedure 006-015 in Use the following procedure for fuel
Section 6. system priming information found in the
Signature, ISX, and QSX15, Service
Manual, Bulletin 3666239. Refer to
STEP 3B: Check fuel shutoff valve voltage.

Condition:
Turn keyswitch ON.
Measure the voltage from the fuel shutoff valve Is the fuel shutoff valve voltage greater than 3C
post to engine block ground. 11-VDC?
YES
Is the fuel shutoff valve voltage greater than 3B-1

11-VDC?
NO
STEP 3B-1: Check ECM keyswitch voltage.

Condition:
Turn keyswitch OFF.
Disconnect the OEM harness from the ECM.
Turn keyswitch ON.
Measure the voltage from the keyswitch input Is the keyswitch voltage equal to battery 3B-2
SIGNAL wire of the OEM harness to engine block voltage?
ground. YES
Is the keyswitch voltage equal to battery Repair

voltage? complete
NO
Repair:
Repair or replace the OEM power harness,
keyswitch, or check the battery connections.
Use the following procedure in the
Electronic Control System Signature and
ISX Engines, Bulletin 4021334. Refer to
STEP 3B-2: Check the fuel shutoff valve wire.

Condition:
Turn keyswitch OFF.
Disconnect the engine harness from the ECM.
Disconnect the fuel shutoff valve wire from the valve terminal post.
Measure the resistance from the fuel shutoff Less than 10 ohms? 3B-3
valve SIGNAL pin in the ECM connector to the YES
fuel shutoff valve eyelet.
Use the circuit diagram or wiring diagram for Less than 10 ohms? Repair
connector pin identification. complete
NO
Use the following procedure for general
resistance measurement techniques. Use the Repair:
following procedure in the Troubleshooting and Repair or replace the engine harness.
Repair Manual, CM870 Electronic Control
System Signature and ISX Engines, Bulletin Use the following procedure in the
4021334. Refer to Procedure 019-360 in Section Troubleshooting and Repair Manual, CM870
19.
STEP 3B-3: Check the ECM power and ground.

Condition:
Turn keyswitch OFF.
Disconnect the ECM power supply connector from the ECM.
Measure the voltage from the ECM battery Is the ECM battery supply voltage equal to Repair
SUPPLY (-) to the ECM battery SUPPLY (+) pins the battery voltage? complete
in the ECM power harness connector. YES
Repair:
Call for authorization to replace the ECM.
Upon receipt of authorization, replace the
ECM. Use the following procedure in the
Is the ECM battery supply voltage equal to Repair

the battery voltage? complete
NO
Repair:
Repair or replace the ECM power harness.
STEP 3C: Check fuel shutoff valve resistance.

Condition:
Turn keyswitch OFF.
Disconnect fuel shutoff valve SIGNAL wire from the fuel shutoff solenoid.
Fuel shutoff valve temperature between 20C [68F] and 25C [78F].
Measure the resistance from the fuel shutoff Is the fuel shutoff solenoid resistance: 3D
solenoid post to engine block ground. 1 to 5 ohms for 6-VDC solenoids
Note: The fuel shutoff solenoid must be between 6 to 15 ohms for 12-VDC solenoids
20C [68F] and 25C [78F] before using the 24 to 50 ohms for 24-VDC solenoids
resistance specifications listed. 42 to 80 ohms for 32-VDC solenoids
46 to 87 ohms for 36-VDC solenoids
645 to 735 ohms for 115-VAC solenoids?
YES
Is the fuel shutoff solenoid resistance: Repair

1 to 5 ohms for 6-VDC solenoids complete
NO
Repair:
Replace the fuel shutoff solenoid. Use the
following procedure in the Troubleshooting
and Repair Manual, CM870 Electronic
Control System Signature and ISX Engines,
Bulletin 4021334. Refer to Procedure
STEP 3D: Check fuel shutoff valve actuator.

Condition:
Turn keyswitch OFF.
Remove the fuel shutoff valve solenoid, valve disc, valve seat, and actuator.
Check the valve disc, valve seat, and actuator Debris or damage found on the valve disc, Repair
disc for dirt, metal debris, bonding separation, valve seat, or actuator disc? complete
corrosion, cracks, or wear. YES
Repair:
Replace the damaged fuel shutoff valve
component. Use the following procedure in
CM870 Electronic Control System
Signature and ISX Engines, Bulletin
Section 19.
Debris or damage found on the valve disc, 3E

valve seat, or actuator disc?
NO
STEP 3E: Check for correct priming pump operation, if equipped.

Condition:
Turn keyswitch OFF.
Assemble fuel shutoff valve components.
Turn keyswitch ON.
Listen for lift pump operation after the keyswitch Does the lift pump operate after turning the 3E-1
is turned to the ON position. keyswitch ON?
Note: Not all ISX engines use a priming pump YES
and not all ISX engines use a priming pump that
actuates at keyswitch ON. Understand which Does the lift pump operate after turning the Repair
system is present on this engine before keyswitch ON? complete
beginning this step.
NO
Repair:
Check or replace the lift pump. Use the
following procedure in the Signature, ISX,
and QSX15 Service Manual, Bulletin
Section 5.
STEP 3E-1: Check priming pump pressure.

Condition:
Turn keyswitch OFF.
Turn keyswitch ON.
Measure the priming pressure at the quick Does pump pressure meet the 69 kPa [10 psi] 3F
connect fitting located on the top of the specification?
integrated fuel system module (IFSM). YES
Use the following procedure in the Signature,
ISX, and QSX15 Service Manual, Bulletin Does pump pressure meet the 69 kPa [10 psi] Repair
3666239. Refer to Procedure 005-045 in Section specification? complete
5.
NO
Repair:
Replace the lift pump.
Signature ISX, and QSX15 Service Manual,
STEP 3F: Check for coolant in the EGR transfer tube.

Condition:
Turn keyswitch OFF.
Remove the EGR transfer hose from the EGR Is coolant present in the crossover tube? Repair
cooler outlet. YES complete
Repair:
tree.
Is coolant present in the crossover tube? 2A

NO
Repair:
Perform the next troubleshooting procedure
as outlined in Step 2

Condition:
Turn keyswitch OFF.
If entering this tree after a component has been Has the fuel system been properly primed? 4B
replaced in the fuel system, or after the engine YES
has been run out of fuel, verify the fuel system
has been properly primed before proceeding.
Verify the fuel system has been properly Has the fuel system been properly primed? repair
primed. NO complete
Repair:
priming information found in the Signature,
ISX, and QSX15, Service Manual, Bulletin Prime the fuel system.
3666239. Refer to Procedure 006-015 in Use the following procedure for fuel
Section 6. system priming information found in the
Signature, ISX, and QSX15, Service
STEP 4B: Check for air in the fuel.

Condition:
Engine operating at low idle (engine cranking if troubleshooting No-Start).
Connect the equipment to the quick-connect Are air bubbles visible in the coil of clear Repair
fitting at the fuel module as shown. tubing? complete
Put a coil in the clear hose. YES
Put the end of the clear hose in a clean
container. Repair:
Operate the engine at low idle with no load. Locate and correct the cause of air ingestion
Slightly open the valve until a steady stream of in the OEM fuel supply system or damaged
fuel is visible. suction-side fuel filter sealing ring.
With EGR:
Check the ECM cooling plate, associated
plumbing, and o-ring seals for failures that
can cause air ingestion. Repair or replace the
malfunctioning component. Use the following
procedure in the Signature, ISX, and
QSX15 Service Manual, Bulletin 3666239.
Air bubbles visible in the coil of clear tubing? 4C

NO
STEP 4C: Check fuel inlet restriction.

Condition:
Connect vacuum gauge to the suction side Compuchek fitting.
Turn keyswitch ON.
Engine operating at high idle (engine cranking if troubleshooting No-Start).
If the engine uses a priming pump, wait until after Is fuel inlet restriction less than the 4D
the priming pump has turned off and observe the specifications listed below?
reading on the vacuum gauge. Dirty - 305 mm-Hg [12 in-Hg]; New - 203 mm-
Check the fuel inlet restriction. Hg [8 in-Hg]
Use the following procedure in the Signature, YES
3666239. Refer to Procedure 006-020 n Section Is fuel inlet restriction less than the Repair
6. specifications listed below? complete
Dirty - 305 mm-Hg [12 in-Hg]; New - 203 mm-
Hg [8 in-Hg]
NO
Repair:
Locate the cause of high fuel inlet restriction.
Check the suction-side fuel filter and fuel
supply lines.
Note: For QSX15 only, check the 300 micron
inlet filter screen for debris. Use the following
STEP 4D: Check drain line restriction.

Condition:
Connect pressure gauge, Part Number 3375278.
Turn keyswitch ON.
Observe reading on the pressure gauge. Is fuel drain line restriction less than 229 mm- 4E
Hg [9 in-Hg]?
YES
Is fuel drain line restriction less than 229 mm- Repair

Hg [9 in-Hg]? complete
NO
Repair:
Locate cause of high fuel drain line restriction
in OEM fuel return line.
STEP 4E: Check rail fuel pressure.

Condition:
Connect pressure gauge, Part Number 3375932, on the Compuchek fitting (as shown)
Turn keyswitch ON.
Read the rail fuel pressure at low idle and high Does the rail fuel pressure meet the Perform the
idle. specification? next
Read the rail fuel pressure while cranking if the YES troubleshooti
ng procedure
engine will not start.
as outlined in
Cranking: greater than 689 kPa [100 psi] at Step 2
130 rpm for at least 10 seconds.
Low idle: 1689 to 1889 kPa [245 to 274 psi] at
Does the rail fuel pressure meet the 4E-2
600 rpm.
specification?
High idle: 1896 to 2068 kPa [275 to 325 psi] at With EGR
1800 rpm. NO 4E-1
With EGR Repair:
Cranking: greater than 689 kPa [100 psi] at Note: When cranking, make sure the fuel
130 rpm for at least 10 seconds. system is primed for at least 30 seconds.
600 rpm.
High idle: 1896 to 2068 kPa [275 to 325 psi] at
1800 rpm.
STEP 4E-1: Check the pressure side fuel filter restriction.

Condition:
Connect pressure gauge, Part Number 3375932, on the rail fuel pressure Compuchek fitting.
Connect pressure gauge, Part Number 3375932, on the gear pump output pressure Compuchek fitting.
Engine operating at high idle (engine cranking if troubleshooting no-start).
Read the fuel pressure drop across the pressure Is the pressure side fuel filter pressure drop 4E-2
side fuel filter at high idle or while cranking if the less than 517 kPa [75 psi]?
engine will not start. YES
Is the pressure side fuel filter pressure drop Repair

less than 517 kPa [75 psi]? complete
NO
Repair:
Replace the pressure side fuel filter. Use the
Section 6.
STEP 4E-2: Check 1724 kPa [250 psi] pressure regulator.

Condition:
Turn keyswitch OFF.
Remove the 1724-kPa [250-psi] fuel pressure Is the 1724 kPa [250 psi] pressure regulator 4E-3
regulator. free of debris or damage?
Inspect for debris or damage or incomplete YES
sealing of the regulator.
Is the 1724 kPa [250 psi] pressure regulator Repair
free of debris or damage? complete
NO
Repair:
Replace 1724 kPa [250 psi] regulator.
Signature, ISX, and QSX15 Service
STEP 4E-3: Check 2206 kPa [320 psi] or 2620 kPa [380 psi] pressure regulator.
Condition:
Turn keyswitch OFF.
Remove the 2206 kPa [320 psi] fuel pressure Is the pressure regulator free of debris or Repair
regulator. damage? complete
Inspect for debris, damage, or incomplete YES
sealing of the regulator. Repair:
With EGR Replace the fuel pump.
Remove the 2620 kPa [380 psi] fuel pressure Use the following procedure in the
regulator. Signature, ISX, and QSX15 Service
Inspect for debris, damage, or incomplete Manual, Bulletin 3666239. Refer to
sealing of the regulator. Procedure 005-016 in Section 5.
Is the pressure regulator free of debris or Repair

damage? complete
NO
Repair:
Replace the 2206 kPa [320 psi] regulator.
With EGR
Replace the 2620 kPa [380 psi] regulator.

STEP 5A: Perform the injector check valve leak test.
Condition:
None
Perform the injector check valve leak test to Did the injector leak test detect a leaking Repair
check for internal injector check valve damage. injector? complete
ISX, and QSX15 Service Manual, Bulletin Repair:
3666239. Refer to Procedure 006-026 in Section
6. Replace the leaking injector. Use the
Note: INSITE electronic service tool Injector and QSX15 Service Manual, Bulletin
Check Valve Diagnostics Test can be used as an 3666239. Refer to Procedure 006-026 in
initial test before performing the mechanical Section 6.
check outlined in Procedure 006-026 in Section
6. If INSITE electronic service tool does not
detect a failed injector, perform the injector leak Did the injector leak test detect a leaking 5B
test. Use the following procedure in the injector?
Signature, ISX, and QSX15 Service Manual, NO
Section 6.
STEP 5B: Perform INSITE electronic service tool Cylinder Performance Test.
Condition:
Troubleshoot any active fault codes before performing the test.
Engine coolant temperature must be greater than 83C [180F].
Engine idling.
Perform INSITE electronic service tool Cylinder Does performing INSITE electronic service 5C-3
Performance Test. tool Cylinder Performance Test identify a
During the initial 30 seconds of the Cylinder
Performance Test, INSITE electronic service YES
tool is checking to make sure all parameters have
been met to enter the test. Does performing INSITE electronic service 5B-1
Once the initial Pass or Fail reading is displayed, tool Cylinder Performance Test identify a
the test is live for the next 2 minutes. Monitor the single malfunctioning injector?
display to see if cylinders or banks drop out NO
during this 2 minute window. A cylinder can
switch from pass to fail and back to pass quickly,
so monitor the screen closely.
STEP 5B-1: Perform INSITE electronic service tool Cylinder Performance Test at 600 rpm.
Condition:
Engine idling at 600 rpm.
Skip this step and move on to step 5B-2 if the rpm Does performing INSITE electronic service 5C-3
value is the same as that used in step 5B. tool Cylinder Performance Test identify a
Adjust the low speed to 600 rpm and perform the
INSITE electronic service tool Cylinder YES
Performance Test.
During the initial 30 seconds of the Cylinder Does performing INSITE electronic service 5B-2
Performance Test, INSITE electronic service tool Cylinder Performance Test identify a
tool is checking to make sure all parameters have single malfunctioning injector?
been met to enter the test. NO
Once the initial Pass or Fail reading is displayed,
the test is live for the next 2 minutes. Monitor the
display to see if cylinders or banks drop out
Condition:
Note: The idle speed may need to be adjusted to perform this test. Toggle the cruise control increment/decrement
switch to see if the idle speed can be adjusted. If not, use INSITE electronic service tool to either enable the
Adjustable Low Idle Speed feature or adjust the Low Idle Speed.
Skip this step and move on to step 5B-3 if the Does performing INSITE electronic service 5C-3
RPM value is the same as that used in step 5B. tool Cylinder Performance Test identify a
Performance Test.
Condition:
"Adjustable Low Idle Speed" feature or adjust the Low Idle Speed.
Skip this step and move on to step 5C if the rpm Does performing INSITE electronic service 5C-3
Performance Test.
During the initial 30 seconds of the Cylinder Does performing INSITE electronic service 5C
STEP 5C: Perform INSITE electronic service tool Cylinder Cutout Test
Condition:
Air conditioning is turned off.
Fan is turned off.
Any electrical loads are disabled.
Engine idling at the engine speed at which the misfire is present.
Perform INSITE electronic service tool cylinder Do all cylinders pass the cylinder cutout test? 5C-1
cutout test. YES
Note: a failing cylinder will have no effect on
engine sound and operation when cut out using Do all cylinders pass the cylinder cutout test? 5C-3
this test.
NO
STEP 5C-1: Perform INSITE electronic service tool cylinder cutout test on individual injector banks.
Condition:
Fan is turned off.
Perform the INSITE electronic service tool Can a malfunctioning bank of injectors be 5D
cylinder cutout test. isolated by operating the engine on either
Operate the engine on the front bank of bank of injectors?
injectors identified by the cylinder cutout test YES
by disabling the rear three cylinders 4, 5, 6
cylinders with INSITE electronic service tool.
Operate the engine on the rear bank of Can a malfunctioning bank of injectors be 5C-2
injectors identified by the Cylinder isolated by operating the engine on either
Performance Test by disabling the front three bank of injectors?
cylinders (1,2,3) with INSITE electronic NO
service tool.
To disable one bank of cylinders with INSITE
electronic service tool, click on the cylinder
numbers associated with that bank. The front
bank consists of cylinders 1, 2, and 3 and the
rear bank is cylinders 4, 5, and 6.
A malfunctioning bank of injectors will cause
the engine to run poorly when the opposite
bank is cut out using this test.
STEP 5C-2: Perform INSITE electronic service tool Cylinder Cutout Test single cylinder operation.
Condition:
Fan is turned off.
Perform the INSITE electronic service tool Can a malfunctioning injector be isolated by 5C-3
cylinder cut out test. operating the engine on a single injector?
Operate the engine on the cylinder identified by YES
the Cylinder Performance Test by disabling 5
cylinders with INSITE electronic service tool Can a malfunctioning injector be isolated by 5D
and only operating on the suspect cylinder. operating the engine on a single injector?
To disable 5 cylinders with INSITE electronic NO
service tool, click on the cylinder numbers until
only 1 cylinder is enabled.
The engine should roughly maintain idle speed
when operating on a single cylinder. A weak or
misfiring cylinder will be detected if the engine
dies or can not maintain idle speed when
operating on a single cylinder.
Continue testing all 6 cylinders by operating the
engine on each individual injector.
Note: If the engine will not run on 1 cylinder
regardless of the cylinder selected, increase the
idle RPM and retest.
Note: Do not run the engine on 1 cylinder for an
extended period of time.
STEP 5C-3: Verify overhead adjustments are correct for the suspected malfunctioning injector.
Condition:
Turn keyswitch OFF.
Remove the rocker lever cover. Use the following procedure in the Signature, ISX, and QSX15 Service Manual,
Bulletin 3666239. Refer to Procedure 003-011 in Section 3.
Measure the overhead settings for the suspected Are the overhead settings within the reset Repair
malfunctioning injector. limits outlined in Procedure 003-004 in complete
Check the valve lash and injector pre-load Section 3?
torque before replacing the injector. YES
3666239. Refer to Procedure 003-004 in Replace the malfunctioning injector.
Section 3.
Are the overhead settings within the reset 5B

limits outlined in Procedure 003-004 in
Section 3?
NO
Repair:
Adjust the overhead settings.
Perform the Cylinder Performance Test to
determine if a misfire still exists after
adjusting the overhead settings.
STEP 5D: Swap the front and rear metering actuators.

Condition:
Turn keyswitch OFF.
Disconnect the engine harness from the timing and metering actuators.
Swap the front and rear metering actuator to Did the cylinder performance test find a Repair
determine if the failed bank of cylinders follows a malfunctioning bank? complete
specific metering actuator. YES
Troubleshooting and Repair Manual, CM870 Repair:
Electronic Control System Signature and ISX Replace the malfunctioning metering
Engines, Bulletin 4021334. Refer to Procedure actuator. Use the following procedure in the
019-110 in Section 19. Troubleshooting and Repair Manual, CM870
Perform INSITE electronic service tool Electronic Control System Signature and
Cylinder Performance Test. ISX Engines, Bulletin 4021334.
Did the cylinder performance test find a 5E

malfunctioning bank?
NO
STEP 5E: Swap the front and rear timing actuators.

Condition:
Turn keyswitch OFF.
Swap the front and rear timing actuator to Does the malfunctioning bank follow the Repair
determine if the failed bank of cylinders follows a timing actuator? Complete
specific timing actuator. YES
Troubleshooting and Repair Manual, CM870 Repair:
Electronic Control System Signature and ISX Replace the timing actuator. Use the
Engines, Bulletin 4021334. Refer to Procedure following procedure in the Troubleshooting
019-111 in Section 19. and Repair Manual, CM870 Electronic
Perform INSITE electronic service tool Control System Signature and ISX Engines,
Cylinder Performance Test. Bulletin 4021334.
Does the malfunctioning bank follow the Perform the

timing actuator? next
NO troubleshooti
ng procedure
as outlined in
Step 2

STEP 6A: Start the engine and read the fault codes.
Condition:
Connect INSITE electronic service tool electronic service tool.
Engine is operating at low idle.
Check the fault codes with the engine running. Active fault codes? Go to
Use INSITE electronic service tool to read the YES appropriate
fault codes. fault code
troubleshooti
ng tree
Active fault codes? 6B

NO
STEP 6B: Inspect the turbocharger blades for damage.

Condition:
Engine OFF.
Remove intake and exhaust connections for turbocharger.
Inspect the compressor and turbine blades for Damage found on turbocharger blades? Repair
damage or wear. YES complete
Repair:
Replace the turbocharger.
Damage found on turbocharger blades? 6C

NO
STEP 6C: Determination of turbocharger type.

Condition:
Determine if the turbocharger is a wastegated or Is the turbocharger a variable geometry 6D

variable geometry turbocharger. turbocharger?
YES
Is the turbocharger a variable geometry 6F

turbocharger?
NO
STEP 6D: Check the variable geometry actuator rod for correct travel.
Condition:
Engine OFF.
Turn keyswitch ON.
Verify vehicle air tanks are charged to at least 586 kPa [85 psi] air pressure.
Use a straight edge steel ruler.
Retract and extend the turbocharger actuator at least 10 times.
Use INSITE electronic service tool to start the Does the turbocharger actuator rod extend 6E
Turbocharger Actuator Test. between 10 and 12 mm [0.394 and 0.472 in]?
Adjust the delay timer in the Turbocharger YES
Actuator Test so that the rod movement can be
observed.
Select the Retract Actuator position with Does the turbocharger actuator rod extend 6D-1
INSITE electronic service tool. between 10 and 12 mm [0.394 and 0.472 in]?
Mark or scribe the VG actuator rod at the base NO
of the actuator.
Select the Extend Actuator position with
INSITE electronic service tool.
Measure the rod travel by measuring the
distance from the base of the turbocharger
actuator to the scribe mark.
Use a straight edge steel ruler.
Retract and extend the turbocharger actuator
at least 10 times.
The turbocharger actuator will move quickly and
crisply. If the actuator rod movement is slow,
there could be a problem with the air supply, a
faulty ground connection on the engine or
chassis, or mechanical problems with the
variable geometry turbocharger assembly.
STEP 6D-1: Check for air leaks and inspect air lines.
Condition:
Engine OFF.
Turn keyswitch ON.
Use INSITE electronic service tool to perform Air leaks found in the system? Repair
the Turbocharger Actuator Test. YES complete
Select the Extend Actuator position. Listen for air Repair:
leaks at the following components:
Repair air leaks.
Turbocharger control valve
Turbocharger control shutoff valve inlet
connection Air leaks found in the system? 6D-2
Turbocharger control shutoff valve outlet NO
connection
Turbocharger control valve inlet connection
Turbocharger control valve outlet connection
Turbocharger actuator inlet connection
Turbocharger actuator.
All air lines including the OEM supply line to
the turbocharger control shutoff valve,
turbocharger control shutoff valve to
turbocharger control valve, and turbocharger
control valve to turbocharger actuator
A small amount of air could possibly be heard
escaping from the turbocharger control valve
during the turbocharger actuator test. This is a
normal condition for the valve to achieve output
regulation pressure. Do not replace the
turbocharger control valve for this condition.
STEP 6D-2: Check the engine and vehicle grounds.

Condition:
Turn keyswitch OFF.
Check for a loose or corroded engine, chassis, or Connections tight and corrosion-free? 6D-3
battery ground connection. YES
Check the engine ground connection.
Check the chassis ground connections.
Check the battery terminal connections. Connections tight and corrosion-free? Repair
NO complete
Repair:
Tighten the connections.
Tighten the loose connections and clean
the terminals. Refer to the OEM service
manual.
STEP 6D-3: Check for air pressure at the turbocharger control valve outlet.
Condition:
Engine OFF.
Turn keyswitch ON.
Use INSITE electronic service tool to perform Is vehicle air tank pressure present at the 6D-4
the Turbocharger Actutator Test. Select the turbocharger control valve outlet?
Retract Actuator position. YES
Remove the air line connection at the outlet of the
turbocharger control valve. Is vehicle air tank pressure present at the 6D-6
Install an M12 Compuchek fitting at the outlet turbocharger control valve outlet?
of the turbocharger control valve. NO
Install an air pressure gauge that is capable of
reading at least 1034 kPa [150 psi].
Use INSITE electronic service tool to perform
the Turbocharger Actuator Test. Select the
Extend Actuator position.
Condition:
Engine OFF.
Turn keyswitch ON.
Verify vehicle air tanks are charged to at least 586 kPa [85 psi air pressure.
Use INSITE electronic service tool to perform Does the pressure gauge read more than 103 Repair
the Turbocharger Actuator Test. Select the kPa [15 psi] after 5 minutes? complete
Retract Actuator position. YES
Remove the air line connection at the outlet of
the turbocharger control valve. Repair:
Install an M12 Compuchek fitting at the outlet Replace the turbocharger control valve.
of the turbocharger control valve.
Install an air pressure gauge that is capable of Use the following procedure in the
reading at least 1034 kPa [150 psi]. Troubleshooting and Repair Manual, CM870
Procedure 019-388 in Section 19, or the OEM
service manual.
Does the pressure gauge read more than 103 6D-5

kPa [15 psi] after 5 minutes?
NO
STEP 6D-5: Check for correct turbocharger actuator travel.

Condition:
Engine OFF.
Turn keyswitch ON.
Damage to the turbocharger can result if the Does the turbocharger actuator rod travel at Repair
proper removal procedure is not followed. least 12 mm [0.472 in]? complete
Remove the variable geometry actuator from the YES
turbocharger. Use the following procedure in the Repair:
Signature, ISX, and QSX15 Service Manual,
Bulletin 3666239. Refer to Procedure 010-113 in Replace the turbocharger assembly.
Section 10. Use the following procedure in the
Use INSITE electronic service tool to perform Signature, ISX, and QSX15 Service
the Turbocharger Actuator Test. Manual, Bulletin 3666239. Refer to
Select the Extend Actuator position.
Does the turbocharger actuator rod travel at Repair
least 12 mm [0.472 in]? complete
NO
Repair:
Replace the turbocharger actuator.
STEP 6D-6: Check for air pressure at the turbocharger control shutoff valve outlet.
Condition:
Engine OFF.
Turn keyswitch ON.
Use INSITE electronic service tool to perform Can air be heard escaping from the Repair
the Turbocharger Actuator Test. turbocharger control shutoff valve outlet? complete
Select the Extend Actuator position. YES
Loosen the air line connection at the
turbocharger control shutoff valve outlet. Repair:
Replace the turbocharger control valve.
service manual.
Can air be heard escaping from the 6D-7

turbocharger control shutoff valve outlet?
NO
STEP 6D-7: Check for air pressure at the turbocharger control shutoff valve inlet.
Condition:
Engine OFF.
Turn keyswitch ON.
Verify the OEM air supply line is connected to the Can air be heard escaping from the 6D-8
correct port on the turbocharger control shutoff turbocharger control shutoff valve inlet?
valve. YES
turbocharger control shutoff valve inlet.
Can air be heard escaping from the Repair
turbocharger control shutoff valve inlet? complete
NO
Repair:
Repair the air supply from the OEM air tanks.
STEP 6D-8: Check for plugged turbocharger control shutoff valve filter.
Condition:
Remove the turbocharger control shutoff valve filter.
Turn keyswitch ON.
Use INSITE electronic service tool to perform Is an air leak present at the turbocharger Repair
the Turbocharger Actuator Test. control shutoff valve filter head? complete
Select the Extend Actuator position. YES
Listen for an air leak at the turbocharger
control shutoff valve filter head. Repair:
Replace the turbocharger control shutoff
valve filter.
Is an air leak present at the turbocharger Repair

control shutoff valve filter head? complete
NO
Repair:
valve.
service manual.
STEP 6E: Perform INSITE Electronic Service Tool EGR Valve/Turbocharger Operational Test.
Condition:
Turn keyswitch ON.
Start the engine and run at low idle.
Use INSITE electronic service tool to select the Does the Turbocharger Operational Test Perform the
EGR/VGT Operational Test . pass? next
YES troubleshooti
Prior to operating INSITE electronic service tool
ng procedure
EGR Valve and EGR Valve/Turbocharger
Operational Test, the ECM Calibration Software as outlined in
Phase can possibly need to be updated to the Step 2
latest Software Phase. The ECM Calibration
Phase Software can be checked in INSITE Does the Turbocharger Operational Test 6E-1
electronic service tool, under 'Features and pass?
Parameters'. Expand the selection for 'System NO
ID and Dataplate' and go to 'Calibration
Information'. If the Software Phase is earlier than
shown below, calibrate the ECM, use the January
2006 INCAL CD-ROM, or later. Engines with the
Software Phase listed below or later do not
require a calibration.
ISX engines with CM870 (engines built after
January 2004) require Software Phase
06050302.
ISX engines with CM870 (engines built before
January 2004) require no changes at this time.
Choose the Turbocharger actuator option
under Test Choices.
STEP 6E-1: Check the engine and vehicle grounds.

Condition:
Turn keyswitch OFF.
Check for a loose or corroded engine, chassis, or Connections tight and corrosion-free? Repair
battery ground connection. YES complete
Check the engine ground connection.
Check the chassis ground connections. Repair:
Check the battery terminal connections. Replace the variable geometry turbocharger.
Connections tight and corrosion-free? Repair

NO complete
Repair:
Tighten the connections.
Tighten the loose connections and clean
the terminals. Refer to the OEM service
manual.
STEP 6F: Inspect the wastegate actuator hose.

Condition:
Engine OFF.
Remove turbocharger if wastegate actuator is inaccessible.
Inspect the integral wastegate actuator hose for Holes or cracks found in the wastegate Repair
cracks or holes. actuator hose? complete
YES
Repair:
Replace wastegate actuator hose.
Holes or cracks found in the wastegate 6G

actuator hose?
NO
STEP 6G: Inspect the wastegate actuator rod for travel.

Condition:
Engine OFF.
Remove the wastegate actuator hose from the wastegate actuator.
Apply a regulated air supply of 310 kPa [45 psi] Does the wastegate actuator rod move? 6H
to the actuator and check for actuator movement. YES
Does the wastegate actuator rod move? 6G-1

NO
STEP 6G-1: Inspect wastegate actuator rod for travel.

Condition:
Engine OFF.
Remove the e-clip from the wastegate pin and disconnect the actuator rod.
Apply a regulated air supply of 310 kPa [45 psi] Does the wastegate actuator rod move? Repair
to the actuator and check for actuator movement. YES complete
Repair:
Move the wastegate lever on the
turbocharger back and forth and check for
smooth operation. Replace turbocharger
assembly if wastegate is seized.
Does the wastegate actuator rod move? Repair

NO complete
Repair:
Replace the wastegate actuator.
STEP 6H: Measure resistance of the four-stage wastegate controllers, if equipped.

Condition:
Engine OFF.
Disconnect the ring terminals from the four-stage wastegate controllers, if equipped.
Measure the resistance from the wastegate Are the wastegate controller solenoid 6I
controller post to engine block ground. resistances between 7.0 and 8.0 ohms?
The wastegate controller solenoids must be YES
between 20C and 26C [68F and 79F] before
using the resistance specifications listed. Are the wastegate controller solenoid Repair
resistances between 7.0 and 8.0 ohms? complete
NO
Repair:
Replace the damaged wastegate controller.
STEP 6I: Inspect four-stage wastegate controller, if equipped.

Condition:
Engine OFF.
Remove the four-stage wastegate controllers.
Check the valve disc, valve seat, and actuator Damage or debris found on the valve disc, Repair
Repair:
Replace or clean damaged components.
Damage or debris found on the valve disc, Perform the

valve seat, or actuator disc? next
NO troubleshooti
ng procedure
as outlined in
Step 2

STEP 7A: Check for air leaks in the EGR system.
Condition:
Check for leaks in the EGR connection tubing Air leaks found in the EGR connection Repair
and connections. tubing? complete
Soot streaks can be noticeable where leaks are YES
present. Repair:
Repair any leaks in the EGR system.
Air leaks found in the EGR connection 7B

tubing?
NO
STEP 7B: Check repair history.

Condition:
Check with the customer for a recent EGR valve Is there any record of the poppet head 7C
replacement. missing?
YES
Repair:
Remove the exhaust manifold and run a wire
through every port to check for the missing
poppet head.
Is there any record of the poppet head 7C

missing?
NO
STEP 7C: Perform EGR Valve Test.

Condition:
Turn keyswitch ON.
Perform INSITE electronic service tool EGR Does the EGR Valve Test pass? Perform the
Valve Test. YES next
troubleshooti
Prior to operating INSITE electronic service tool
EGR Valve and EGR Valve/Turbocharger ng procedure
as outlined in
Operational Test, the ECM Calibration Software
Step 2
Phase can possibly need to be updated to the
latest Software Phase. The ECM Calibration
Phase Software can be checked in INSITE Does the EGR Valve Test pass? Repair
electronic service tool, under 'Features and NO complete
Parameters'. Expand the selection for 'System
ID and Dataplate' and go to 'Calibration Repair:
Information'. If the Software Phase is earlier than Replace the EGR valve.
shown below, calibrate the ECM, use the January
2006 INCAL CD-ROM, or later. Engines with the Use the following procedure in the
Software Phase listed below or later do not Signature, ISX, and QSX15 Service
require a calibration. Manual, Bulletin 3666239. Refer to
ISX engines with CM870 (engines built after
January 2004) require Software Phase
06050302.
ISX engines with CM870 (engines built before
January 2004) require no changes at this time.
Check for complete travel of the EGR valve by
selecting Open Valve and verifying the EGR
Valve opens 100 percent.

STEP 8A: Verify accelerator pedal travel.
Condition:
Turn keyswitch ON.
Use INSITE electronic service tool to monitor Does the Accelerator Pedal read 0 percent 8B
Accelerator Pedal while fully depressing and when the accelerator is released and 100
releasing the accelerator pedal. percent when the accelerator is depressed?
YES
Does the Accelerator Pedal read 0 percent Repair

when the accelerator is released and 100 complete
percent when the accelerator is depressed?
NO
Repair:
Determine and correct the cause of
accelerator pedal restriction.
STEP 8B: Monitor vehicle speed.

Condition:
Turn keyswitch ON.
Start the engine.
Use INSITE electronic service tool to monitor Does the vehicle speed read 0 when the 8C
Vehicle Speed while the vehicle is not moving. vehicle is not moving?
YES
Does the vehicle speed read 0 when the Repair

vehicle is not moving? complete
NO
Repair:
Check the vehicle speed sensor and circuit
or locate the cause of the vehicle speed
interference.
STEP 8C: Verify electronic feature settings are correct.

Condition:
Turn keyswitch ON.
Use INSITE electronic service tool to verify the Are the electronic features set correctly? Step 8D
following adjustable parameters are correctly YES
set:
Maximum vehicle speed
Powertrain protection Are the electronic features set correctly? Repair
Rear axle ratio NO complete
Number of transmission tailshaft gear teeth
Repair:
Tire revolutions per mile
Gear-down protection Correct programmable features.
Cruise control droop settings
Cruise control maximum vehicle speed.
STEP 8D: Check the barometric pressure sensor reading.

Condition:
Connect all components.
Turn keyswitch ON.
Check for correct barometric pressure sensor Is the barometric pressure sensor reading in Perform the
reading. INSITE electronic service tool within 5 next
Compare the barometric pressure sensor percent of the present local barometric troubleshooti
reading in INSITE electronic service tool data pressure reading? ng procedure
monitor/logger to the present local barometric YES as outlined in
pressure. Step 2
Is the barometric pressure sensor reading in Repair

INSITE electronic service tool within 5 complete
percent of the present local barometric
pressure reading?
NO
Repair:
Replace the barometric pressure sensor. Use
the following procedure in the
service manual.

STEP 9A: Verify overhead adjustments are correct.
Condition:
Turn keyswitch OFF.
Remove valve cover.
Measure the overhead settings. Are the overhead settings within the reuse 9B
Valve Lash Reuse Limits: limits?
YES
Intake valve lash: 0.102 mm [0.004 in] to 0.483
mm [0.019 in]
Exhaust valve lash: 0.508 mm [0.020 in] to Are the overhead settings within the reuse Repair
0.813 mm [0.032 in]. limits? complete
NO
Repair:
STEP 9B: Check air intake restriction.

Condition:
Turn keyswitch ON.
Operate the engine at advertised horsepower and rpm.
Check the intake system restriction by installing Is air intake restriction greater than 635 mm- Repair
a vacuum gauge or water manometer into the air H 2O [25 in-H 2O] for a used air filter or 254 complete
intake system. mm-H 2O [10 in-H 2O] for a new filter?
3666239. Refer to Procedure 010-031 in Section Repair:
10. Correct the cause of high intake air
restriction.
Check for plugged air filter or restricted air
intake piping.
Is air intake restriction greater than 635 mm- 9C

H 2O [25 in-H 2O] for a used air filter or 254
mm-H 2O [10 in-H 2O] for a new filter?
NO
STEP 9C: Check exhaust restriction.

Condition:
Install a pressure gauge into the exhaust system.
Turn keyswitch ON.
Operate the engine at advertised horsepower and rpm.
Check exhaust restriction by installing a pressure Is exhaust restriction between 518 mm-H 2O 9D
gauge into the exhaust system just past the [20.4 in-H 2O] or 38 mm-Hg [1.5 in-Hg] and
turbocharger outlet. 1036 mm-H 2O [40.8 in-H 2O] or 76 mm-Hg
Use the following procedure in the Signature, [3.0 in-Hg]?
ISX, and QSX15 Service Manual, Bulletin YES
11.
Is exhaust restriction between 518 mm-H 2O Repair
[20.4 in-H 2O] or 38 mm-Hg [1.5 in-Hg] and complete
1036 mm-H 2O [40.8 in-H 2O] or 76 mm-Hg
[3.0 in-Hg]?
NO
Repair:
Repair exhaust system for source of high
restriction.
STEP 9D: Pressure test the charge air cooler.

Condition:
Turn keyswitch OFF.
Pressure test the charge air cooler. Is the pressure drop 34 kPa [5 psi] or less in 9E
Use the following procedure in the Signature, 15 seconds?
Section 10.
Is the pressure drop 34 kPa [5 psi] or less in Repair
15 seconds? complete
NO
Repair:
Repair the charge air cooler.
STEP 9E: Verify engine brake adjustment.

Condition:
Turn keyswitch OFF.
Remove valve cover.
Verify the engine brakes are operating correctly. Are the engine brake settings within the 9F
Measure the engine brake settings. Use the reuse limits?
following procedure in the Signature, ISX, YES
and QSX15 Service Manual, Bulletin 3666239.
Are the engine brake settings within the Repair
reuse limits? complete
NO
Repair:
Adjust the engine brake settings.
STEP 9F: Measure turbocharger axial and radial clearance.

Condition:
Engine OFF.
Disconnect exhaust and intake connections from the turbocharger.
Measure the axial and radial clearance of the Are the axial and radial clearances within 9G
turbocharger. specification?
3666239. Refer to Procedure 010-033 in Section Are the axial and radial clearances within Repair
10. specification? complete
NO
Repair:
Replace the turbocharger assembly.
STEP 9G: Verify engine blowby is within specification.

Condition:
Turn keyswitch OFF.
Connect the appropriate orifice to the end of the blowby draft tube.
Start engine.
Load engine to rated rpm on a chassis Are the engine blowby measurements within 9H
dynamometer. specification?
Measure the engine blowby. YES
ISX, and QSX15 Service Manual, Bulletin Are the engine blowby measurements within 9G-1
3666239. Refer to Procedure 014-002 in Section specification?
14. NO
STEP 9G-1: Verify turbocharger contribution to engine blowby.
WARNING
Do not run the engine for more than 1 minute. Severe engine damage can occur if the engine is run too
long with the turbocharger oil drain line disconnected from the block.
Condition:
Turn keyswitch OFF.
Verify oil level is full.
Remove turbocharger oil drain line from the block and drain into a bucket.
Make sure the turbocharger oil drain port in the block is plugged so no crankcase gases escape.
Start engine.
Load engine to rated rpm on a chassis Did the total engine blowby drop more than Repair
dynamometer. 30 percent? complete
Use the following procedure in the Signature, Repair:
ISX, and QSX15 Service Manual, Bulletin Replace the turbocharger assembly.
14. Use the following procedure in the
Did the total engine blowby drop more than Repair

30 percent? complete
NO
Repair:
Engine could need to be rebuilt.
See engine rebuild specifications.
STEP 9H: Verify base engine timing is correct.

Condition:
Turn keyswitch OFF.
Verify the base engine timing is correct. Is the base engine timing within 9I
specification?
1. Is the base engine timing within Repair
specification? complete
NO
Repair:
Correct the base engine timing.
STEP 9I: Check for a damaged vibration damper.

Condition:
Engine not operating.
Remove and visually inspect the vibration Is the vibration damper damaged or out of Repair
damper. specification? complete
Use Procedure 001-052 in the appropriate YES
service manual for vibration damper
inspection specifications. Repair:
Replace the vibration damper. Use
Procedure 001-052 in the appropriate service
manual for replacement instructions.
Is the vibration damper damaged or out of Perform the

specification? next
NO troubleshooti
ng procedure
as outlined in
Step 2
STEP 10: Check the EGR differential pressure sensor and exhaust gas pressure sensor
tubes.
STEP 10A: Check the EGR differential pressure tubes for cracks, restrictions, or leaks.
Condition:
Turn keyswitch OFF.
Inspect the EGR differential pressure tubes for Are cracks, restrictions, or leaks present? Repair
cracks, restrictions, or leaks. YES complete
Soot streaks can indicate that the line is loose or Repair:
cracked.
Tighten or replace the EGR differential
pressure tubes.
Are cracks, restrictions, or leaks present? 10B

NO
STEP 10B: Check the exhaust gas pressure tubes for cracks, restrictions, or leaks.
Condition:
Turn keyswitch OFF.
Inspect the exhaust gas pressure tubes for Are cracks, restrictions, or leaks present? Repair
cracks, restrictions, or leaks. YES complete
Soot streaks can indicate that the line is loose or Repair:
cracked.
Tighten or replace the exhaust gas pressure
tubes.
Are cracks, restrictions, or leaks present? Perform the

NO next
troubleshooti
ng procedure
as outlined in
Step 2
Signature, ISX, and QSX15 Eng [...] Engine Performance Troubleshooting Tree - ISX with CM87 [...]
Engine Performance Troubleshooting Tree - ISX with CM871

Engine Acceleration or Response Poor
Cranking Fuel Pressure is Low
Engine Operating Fuel Pressure is Low
Engine Difficult to Start or Will Not Start (Exhaust Smoke)
Engine Difficult to Start or Will Not Start (No Exhaust Smoke)
Engine Power Output Low
Engine Runs Rough at Idle
Engine Runs Rough or Misfires
Engine Speed Surges at Low or High Idle
Engine Speed Surges Under Load or in Operating Range
Smoke, Black - Excessive
Smoke, White - Excessive
Engine Shuts Off or Dies Unexpectedly or Dies During Deceleration
Engine Starts But Will Not Keep operating
Engine Will Not Reach Rated Speed (rpm)
Engine Run-on or Will Not Shut Down.

This symptom tree can be used to troubleshoot all performance based symptoms listed above. Start by performing
Step 1 troubleshooting. Step 2 asks a series of questions and will provide a list of troubleshooting steps to perform,
depending on the symptom. Perform the list of troubleshooting in the sequence shown in the Specifications/Repair
section of the tree.
Shop Talk:
Verify the electronic control module (ECM) calibration is correct. Check the calibration revision history found on
QuickServe Online for applicable fixes to the calibration stored in the ECM. If necessary, calibrate the ECM. Refer
Engine Performance Troubleshooting Tree - ISX with CM87 [...] Signature, ISX, and QSX15 Eng [...]

STEP 1A: Check for active fault codes or Active fault codes or high counts
codes.
STEP 1B: Perform basic troubleshooting All steps have been verified to
checks. be correct?
STEP 1C: Perform INSITE electronic Is 'Engine Operating State'
service tool monitor test. reading a value that can cause
an engine derate?
STEP 2A: Low power, poor acceleration, Is the engine symptom low
or poor response. power, poor acceleration, or
poor response?
STEP 2B: Engine misfire. Is the engine symptom Engine
Misfires?
STEP 2C: Excessive black smoke. Is the engine symptom
Excessive Black Smoke?
STEP 2D: Excessive white smoke. Is the engine symptom
STEP 2D-1: Excessive white smoke. Is the engine symptom
STEP 2E: Engine speed surge or engine Is the engine symptom Engine
speed unstable. Speed Surge or Engine Speed
Unstable?
STEP 2F: Engine will not start or difficult Is the symptom Engine Difficult
to start. to Start or Will Not Start?
STEP 2G: Engine stalls or shuts off Is the symptom Engine Stalls or
unexpectedly. Shuts Off Unexpectedly?
STEP 2H: Engine run on or will not shut Is the engine symptom Engine
down. Run On or Slow to Shut Down
after operated at high idle for 1
minute then keyed off?
STEP 3B: Check fuel shutoff valve voltage. Is the fuel shutoff valve voltage
greater than 11-VDC?
STEP 3B-1: Check the keyswitch Is the keyswitch voltage equal to
voltage. battery voltage?
STEP 3B-2: Check the fuel shutoff valve Less than 10 ohms?
wire.
STEP 3B-3: Check the ECM power and Is the ECM battery supply
ground. voltage equal to the battery
voltage?
STEP 3C: Check fuel shutoff valve Is the fuel shutoff solenoid
resistance. resistance: 1 to 5 ohms for 6-
VDC solenoids; 6 to 15 ohms for
12-VDC solenoids; 24 to 50 ohms
for 24-VDC solenoids; 42 to 80
ohms for 32-VDC solenoids; 46
to 87 ohms for 36-VDC
solenoids; 92 to 145 ohms for 48-
VDC solenoids; 315 to 375 ohms
for 74-VDC solenoids; or 645 to
735 ohms for 115-VAC
solenoids?
STEP 3D: Check the fuel shutoff valve Debris or damage found on the
actuator. valve disc, valve seat, or
actuator disc?
STEP 3E: Check for correct priming pump Does the lift pump operate after
operation, if equipped. turning the keyswitch ON?
STEP 3E-1: Check priming pump Does pump pressure meet the 69
pressure. kPa [10 psi] specification?
STEP 3F: Check for coolant in the EGR Is coolant present in the
transfer tube. crossover tube?
STEP 4B: Check for air in the fuel. Air bubbles visible in the coil of
clear tubing?
STEP 4C: Check the fuel inlet restriction. Is fuel inlet restriction less than
the specifications listed? Dirty -
305 mm-Hg [12 in-Hg]; New - 203
mm-Hg [8 in-Hg]
STEP 4D: Check drain line restriction. Is fuel drain line restriction less
than 229 mm-Hg [9 in-Hg]?
STEP 4E: Check rail fuel pressure. Does the rail fuel pressure meet
the specification?
STEP 4E-1: Check the pressure side fuel Is the pressure side fuel filter
filter restriction pressure drop less than 517 kPa
[75 psi]?
STEP 4E-2: Check 1724 kPa [250 psi] Is the 1724 kPa [250 psi]
pressure regulator. pressure regulator free of debris
or damage?
STEP 4E-3: Check 2206 kPa [320 psi] or Is the pressure regulator free of
2620 kPa [380 psi] pressure debris or damage?
regulator.
STEP 5A: Perform the injector check valve Did the injector leak test detect
leak test. a leaking injector?
STEP 5B: Perform INSITE electronic Does performing INSITE
Performance Test. Performance Test isolate to a
Performance Test isolate to a
Performance Test at 600

rpm.
STEP 5C: Perform INSITE electronic Do all cylinders pass the cylinder
service tool Cylinder Cutout cutout test?
Test.
STEP 5C-1: Perform INSITE electronic Can a malfunctioning bank of
service tool Cylinder Cutout injectors be isolated by
Test on both injector banks. operating the engine on either
bank of injectors?
STEP 5C-2: Perform INSITE electronic Can a malfunctioning injector be
service tool Cylinder Cutout isolated by operating the engine
Test. on a single injector?
adjustments are correct for the reset limits outlines in
the suspected Procedure 003-004?
adjustments are correct for the reset limits outlined in
the suspected Procedure 003-004?
STEP 5D: Swap the front and rear Does the malfunctioning bank
metering actuators. follow the metering actuator?
STEP 5E: Swap the front and rear timing Does the malfunctioning bank
actuators. follow the timing actuator?
STEP 6A: Start the engine and read the Active fault codes?
fault codes.
STEP 6B: Check air intake restriction. Is air intake restriction greater
than 635 mm-H 2O [25 in-H 2O]
for a used air filter or 254 mm-H
2O [10 in-H 2O] for a new filter?
STEP 6C: Inspect charge-air cooler. Is the pressure drop 34 kPa [5

psi] or less in 15 seconds?
STEP 6D: Inspect the turbocharger shaft Does the nozzle slide evenly
movement. from stop to stop and are the
gear teeth undamaged?
STEP 6E: Inspect the turbocharger blades Damage found on turbocharger
for damage. blades?
STEP 7A: Check for EGR related fault EGR related fault codes present?
codes.
STEP 7B: Check for inactive EGR Fault Code 1866, 2273, or 2274
differential pressure sensor fault active?
codes.
STEP 7C: Check the EGR differential Leaks detected at either the low
pressure tubes for leaks. or high EGR differential pressure
tubes?
STEP 7D: Check the EGR differential Leaks detected at the EGR
pressure sensor adapter for differential pressure sensor
leaks. adapter?
STEP 7E: Check the EGR differential Debris or soot found in either
pressure tubes for plugging. EGR differential pressure tube?
STEP 7F: Check for air leaks in the EGR Air leaks found in the EGR
system. connection tubing?
STEP 8A: Verify accelerator pedal travel. Does the Accelerator Pedal read
0 when the accelerator is
released and 100 percent when
the accelerator is depressed?
STEP 8B: Monitor vehicle speed. Does the vehicle speed read 0
when the vehicle is not moving?
STEP 8C: Verify electronic feature settings Are the electronic features set
are correct. correctly?
STEP 8D: Check the ambient air pressure Is the barometric pressure
sensor accuracy. sensor reading in INSITE
electronic service tool within 5
percent of the present local
barometric pressure reading?
STEP 8E: Check the intake manifold INSITE electronic service tool
pressure sensor accuracy. reading within 17 kPa [2.5 psi] of
mechanical gauge reading?
STEP 9A: Verify overhead adjustments are Are the overhead settings within
correct. the reset limits?
STEP 9B: Verify engine brake adjustment. Are the engine brake settings
within the reset limits?
STEP 9C: Check exhaust restriction. Is exhaust restriction greater
than 305 mm-Hg [12.0 in-Hg]?
STEP 9D: Verify engine blowby is within Are the engine blowby
specification. measurements within
specification?
STEP 9D-1: Verify turbocharger Did the total engine blowby drop
contribution to engine more than 30 percent?
blowby
STEP 10: Aftertreatment checks.
STEP 10A: Check for aftertreatment related Fault codes related to the
fault codes. aftertreatment system are found
to be active?
STEP 10B: Perform basic aftertreatment All parts have been inspected
troubleshooting checks. and appear to be functioning
properly?
STEP 10C: Check for signs of internal Any visible smoke (black or
damage to the aftertreatment white) present during the snap
system. throttle acceleration?
STEP 10D: Check exhaust restriction. Is exhaust restriction greater

than 305 mm-Hg [12.0 in-Hg]?

STEP 1A: Check for active fault codes or high counts of inactive fault codes.
Condition:
Turn keyswitch ON.
Check for active fault codes or high counts of Active fault codes or high counts of inactive Go to
inactive fault codes. fault codes? appropriate
ng tree
Active fault codes or high counts of inactive 1B

fault codes?
NO
STEP 1B: Perform basic troubleshooting checks.

Condition:
The following items must be checked or verified All steps have been verified to be correct? 1C
before continuing: YES
Verify the fuel level in the tanks
Verify there have not been any changes to
CPL components on the engine All steps have been verified to be correct? Repair
Verify fuel grade is correct for the application NO complete
Verify the engine is operating within the
Repair:
recommended altitude
Verify engine oil is at the correct level Correct the out of specification item and
Verify engine parasitics have not changed verify complaint is no longer present after
Verify engine duty cycle has not changed repair.
Verify engine cranking speed is greater than
150 rpm.
Verify battery voltage is within specification.
STEP 1C: Perform INSITE electronic service tool monitor test.

Condition:
Connect INSITE electronic service tool
Engine operating at the speed and load where the symptom occurs.
Use INSITE electronic service tool to monitor Is 'Engine Operating State' reading a value 2A
the parameter 'Engine Operating State' at the that can cause an engine derate?
same engine operating conditions where the YES
symptom occurs.
Repair:
Refer to Advanced Engine Performance
Troubleshooting Techniques, Bulletin 4021686, Determine if the engine derate is being
for a description of what "User Fueling States" or caused by normal engine operation or by an
"Engine Operating State" can cause engine actual engine failure.
derates. Continue following troubleshooting steps as
outlined in Step 2 if an engine failure is
suspected.
Is 'Engine Operating State' reading a value 2A

that can cause an engine derate?
NO

STEP 2A: Low power, poor acceleration, or poor response.
Condition:
None
Interview the driver and verify the complaint. Is the engine symptom low power, poor Perform the
acceleration, or poor response? troubleshooti
YES ng steps
suggested in
Repair: the repair
Step 7 - EGR Checks
Step 10 - Aftertreatment Checks
Step 8 - Electronic Checks
Is the engine symptom low power, poor 2B

acceleration, or poor response?
NO
STEP 2B: Engine misfire.

Condition:
None
Interview the driver and verify the complaint. Is the engine symptom Engine Misfires? Perform the
YES troubleshooti
ng steps
Repair: suggested in
Perform the troubleshooting steps in the the repair
recommended order listed below: procedure
Step 7 - EGR Checks
Is the engine symptom Engine Misfires? 2C

NO
STEP 2C: Excessive black smoke.

Condition:
None
Interview the driver and verify the complaint. Is the engine symptom Excessive Black Perform the
Note: Progressive damage to the aftertreatment Smoke? troubleshooti
YES ng steps
system has occurred if black smoke is visible.
suggested in
Remove the exhaust aftertreatment system from Repair:
the vehicle and inspect for reuse. Use the the repair
following procedure in the Signature, ISX, and
QSX15 Service Manual, Bulletin 3666239. recommended order listed below:
Inspect the aftertreatment system for a potential Step 6 - Air Handling Checks
damage. Refer to Procedure 011-049 in Section Step 7 - EGR Checks
11. Step 4 - Fuel System Checks
Step 5 - Injector and Actuator Diagnostics
Is the engine symptom Excessive Black 2D

Smoke?
NO
STEP 2D: Excessive white smoke.

Condition:
None
Smoke and the engine is using coolant? troubleshooti
YES ng steps
suggested in
Repair: the repair
tree.
Is the engine symptom Excessive White 2D-1

Smoke and the engine is using coolant?
NO
STEP 2D-1: Excessive white smoke.

Condition:
None
Smoke and the engine is not using coolant? troubleshooti
YES ng steps
suggested in
Repair: the repair
Step 10 - Aftertreatment Checks
Is the engine symptom Excessive White 2E

Smoke and the engine is not using coolant?
NO
STEP 2E: Engine speed surge or engine speed unstable.

Condition:
None
Interview the driver and verify the complaint. Is the engine symptom Engine Speed Surge Perform the
or Engine Speed Unstable? troubleshooti
YES ng steps
suggested in
Repair: the repair
Step 7 - EGR Checks
Step 8- Electronics Checks
Is the engine symptom Engine Speed Surge 2F

or Engine Speed Unstable?
NO
STEP 2F: Engine will not start or difficult to start.

Condition:
None
Interview the driver and verify the complaint. Is the symptom Engine Difficult to Start or Perform the
Will Not Start? troubleshooti
YES ng steps
suggested in
Repair: the repair
Perform the troubleshooting steps that procedure
pertain to difficult to start or will not start
concerns per the troubleshooting steps in the
Check the engine base timing. Use the
following procedure in the Signature,
Section 1.
Is the symptom Engine Difficult to Start or 2G

Will Not Start?
NO
STEP 2G: Engine stalls or shuts off unexpectedly.

Condition:
None
Interview the driver and verify the complaint. Is the symptom Engine Stalls or Shuts Off Perform the
Unexpectedly? troubleshooti
YES ng steps
suggested in
Repair: the repair
Perform the troubleshooting steps that procedure
pertain to stalls or shuts off unexpectedly per
the troubleshooting steps in the
Is the symptom Engine Stalls or Shuts Off 2H

Unexpectedly?
NO
STEP 2H: Engine run on, or will not shut down.

Condition:
None
Interview the driver and verify the complaint. Is the engine symptom Engine Run On or Perform the
Slow to Shut Down after operated at high idle troubleshooti
for 1 minute then keyed off? ng steps
YES suggested in
the repair
Repair: procedure
Perform the troubleshooting steps in the
Is the engine symptom Engine Run On or Return to

Slow to Shut Down after operated at high idle appropriate
for 1 minute then keyed off? symptom
NO tree

Condition:
Turn keyswitch OFF.
Verify the fuel system has been primed. Has the fuel system been properly primed? 3B
If entering this tree after a component has been YES
replaced in the fuel system, or after the engine
has been run out of fuel, verify the fuel system Has the fuel system been properly primed? Repair
has been properly primed before proceeding. complete.
NO
priming found in the Signature, ISX, and QSX Repair:
Service Manual, Bulletin 3666239. Refer to Prime the fuel system.
Use the following procedure for fuel
system priming found in the Signature,
ISX, and QSX Service Manual, Bulletin
Section 6.
STEP 3B: Check fuel shutoff valve voltage.

Condition:
Turn keyswitch ON.
Measure the voltage from the fuel shutoff valve Is the fuel shutoff valve voltage greater than 3C
post to engine block ground. 11-VDC?
YES
Is the fuel shutoff valve voltage greater than 3B-1

11-VDC?
NO
STEP 3B-1: Check ECM keyswitch voltage.

Condition:
Turn keyswitch OFF.
Disconnect the OEM harness from the ECM.
Turn keyswitch ON.
Measure the voltage from the keyswitch input Is the keyswitch voltage equal to battery 3B-2
SIGNAL wire of the OEM harness to engine block voltage?
ground. YES
Is the keyswitch voltage equal to battery Repair

voltage? complete
NO
Repair:
Repair or replace the OEM power harness,
keyswitch, or check the battery connections.
Use the following procedure found in the ISX
CM871 and ISM CM876 Electronic Control
System, Bulletin 4021560. Refer to
STEP 3B-2: Check the fuel shutoff valve wire.

Condition:
Turn keyswitch OFF.
Disconnect the engine harness from the ECM.
Disconnect the fuel shutoff valve wire from the valve terminal post.
Measure the resistance from the fuel shutoff Less than 10 ohms? 3B-3
valve SIGNAL pin in the ECM connector to the YES
fuel shutoff valve eyelet.
Repair:
Use the following procedure for general
resistance measurement techniques. Use the Call for authorization to replace the ECM.
following procedure found in the ISX CM871 and Upon receipt of authorization, replace the
ISM CM876 Electronic Control System, Bulletin ECM. Use the following procedure found in
4021560. Refer to Procedure 019-360 in Section the ISX CM871 and ISM CM876 Electronic
19. Control System, Bulletin 4021560. Refer to
Less than 10 ohms? Repair

NO complete
Repair:
Repair or replace the engine harness.
STEP 3B-3: Check the ECM power and ground.

Condition:
Turn keyswitch OFF.
Disconnect the ECM power supply connector from the ECM.
Measure the voltage from the ECM battery Is the ECM battery supply voltage equal to Repair
SUPPLY (-) to the ECM battery SUPPLY (+) pins the battery voltage? complete
in the ECM power harness connector. YES
Repair:
Call for authorization to replace the ECM.
Upon receipt of authorization, replace the
ECM. Use the following procedure found in
the ISX CM871 and ISM CM876 Electronic
Control System, Bulletin 4021560. Refer to
Is the ECM battery supply voltage equal to Repair

the battery voltage? complete
NO
STEP 3C: Check fuel shutoff valve resistance.

Condition:
Turn keyswitch OFF.
Disconnect fuel shutoff valve SIGNAL wire from the fuel shutoff solenoid.
Fuel shutoff valve temperature between 20C [68F] and 25C [78F].
Measure the resistance from the fuel shutoff Is the fuel shutoff solenoid resistance: 3D
solenoid post to engine block ground. 1 to 5 ohms for 6-VDC solenoids
Note: The fuel shutoff solenoid must be between 6 to 15 ohms for 12-VDC solenoids
20C [68F] and 25C [78F] before using the 24 to 50 ohms for 24-VDC solenoids
resistance specifications listed. 42 to 80 ohms for 32-VDC solenoids
Use the following procedure for general 92 to 145 ohms for 48-VDC solenoids
resistance measurement techniques. Use the 315 to 375 ohms for 74-VDC solenoids
following procedure found in the ISX CM871 and
ISM CM876 Electronic Control System, Bulletin YES
19.
Is the fuel shutoff solenoid resistance: Repair
1 to 5 ohms for 6-VDC solenoids complete
NO
Repair:
Replace the fuel shutoff solenoid. Use the
following procedure found in the ISX CM871
and ISM CM876 Electronic Control System,
STEP 3D: Check fuel shutoff valve actuator.

Condition:
Turn keyswitch OFF.
Remove the fuel shutoff valve solenoid, valve disc, valve seat, and actuator.
Check the valve disc, valve seat, and actuator Debris or damage found on the valve disc, Repair
Repair:
Replace the damaged fuel shutoff valve
component. Use the following procedure
found in the ISX CM871 and ISM CM876
Electronic Control System, Bulletin 4021560.
Debris or damage found on the valve disc, 3E

NO
STEP 3E: Check for correct priming pump operation, if equipped.

Condition:
Turn keyswitch OFF.
Assemble fuel shutoff valve components.
Turn keyswitch ON.
Listen for lift pump operation after the keyswitch Does the lift pump operate after turning the 3E-1
is turned to the ON position. keyswitch ON or does the engine not use a
NOTE: Not all ISX engines use a priming pump priming pump?
and not all ISL engines use a priming pump that YES
actuates at Keyswitch ON. Verify the type of
pump system on the engine before beginning this Does the lift pump operate after turning the Repair
step. keyswitch ON or does the engine not use a complete
priming pump?
NO
Repair:
Check or replace lift pump. Use the following
STEP 3E-1: Check priming pump pressure.

Condition:
Turn keyswitch OFF.
Turn keyswitch ON.
Measure the priming pressure at the quick Does pump pressure meet the 69 kPa [10 psi] 3F
connect fitting located on the top of the specification?
integrated fuel system module (IFSM). YES
ISX, and QSX15 Service Manual, Bulletin Does pump pressure meet the 69 kPa [10 psi] Replace the
3666239. Refer to Procedure 005-045 in Section specification? lift pump.
5. Use the
NO
following
procedure in
the
Signature,
ISX, and
QSX15
Service
Manual,
Bulletin
3666239.
Refer to
Procedure
005-045 in
Section 5.
STEP 3F: Check for coolant in the EGR transfer tube.

Condition:
Turn keyswitch OFF.
Remove the EGR transfer hose from the EGR Is coolant present in the crossover tube? Repair
cooler outlet. YES complete
Repair:
tree.
Is coolant present in the crossover tube? 2A

NO
Repair:
Perform the next troubleshooting procedure
as outlined in Step 2

Condition:
Turn keyswitch OFF.
Verify the fuel system has been primed. Has the fuel system been properly primed? 4B
If entering this tree after a component has been YES
replaced in the fuel system, or after the engine
has been emptied of fuel, verify the fuel system Has the fuel system been properly primed? Repair
has been properly primed before proceeding. complete.
NO
priming found in the Signature, ISX, and QSX Repair:
Service Manual, Bulletin 3666239. Refer to Prime the fuel system.
Use the following procedure for fuel
system priming found in the Signature,
ISX, and QSX Service Manual, Bulletin
Section 6.
STEP 4B: Check for air in the fuel.

Condition:
Connect the equipment to the quick-connect Air bubbles visible in the coil of clear tubing? Repair
fitting at the fuel module as shown. YES complete
Put a coil in the clear hose.
Put the end of the clear hose in a clean Repair:
container. Locate and correct the cause of air ingestion
Operate the engine at low idle with no load. in the OEM fuel supply system or damaged
Slightly open the valve until a steady stream of fuel filter sealing ring.
fuel is visible.
With EGR
Check the ECM cooling plate, associated
plumbing, and o-ring seals for failures that
can cause air ingestion. Repair or replace the
malfunctioning component.
Air bubbles visible in the coil of clear tubing? 4C

NO
STEP 4C: Check fuel inlet restriction.

Condition:
Connect a vacuum gauge to the suction side Compuchek fitting.
Turn keyswitch ON.
If the engine uses a priming pump, wait until after Is fuel inlet restriction less than the 4D
the priming pump has turned off and observe the specifications listed below?
reading on the vacuum gauge. Dirty - 305 mm-Hg [12 in-Hg];
Check the fuel inlet restriction. New - 203 mm-Hg [8 in-Hg]
3666239. Refer to Procedure 006-020 in Section Is fuel inlet restriction less than the Repair
6. specifications listed below? complete
Dirty - 305 mm-Hg [12 in-Hg];
New - 203 mm-Hg [8 in-Hg]
NO
Repair:
supply lines.
STEP 4D: Check drain line restriction.

Condition:
Turn keyswitch ON.
Observe reading on the pressure gauge. Is fuel drain line restriction less than 229 mm- 4E
Hg [9 in-Hg]?
YES
Is fuel drain line restriction less than 229 mm- Repair

Hg [9 in-Hg]? complete
NO
Repair:
Locate the cause of high fuel drain line
restriction in the OEM fuel return line.
STEP 4E: Check rail fuel pressure.

Condition:
Connect pressure gauge, Part Number 3375932, on the Compuchek fitting (as shown)
Turn keyswitch ON.
Read the rail fuel pressure at low idle and high Does the rail fuel pressure meet the Perform the
idle. specification? next
Read the rail fuel pressure while cranking if the YES troubleshooti
ng procedure
engine will not start.
as outlined in
Cranking: greater than 689 kPa [100 psi] at Step 2
130 rpm for at least 10 seconds.
Does the rail fuel pressure meet the 4E-1
600 rpm.
specification?
High idle: 1896 to 2068 kPa [275 to 325 psi] at with EGR
1800 rpm. NO 4E-2
STEP 4E-1: Check the pressure side fuel filter restriction.

Condition:
Connect pressure gauge, Part Number 3375932, on the rail fuel pressure Compuchek fitting.
Connect pressure gauge, Part Number 3375932, on the gear pump output pressure Compuchek fitting.
Engine operating at high idle (engine cranking if troubleshooting no-start).
Read the fuel pressure drop across the pressure Is the pressure side fuel filter pressure drop 4E-2
side fuel filter at high idle or while cranking if the less than 517 kPa [75 psi]?
engine will not start. YES
Is the pressure side fuel filter pressure drop Repair

less than 517 kPa [75 psi]? complete
NO
Repair:
Replace the pressure side fuel filter. Use the
Section 6.
STEP 4E-2: Check 1724 kPa [250 psi] pressure regulator.

Condition:
Turn keyswitch OFF.
Remove the 1724 kPa [250 psi] fuel pressure Is the 1724 kPa [250 psi] pressure regulator 4E-3
regulator. free of debris or damage?
Inspect for debris or damage or incomplete YES
Is the 1724 kPa [250 psi] pressure regulator Repair
free of debris or damage? complete
NO
Repair:
STEP 4E-3: Check 2206 kPa [320 psi] or 2620 kPa [380 psi] pressure regulator.
Condition:
Turn keyswitch OFF.
Remove the 2206 kPa [320 psi] fuel pressure Is the pressure regulator free of debris or Repair
regulator. damage? complete
Inspect for debris, damage, or incomplete YES
Repair:
Replace the gear pump module.
Is the pressure regulator free of debris or Repair

damage? complete
NO
Repair:

STEP 5A: Perform the injector check valve leak test.
Condition:
None
Perform the injector check valve leak test to Did the injector leak test detect a leaking Repair
check for internal injector check valve damage. injector? complete
6. Replace the leaking injector. Use the
Section 6.
Did the injector leak test detect a leaking 5B

injector?
NO
STEP 5B: Perform INSITE electronic service tool Cylinder Performance Test.
Condition:
Engine idling.
Perform the INSITE electronic service tool Does performing INSITE electronic service 5C-3
Cylinder Performance Test. tool Cylinder Performance Test identify a
During the initial 30 seconds of the Cylinder single malfunctioning injector?
Performance Test, INSITE electronic service YES
tool is checking to make sure all parameters have
been met to enter the test. Does performing INSITE electronic service 5B-1
Once the initial Pass or Fail reading is displayed, tool Cylinder Performance Test identify a
the test is live for the next 2 minutes. You will single malfunctioning injector?
need to monitor the display to see if cylinders or NO
banks drop out during this 2 minute window. A
cylinder can switch from pass to fail and back to
pass quickly, so monitor the screen closely.
Condition:
Skip this step and move on to step 5B-2 if the rpm Does performing INSITE electronic service 5C-3
Performance Test.
Condition:
Adjustable Low Idle Speed feature or adjust the Low Idle Speed.
Skip this step and move on to step 5B-3 if the Does performing INSITE electronic service 5C-3
RPM value is the same as that used in step 5B. tool Cylinder Performance Test identify a
Adjust the low speed to 700 rpm and perform the single malfunctioning injector?
Performance Test.
Condition:
"Adjustable Low Idle Speed" feature or adjust the Low Idle Speed.
Skip this step and move on to step 5C if the rpm Does performing INSITE electronic service 5C-3
Performance Test.
During the initial 30 seconds of the Cylinder Does performing INSITE electronic service 5C
STEP 5C: Perform INSITE electronic service tool Cylinder Cutout Test
Condition:
Fan is turned off.
Perform INSITE electronic service tool cylinder Do all cylinders pass the cylinder cutout test? 5C-1
cutout test. YES
Note: A failing cylinder will have no effect on
engine sound and operation when cut out using Do all cylinders pass the cylinder cutout test? 5C-3
this test.
NO
STEP 5C-1: Perform INSITE electronic service tool cylinder cutout test on individual injector banks.
Condition:
Fan is turned off.
Perform the INSITE electronic service tool Can a malfunctioning bank of injectors be 5D
cylinder cutout test. isolated by operating the engine on either
Operate the engine on the front bank of bank of injectors?
injectors identified by the cylinder cutout test YES
by disabling the rear three cylinders 4, 5, 6
cylinders with INSITE electronic service tool.
Operate the engine on the rear bank of Can a malfunctioning bank of injectors be 5C-2
injectors identified by the Cylinder isolated by operating the engine on either
Performance Test by disabling the front three bank of injectors?
cylinders (1,2,3) with INSITE electronic NO
service tool.
To disable one bank of cylinders with INSITE
electronic service tool, click on the cylinder
numbers associated with that bank. The front
bank consists of cylinders 1, 2, and 3 and the
rear bank is cylinders 4, 5, and 6.
A malfunctioning bank of injectors will cause
the engine to run poorly when the opposite
bank is cut out using this test.
STEP 5C-2: Perform INSITE electronic service tool Cylinder Cutout Test single cylinder operation.
Condition:
Fan is turned off.
Perform the INSITE electronic service tool Can a malfunctioning injector be isolated by 5C-3
cylinder cut out test. operating the engine on a single injector?
Operate the engine on the cylinder identified by YES
the Cylinder Performance Test by disabling 5
cylinders with INSITE electronic service tool Can a malfunctioning injector be isolated by 5D
and only operating on the suspect cylinder. operating the engine on a single injector?
To disable 5 cylinders with INSITE electronic NO
service tool, click on the cylinder numbers until
only 1 cylinder is enabled.
The engine should roughly maintain idle speed
when operating on a single cylinder. A weak or
misfiring cylinder will be detected if the engine
dies or can not maintain idle speed when
operating on a single cylinder.
Continue testing all 6 cylinders by operating the
engine on each individual injector.
Note: If the engine will not run on 1 cylinder
regardless of the cylinder selected, increase the
idle RPM and retest.
Note: Do not run the engine on 1 cylinder for an
extended period of time.
Condition:
Turn keyswitch OFF.
malfunctioning injector. limits outlined in Procedure 003-004? complete
Check the valve lash and injector pre-load YES
torque before replacing the injector.
ISX, and QSX15 Service Manual, Bulletin Replace the malfunctioning injector.

limits outlined in Procedure 003-004?
NO
Repair:
Condition:
Turn keyswitch OFF.
malfunctioning injector. limits outlined in Procedure 003-004? complete
Check the valve lash and injector pre-load YES
torque before replacing the injector.
ISX, and QSX15 Service Manual, Bulletin Replace the malfunctioning injector.

limits outlined in Procedure 003-004?
NO
Repair:
Adjust the overhead settings
STEP 5D: Swap the front and rear metering actuators.

Condition:
Turn keyswitch OFF.
Swap the front and rear metering actuators to Did the cylinder performance test find a Repair
determine if the malfunctioning bank of cylinders malfunctioning bank? complete
follows a specific metering actuator. YES
CM871 and ISM CM876 Electronic Control Repair:
System, Bulletin 4021560. Refer to Procedure Replace the malfunctioning metering
019-110 in Section 19. actuator.
Perform INSITE electronic service tool
Cylinder Performance Test. Use the following procedure found in the
ISX CM871 and ISM CM876 Electronic
Control System, Bulletin 4021560. Refer to
Did the cylinder performance test find a 5E

malfunctioning bank?
NO
STEP 5E: Swap the Front and Rear Timing Actuators

Condition:
Turn keyswitch OFF.
Swap the front and rear timing actuators to Does the malfunctioning bank follow the Repair
determine if the malfunctioning bank of cylinders timing actuator? Complete
follows a specific timing actuator. YES
CM871 and ISM CM876 Electronic Control Repair:
System, Bulletin 4021560. Refer to Procedure Replace the timing actuator.
Perform INSITE electronic service tool Use the following procedure found in the ISX
Cylinder Performance Test. CM871 and ISM CM876 Electronic Control
Does the malfunctioning bank follow the Perform the

timing actuator? next
NO troubleshooti
ng procedure
as outlined in
Step 2

Condition:
Engine is operating at low idle.
Check the fault codes with the engine running. Active fault codes? Go to
Use INSITE electronic service tool to read the YES appropriate
fault codes. fault code
troubleshooti
ng tree
Active fault codes? 6B

NO
STEP 6B: Check air intake restriction.

Condition:
Turn keyswitch ON.
Run engine at advertised horsepower and rpm.
Check the intake system restriction by installing Is air intake restriction greater than 635 mm- Repair
a vacuum gauge or water manometer into the air H 2O [25 in-H 2O] for a used air filter or 254 complete
intake system. mm-H 2O [10 in-H 2O] for a new filter?
3666239. Refer to Procedure 010-031 in Section Repair:
10. Correct the cause of high intake air
restriction.
intake piping.
Is air intake restriction greater than 635 mm- 6C

H 2O [25 in-H 2O] for a used air filter or 254
mm-H 2O [10 in-H 2O] for a new filter?
NO
STEP 6C: Inspect charge-air cooler

Condition:
Turn keyswitch OFF.
Pressure test the charge air cooler. Is the pressure drop 34 kPa [5 psi] or less in 6D
Use the following procedure in the Signature, 15 seconds?
Section 10.
Is the pressure drop 34 kPa [5 psi] or less in Repair
15 seconds? complete
NO
Repair:
Repair the charge-air cooler assembly. Refer
to the OEM serivce manual.
STEP 6D: Inspect the turbocharger shaft movement.

Condition:
Turn keyswitch OFF.
VGT actuator removed from the turbocharger.
Inspect the sector gear on the turbocharger for Does the nozzle slide evenly from stop to stop 6E
damaged or broken gear teeth. and are the gear teeth undamaged?
Move the sector gear lever on the turbocharger YES
bearing housing up and down from stop to stop. Repair:
Check for smooth movement between the stops.
Install the turbocharger actuator.
There will be an initial friction force that must be
overcome before the actuator lever will move. Use the following procedure in the
Once movement is started, the actuator lever Signature, ISX and QSX15 Service Manual,
should move to the other stop position by hand. Bulletin 3666239. Refer to Procedure
ISX and QSX15 Service Manual, Bulletin
3666239. Refer to Procedure 010-134 in Section Does the nozzle slide evenly from stop to stop Repair
10. and are the gear teeth undamaged? complete.
NO
Repair:
A turbocharger mechanical malfunction has
been detected.
NOTE: This malfunction may have been
caused by debris exiting the engine, causing
the turbocharger nozzle to stop moving.
Inspect the base engine components for
damage.
Replace the turbocharger assembly.
Signature, ISX and QSX15 Service Manual,
STEP 6E: Inspect the turbocharger blades for damage.

Condition:
Engine OFF.
Remove intake and exhaust connections from turbocharger.
Inspect the compressor and turbine fins for Damage found on turbocharger blades? Repair
damage or wear. YES complete
3666239. Refer to Procedure 010-033 in Section Replace the turbocharger.
Damage found on turbocharger blades? Perform next

NO troubleshooti
ng procedure
as outlined in
Step 2

STEP 7A: Check for EGR-related fault codes
Condition:
Turn keyswitch OFF
Wait 30 seconds
Turn keyswitch ON
Check for any EGR-related fault codes. EGR-related fault codes present? Appropriate
YES fault code
None
troubleshooti
Repair: ng trees
Troubleshoot electronic fault codes.
EGR-related fault codes present? 7B

NO
STEP 7B: Check for inactive EGR differential pressure sensor fault codes.
Condition:
Turn keyswitch ON.
Check for active fault codes. Fault Code 1866, 2273, or 2274 active? Appropriate
ng tree
Fault Code 1866, 2273, or 2274 active? 7C

NO
STEP 7C: Check the EGR differential pressure tubes for leaks.
Condition:
Leaks will be easily noted by traces of soot.
Check the lines for leaks. Leaks detected at either the low or high EGR Repair
differential pressure tubes? complete
YES
Repair:
Tighten the fittings, or replace the EGR
differential pressure tube.
Leaks detected at either the low or high EGR 7D

differential pressure tubes?
NO
STEP 7D: Check the EGR differential pressure sensor adapter for leaks.
Condition:
Turn keyswitch OFF.
Inspect the EGR differential pressure sensor Leaks detected at the EGR differential Repair
adapter for leaks. pressure sensor adapter? complete
Leaks will be easily noted by traces of soot, YES
however, if necessary remove the sensor to
inspect the o-rings between the EGR Repair:
differential pressure sensor and the adapter Replace the EGR differential pressure sensor
for proper sealing. Use the following adapter.
procedure in the Signature, ISX, and QSX15
Service Manual, Bulletin 3666239. Refer to Use the following procedure in the
Procedure 011-028 in Section 11. Signature, ISX, and QSX15 Service
Leaks detected at the EGR differential 7E

pressure sensor adapter?
NO
STEP 7E: Check the EGR differential pressure tubes for plugging.
Condition:
Turn keyswitch OFF.
Remove the EGR differential pressure tubes.
Inspect the EGR differential pressure tubes for Debris or soot found in either EGR differential Repair
restrictions, soot plugging, and plugging. pressure tube? complete
YES
Repair:
Clear the debris or replace the EGR
differential pressure tube.
Remove the exhaust aftertreatment system
form the vehicle and inspect for reuse.
Debris or soot found in either EGR differential 7F

pressure tube?
NO
STEP 7F: Check for air leaks in the EGR system.

Condition:
None
Check for leaks in the EGR connection tubing Air leaks found in the EGR connection Repair
and connections. tubing? complete
Soot streaks are noticeable where leaks are YES
present. Repair:
Repair any leaks in the EGR system.
Air leaks found in the EGR connection Perform the

tubing? next
NO troubleshooti
ng procedure
as outlined in
Step 2

STEP 8A: Verify accelerator pedal travel.
Condition:
Turn keyswitch ON.
With INSITE electronic service tool, monitor Does the Accelerator Pedal read 0 percent 8B
Accelerator Pedal while fully depressing and when the accelerator is released and 100
releasing the accelerator pedal. percent when the accelerator is depressed?
YES
Does the Accelerator Pedal read 0 percent Repair

when the accelerator is released and 100 complete
percent when the accelerator is depressed?
NO
Repair:
Determine and correct the cause of
accelerator pedal restriction.
STEP 8B: Monitor vehicle speed.

Condition:
Turn keyswitch ON.
Start the engine.
With INSITE electronic service tool, monitor Does the vehicle speed read 0 when the 8C
Vehicle Speed while the vehicle is not moving. vehicle is not moving?
YES
Does the vehicle speed read 0 when the Repair

vehicle is not moving? complete
NO
Repair:
Check the vehicle speed sensor and circuit
or locate the cause of the vehicle speed
interference.
STEP 8C: Verify electronic feature settings are correct.

Condition:
Turn keyswitch ON.
With INSITE electronic service tool, verify the Are the electronic features set correctly? 8D
following adjustable parameters are correctly YES
set:
Maximum vehicle speed
Powertrain protection Are the electronic features set correctly? Repair
Rear axle ratio NO complete
Number of transmission tailshaft gear teeth
Repair:
Tire revolutions per mile
Gear-down protection Correct programmable features.
Cruise control droop settings
Cruise control maximum vehicle speed.
STEP 8D: Check the ambient air pressure sensor accuracy

Condition:
Turn keyswitch ON.
Check for correct barometric pressure sensor Is the barometric pressure sensor reading in 8E
reading. INSITE electronic service tool within 5
Compare the barometric pressure sensor percent of the present local barometric
reading in INSITE electronic service tool data pressure reading?
monitor/logger to the present local barometric YES
pressure.
Is the barometric pressure sensor reading in Repair
INSITE electronic service tool within 5 complete
percent of the present local barometric
pressure reading?
NO
Repair:
Replace the barometric pressure sensor. Use
the following procedure found in the ISX
STEP 8E: Check the intake manifold pressure sensor accuracy.

Condition:
Turn keyswitch ON.
Start and operate the engine at high idle after connecting the mechanical intake manifold pressure gauge.
Connect a mechanical intake manifold pressure INSITE electronic service tool reading Perform the
gauge to the engine, as close to the intake within 17 kPa [2.5 psi] of mechanical gauge next
manifold pressure sensor as possible. reading? troubleshooti
Start INSITE electronic service tool Data YES ng procedure
Monitor/Logger and compare INSITE as outlined in
electronic service tool reading for intake Step 2
manifold pressure to the mechanical gauge.
INSITE electronic service tool reading Repair
within 17 kPa [2.5 psi] of mechanical gauge complete
reading?
NO
Repair:
Remove and clean the intake manifold
pressure sesnor.

STEP 9A: Verify overhead adjustments are correct.
Condition:
Turn keyswitch OFF.
Remove valve cover.
Measure the overhead settings. Are the overhead settings within the reset 9B
limits?
3. Are the overhead settings within the reset Repair
limits? complete
NO
Repair:
STEP 9B: Verify engine brake adjustment.

Condition:
Turn keyswitch OFF.
Remove valve cover.
Verify the engine brakes are operating correctly. Are the engine brake settings within the reset 9C
Measure the engine brake settings. Use the limits?
following procedure in the Signature, ISX, YES
and QSX15 Service Manual, Bulletin 3666239.
Are the engine brake settings within the reset Repair
limits? complete
NO
Repair:
Adjust the engine brake settings.
STEP 9C: Check exhaust restriction.

Condition:
Install a pressure gauge into the exhaust system.
Turn keyswitch ON.
Check exhaust restriction by installing a pressure Is exhaust restriction greater than 305 mm- Repair
gauge into the exhaust system just past the Hg [12.0 in-Hg]? complete
turbocharger outlet. YES
If a port is not found in the exhaust system, Repair:
remove the exhaust gas temperature 1 sensor
and install the pressure gauge in the temperature Remove the exhaust aftertreatment system
sensor port. from the vehicle and inspect for reuse.
Use the following procedure in the Signature, Remove the exhaust aftertreatment system
ISX, and QSX15 Service Manual, Bulletin from the vehicle and inspect for reuse. Use
3666239. Refer to Procedure 011-009 in Section the following procedure in the Signature,
11. ISX, and QSX15 Service Manual, Bulletin
Section 11.
Is exhaust restriction greater than 305 mm- 9D

Hg [12.0 in-Hg]?
NO
STEP 9D: Verify engine blowby is within specification.

Condition:
Turn keyswitch OFF.
Start engine.
Load engine to rated rpm on a chassis Are the engine blowby measurements within Perform the
dynamometer. specification? next
Measure the engine blowby. YES troubleshooti
ng procedure
Use the following procedure in the Signature, as outlined in
ISX, and QSX15 Service Manual, Bulletin Step 2
14. Are the engine blowby measurements within 9D-1
specification?
NO
STEP 9D-1: Verify turbocharger contribution to engine blowby.

Condition:
Turn keyswitch OFF.
Remove turbocharger oil drain line from the block and drain into a bucket.
Make sure the turbocharger oil drain port in the block is plugged so no crankcase gases escape.
Start engine.
Load engine to rated rpm on a chassis Did the total engine blowby drop more than Repair
dynamometer. 30 percent? complete
ISX, and QSX15 Service Manual, Bulletin Replace the turbocharger assembly.
Did the total engine blowby drop more than Repair

30 percent? complete
NO
Repair:
Engine may need to be rebuilt.
See engine rebuild specifications.
STEP 10: Aftertreatment checks.

STEP 10A: Check for aftertreatment related fault codes.
Condition:
Turn keyswitch OFF
Use INSITE electronic service tool to read the Fault codes related to the aftertreatment Appropriate
fault codes. system are found to be active? fault code
YES troubleshooti
Check for any aftertreatment fault codes.
Specifically fault codes related to high soot in the ng tree
aftertreatment particulate trap, face plugging of
the aftertreatment catalyst, and aftertreatment Fault codes related to the aftertreatment 10B
catalyst efficiency. system are found to be active?
NO
STEP 10B: Perform basic aftertreatment troubleshooting checks.

Condition:
None
The following items must be checked or verified All parts have been inspected and appear to 10C
before continuing: be functioning properly?
Check to make sure that Ultra Low Sulfur YES
Diesel fuel is being used in the vehicle.
Check for any fuel leaks around the
aftertreatment fuel shutoff valve or All parts have been inspected and appear to Repair
aftertreatment injector components. be functioning properly? complete
Check for any noticeable exhaust leaks NO
around any aftertreatment components.
Repair:
Check the exhaust pipes for restrictions that
can create high exhaust back pressure. Correct the damage and verify complaint is
Check the aftertreatment sensors, wires, no longer present after repair.
connectors, and harnesses for proper
connections.
Check the exhaust gas filter differential
pressure sensor tubes for proper connections.
STEP 10C: Check for signs of an internal damage to the aftertreatment system.
Condition:
Engine warmed up to normal operating temperature
Vehicle must be stationary.
Quickly snap the throttle pedal accelerating the Any visible smoke (black or white) present Repair
engine from low idle to high idle while checking during the snap throttle acceleration? complete.
for smoke at the exhaust outlet. YES Troubleshoot
the smoke
Inspect for the following during the snap throttle Repair: complaint,
acceleration.
Damage in the aftertreatment system. use the
Smoke (any color) coming out of the vehicle proper TT
tailpipe. Remove the exhaust gas aftertreatment tree steps
Soot or signs of fuel, coolant, or oil inside the system from the vehicle and inspect for
tailpipe. reuse.
Note: If the aftertreatment system is operating Use the following procedure in the
correctly, no visible smoke will be present during Signature, ISX, and QSX15 Service
the snap throttle acceleration. Any visible smoke Manual, Bulletin 3666239. Refer to
is an indication of a possible malfunction in the Procedure 011-050 in Section 11.
aftertreatment system.
Any visible smoke (black or white) present 10D
during the snap throttle acceleration?
NO
STEP 10D: Check exhaust restriction.

Condition:
Install a pressure gauge into the exhaust system
Turn keyswitch ON
Check exhaust restriction by installing a pressure Is exhaust restriction greater than 305 mm- Repair
gauge into the exhaust system just past the Hg [12.0 in-Hg]? complete
turbocharger outlet. YES
If a port is not found in the exhaust system, Repair:
remove the exhaust gas temperature 1 sensor
and install the pressure gauge in the temperature Remove the exhaust aftertreatment system
sensor port. from the vehicle and inspect for reuse.
Use the following procedure in the Signature, Use the following procedure in the
ISX, and QSX15 Service Manual, Bulletin Signature, ISX, and QSX15 Service
3666239. Refer to Procedure 011-009 in Section Manual, Bulletin 3666239. Refer to
Is exhaust restriction greater than 305 mm- Perform the

Hg [12.0 in-Hg]? next
NO troubleshooti
ng procedure
as outlined in
Step 2
Fuel Economy Troubleshooting Tree Signature, ISX, and QSX15 Eng [...]
Fuel Economy Troubleshooting Tree

Fuel Consumption Excessive.

This symptom tree is to be used to troubleshoot fuel economy complaints. This tree is used along with the Fuel
Consumption - Customer Complaint Form and the Driveability Low Power/Excessive Fuel - Consumption Checklist to
help isolate engine, chassis, or driver issues associated with excessive fuel consumption.
Shop Talk:
The Fuel Consumption - General Information section of this manual and Troubleshooting Excessive Fuel
Consumption, Bulletin 3666094, should be referenced prior to any troubleshooting being performed on a customer's
engine.
The cause of excessive fuel consumption is difficult to diagnose and correct because of the potential number of factors
Engine factors
Vehicle factors and specifications
Environmental factors
Driver technique and operating practices
Fuel system factors
Low power or driveability problems.
Form is a valuable list of questions that can be used to assist the service technician in determining the cause of the
problem. Complete the form before troubleshooting the complaint. The following are some of the factors that must
be considered when troubleshooting fuel consumption complaints.
Excessive Idling Time: Idling the engine can use from 0.5 to 1.5 gallons per hour depending on the engine idle
speed.
Vehicle Aerodynamics: The largest single power requirement for a truck is the power needed to overcome air
resistance. As a general rule, each 10 percent reduction in air resistance results in a 5 percent increase in mile per
gallon.
Rolling Resistance: Rolling resistance is the second largest consumer of power on a truck. The type of tire and
Environmental and Seasonal Weather Changes: There can be as much as 1 to 1.5 mile per gallon difference in fuel
consumption, depending on the season and the weather conditions.
Truck Route and Terrain: East and west routes experience almost continual crosswinds and head winds. Less fuel
can be used on north and south routes where parts of the trip are not only warmer, but have less wind resistance.
Driver Technique and Operating Practices: A 1 mile per hour increase in road speed equals a 0.1 mile per gallon
increase in fuel consumption. This means that increasing road speed from 50 to 60 mph will result in a loss of fuel
mileage of 1 mpg.
Result of a Low Power or Driveability Problem: An operator will change driving style to compensate for a low power
or driveability problem. Some things the driver is likely to do are (a) shift to a higher engine rpm or (b) run on the
droop curve in a lower gear instead of upshifting to drive at part-throttle conditions. These changes in driving style
will increase the amount of fuel used.
Additional vehicle factors, vehicle specifications, and axle alignment can also affect fuel consumption. For additional
Bulletin 3387245.
Signature, ISX, and QSX15 Eng [...] Fuel Economy Troubleshooting Tree

STEP 1: Verify the complaint.
STEP 1A: Fill out the Fuel Consumption -
Customer Complaint Form.
STEP 1B: Run VE/VMS.
STEP 2: Electronic checks using INSITE.
STEP 2A: Check for fault codes.
STEP 2B: Confirm Features and
Parameters.
STEP 2C: Check the ECM calibration.
STEP 2D: Monitor vehicle speed.
STEP 2D-1: Inspect the engine and
chassis grounds.
STEP 3: Fuel system inspection.
STEP 3A: Inspect the vehicle for fuel
leaks.
STEP 3B: Check the fuel inlet restriction.
STEP 3C: Check the drain line restriction.
STEP 3D: Check the fuel grade.
STEP 3E: Perform the INSITE Cylinder
Performance Test.
STEP 3E-1: Interpret the results of the
Cylinder Performance Test.
STEP 3E-2: Interpret the results of the
Cylinder Performance Test.
STEP 3E-3: Measure the resistance
between the actuator and
the actuator base.
STEP 3E-4: Swap the front and rear
metering actuator.
STEP 3E-5: Swap the front and rear
timing actuator.
STEP 4: Check the air handling system.
STEP 4A: Check the air intake restriction.
STEP 4B: Pressure test the charge air
cooler.
STEP 4C: Inspect the charge air cooler.
STEP 4D: Check the exhaust restriction.
STEP 5A: Start the engine and read the
fault codes.
STEP 5B: Inspect the turbocharger blades.
STEP 5C: Determination of turbocharger

type.
STEP 5D: Check the variable geometry
actuator rod for correct travel.
STEP 5D-1: Check for air leaks and
inspect air lines.
STEP 5D-2: Check the engine and
vehicle grounds.
STEP 5D-3: Check for air pressure at the
turbocharger control valve
outlet.
turbocharger control valve
outlet.
STEP 5D-5: Check for correct
turbocharger actuator
travel.
turbocharger control shutoff
valve outlet.
valve inlet.
STEP 5D-8: Check for plugged
valve filter.
STEP 5E: Perform the INSITE EGR Valve/
Turbocharger Operational Test.
STEP 5E-1: Check the engine and
vehicle grounds.
STEP 5F: Inspect the wastegate actuator
hose.
STEP 5G: Inspect the wastegate actuator
rod for travel.
STEP 5G-1: Inspect the wastegate
actuator rod for travel.
STEP 5H: Measure the resistance of the
four-stage wastegate
controllers, if equipped.
STEP 5I: Inspect the four-stage
wastegate controller, if
equipped.
STEP 6: Base engine checks.
STEP 6A: Verify the overhead adjustments
are correct.
STEP 6B: Verify the dipstick calibration.
STEP 6C: Analyze the engine oil.
STEP 6D: Check for internal engine
damage.

STEP 1A: Fill out the Fuel Consumption - Customer Complaint Form.
Condition:
fill out the fuel consumption - customer complaint Is the problem caused by vehicle factors, Repair
form in the troubleshooting and repair manual, environmental factors, or driver technique? complete
signature, isx, and qsx15 engines, bulletin YES
3666239.
Is the problem caused by vehicle factors, 1B
environmental factors, or driver technique?
NO

Condition:
fill out the driveability/low power/excessive fuel Taking into consideration the adverse effect 2A
consumption - checklist in the troubleshooting of ambient conditions, does the VE/VMS
and repair manual, signature, isx, and qsx15 fuel economy conflict with the customer's
engines, bulletin 3666239. current fuel economy?
Use the data gathered to run VE/VMS or YES
provide the data to the appropriate support
personnel to run VE/VMS. Taking into consideration the adverse effect Repair
NOTE: VE/VMS does not account for adverse of ambient conditions, does the VE/VMS complete
ambient conditions. fuel economy conflict with the customer's
current fuel economy?
NO
Repair:
Explain to the customer the effects of driving
habits and vehicle set up on fuel
consumption.
See Shop Talk for specific examples of how
fuel economy can be effected based on
driving habits and vehicles set up.

Condition:
Turn keyswitch ON.
use insite to read the fault codes. Are there any active or high counts of inactive Troubleshoot
fault codes? fault codes.
YES
Are there any active or high counts of inactive 2B

fault codes?
NO
STEP 2B: Confirm features and parameters.

Condition:
Turn keyswitch ON.
confirm the programmable features and Are the features and parameters set 2C
parameters are set correctly. correctly?
Verify the following features and parameters: YES
Maximum Cruise Control Speed
Cruise Control Upper Droop Are the features and parameters set Repair
Cruise Control Lower Droop correctly? complete
Gear-Down Maximum Vehicle Speed (Heavy NO
Engine Load) = (peak horsepower rpm x 60
min/hr) / (Gear Down Transmission Gear Ratio Repair:
x Rear Axle Ratio x Tire Size) Reset the Features and Parameters to the
Gear-Down Maximum Vehicle Speed (Light appropriate values.
Engine Load ) = (peak torque rpm x 60 min/
hr) / (Top Gear Transmission Gear Ratio x
Rear Axle Ratio x Tire Size)
Maximum Accelerator Vehicle Speed
Road Speed Governor Upper Droop
Road Speed Governor Lower Droop.
NOTE: Refer to the Feature Help Description in
INSITE for additional information.

Condition:
Turn keyswitch ON.
compare the ecm code with the engine rating and Is the calibration correct? 2D
cpl. verify the calibration is correct. YES
Use the calibration notes field in INSITE to
confirm the calibration is correct for the Is the calibration correct? Repair
application and CPL. complete
NO
Verify the calibration is not set up for STx, LBSC,
or Multiplexing if the application does not require Repair:
it. Recalibrate the ECM with the correct ECM
Code.

Condition:
Turn keyswitch ON.
Start the engine.
with insite, monitor vehicle speed while the Does vehicle speed read zero when the 3A
vehicle is not moving. vehicle is not moving and the engine is
running?
YES
Does vehicle speed read zero when the 2D-1

vehicle is not moving and the engine is
running?
NO
STEP 2D-1: Inspect the engine and chassis grounds.

Condition:
Turn keyswitch OFF.
check for loose or corroded engine, chassis, or Are all grounds present, properly grounded, Repair
battery ground connections. free of corrosion, and tight? complete
Check the engine ground connection. YES
Check the battery terminal connections. Repair:
Check the VSS and the VSS circuit.
Refer to Procedure 019-090, 019-091 and
019-092 in the Troubleshooting Manual,
Signature Fuel System, Signature Engines,
Bulletin 3666259.
Are all grounds present, properly grounded, Repair

free of corrosion, and tight? complete
NO
Repair:
Replace, clean, or tighten the grounds.
STEP 3: Fuel system inspection.

STEP 3A: Inspect the vehicle for fuel leaks.
Condition:
Turn keyswitch OFF.
check the suction fuel lines, oem fuel Are any leaks present? Repair
connections, suction-side fuel filter, fuel pump, YES complete
ifsm, and actuators for leaks.
Repair:
With EGR
Repair or replace the failed component.
Check for pressure-side fuel filter, fittings and
hoses to and from the ECM, cooling plate, fuel
pump, IFSM, and actuators for leaks. Are any leaks present? 3B
NOTE: Dye can be placed in the fuel to assist in NO
finding fuel system leaks.
STEP 3B: Check the fuel inlet restriction.

Condition:
Connect vacuum gauge to the suction-side Compucheck fitting.
Turn keyswitch ON.
Engine running at high idle.
if the engine uses a fuel lift pump, wait until after Is fuel inlet restriction less than the 3C
priming pump has turned off and observe the specifications listed below?
reading on the vacuum gauge. Dirty: 305 mm Hg [12 in Hg]
New: 203 mm Hg [8 in Hg].
YES
Is fuel inlet restriction less than the Repair

specifications listed below? complete
Dirty: 305 mm Hg [12 in Hg]
New: 203 mm Hg [8 in Hg].
NO
Repair:
supply lines.
STEP 3C: Check the drain line restriction.

Condition:
Turn keyswitch ON.
Engine running at high idle.
observe the reading on the pressure gauge. Is fuel drain line restriction less than 229 mm 3D
Hg [9 in Hg]?
YES
Is fuel drain line restriction less than 229 mm Repair

Hg [9 in Hg]? complete
NO
Repair:
Locate the cause of the high fuel drain line
restriction in the OEM fuel return line.
STEP 3D: Check the fuel grade.

Condition:
Turn keyswitch OFF.
verify the fuel grade used is appropriate for the Is the fuel grade used and the quality 3E
application and ambient conditions and fuel acceptable?
quality is acceptable. YES
Run the engine on an alternate, known good fuel
source and verify engine performance if the fuel Is the fuel grade used and the quality Repair
can not be tested appropriately. acceptable? complete
NOTE: Refer to Fuel for Cummins Engines, NO
Bulletin 3379001.
Repair:
Instruct the driver or owner to refuel with
acceptable fuel.
STEP 3E: Perform the INSITE Cylinder Performance Test.

Condition:
Engine running at low idle.
perform the insite cylinder performance test. Do all injectors and both banks pass the 4A
NOTE: Do not run the engine above 900 rpm Cylinder Performance Test?
when performing the Cylinder Performance Test. YES
Do all injectors and both banks pass the 3E-1

Cylinder Performance Test?
NO
STEP 3E-1: Interpret the results of the Cylinder Performance Test.

Condition:
interpret the results of the insite cylinder Did the Cylinder Performance Test find an Repair
performance test. individual failed cylinder? complete
If the Cylinder Performance Test displays bar YES
graphs for each cylinder's contribution, use
the INSITE help file to interpret the results. Repair:
If the Cylinder Performance Test displays pass Replace the failed injector.
or fail for each cylinder, run the test at least 3
times to verify the results. Read the Test Refer to Procedure 006-026.
Results under the Results section of the test.
Did the Cylinder Performance Test find an 3E-2
individual failed cylinder?
NO
STEP 3E-2: Interpret the results of the Cylinder Performance Test.

Condition:
interpret the results of the insite cylinder Did the Cylinder Performance Test find an 3E-3
performance test. individual failed bank?
If the Cylinder Performance Test displays bar YES
graphs for each bank's contribution, use the
INSITE help file to interpret the results.
If the Cylinder Performance Test displays pass Did the Cylinder Performance Test find an 4A
or fail for each bank, run the test at least 3 individual failed bank?
times to verify the results. Read the Test NO
Results under the Results section of the test.
STEP 3E-3: Measure the resistance between the actuator and the actuator base.
Condition:
Turn keyswitch OFF.
Disconnect the engine harness from the timing and fueling actuators.
measure the resistance between the actuator Greater than 100k ohms? 3E-4
and the actuator mounting base. YES
Greater than 100k ohms? Repair

NO complete
Repair:
Replace the failed fueling or timing actuator.
Refer to Procedure 019-110 or 019-111 in the
Troubleshooting Manual, Signature Fuel
System, Signature Engines, Bulletin
4021334.
STEP 3E-4: Swap the front and rear fueling actuator.

Condition:
swap the front and rear fueling actuator to Does the failed bank follow the metering Repair
determine if the failed bank of cylinders follows actuator? complete
the actuator. YES
Refer to Procedure 019-110 in the
Troubleshooting Manual, Signature Fuel Repair:
System, Signature Engines, Bulletin 4021334 Replace the failed fueling actuator. Refer to
for removal and installation. Procedure 019-110 in the Troubleshooting
Perform the INSITE Cylinder Performance Manual, Signature Fuel System, Signature
Test. Engines, Bulletin 4021334.
Does the failed bank follow the metering 3E-5

actuator?
NO
STEP 3E-5: Swap the front and rear timing actuator.

Condition:
swap the front and rear timing actuators to Does the failed bank follow the timing Repair
determine if the failed bank of cylinders follows actuator? complete
the timing actuator. YES
Troubleshooting Manual, Signature Fuel Repair:
System, Signature Engines, Bulletin 4021334 Replace the failed timing actuator.
for removal and installation.
Perform the INSITE Cylinder Performance Refer to Procedure 019-111 in the
Test. Troubleshooting Manual, Signature Fuel
4021334.
Does the failed bank follow the timing 3A

actuator?
NO
Repair:
Troubleshooting procedures need to be
repeated from the beginning. A failed injector
or actuator should have been detected.
STEP 4: Check the air handling system.

STEP 4A: Check the air intake restriction.
Condition:
Run the engine at advertised horsepower and rpm.
check the intake system restriction by installing Is air intake restriction greater than 635 mm Repair
a vacuum gauge or water manometer into the air H2O [25 in H2O] for a used filter or 254 in complete
intake system. H2O [10 in H2O] for a new filter?
Refer to Procedure 010-031. YES
Repair:
Correct the cause of high intake air
restriction.
intake piping.
Is air intake restriction greater than 635 mm 4B

H2O [25 in H2O] for a used filter or 254 in
H2O [10 in H2O] for a new filter?
NO
STEP 4B: Pressure test the charge air cooler.

Condition:
Turn keyswitch OFF.
pressure test the charge air cooler. Is the pressure drop 5 psi or less in 15 4C
seconds?
YES
Is the pressure drop 5 psi or less in 15 Repair

seconds? complete
NO
Repair:
Repair the charge air cooler.
STEP 4C: Inspect the charge air cooler.

Condition:
Turn keyswitch OFF.
inspect the charge air cooler for bent or plugged Is the charge air cooler free from bent or 4D
fins. plugged fins?
Bent or plugged fins will force the temperature of YES
the air exiting the cooler to raise and force the
engine to work harder to obtain the desired Is the charge air cooler free from bent or Repair
charge flow. A harder working engine will use plugged fins? complete
more fuel.
NO
Repair:
Clean the charge air cooler.
STEP 4D: Check the exhaust restriction.

Condition:
check the exhaust restriction by installing a Is exhaust restriction less than 76 mm Hg [3 5A

pressure gauge into the exhaust system just past in Hg]?
the turbocharger. YES
Is exhaust restriction less than 76 mm Hg [3 Repair
in Hg]? complete
NO
Repair:
Repair the exhaust for source of high
restriction.

Condition:
check the fault codes with the engine running. Are Fault Codes 2355 or 2356 active? Go to
YES appropriate
Use INSITE to read the fault codes.
Fault Code
troubleshooti
ng tree.
Are Fault Codes 2355 or 2356 active? 5B

NO
STEP 5B: Inspect the turbocharger blades.

Condition:
Engine OFF.
Remove intake and exhaust connections for turbocharger.
inspect the compressor and turbine fins for Was damage found on turbocharger fins or Repair
damage or wear. was axial or radial movement out of complete
specification?
Measure the turbocharger wheel axial
movement. YES
Check the radial movement of the turbocharger Repair:
wheel. Replace the turbocharger.
Refer to Procedure 010-033. Refer to Procedure 010-033.
Was damage found on turbocharger fins or 5C

was axial or radial movement out of
specification?
NO
STEP 5C: Determination of turbocharger type.

Condition:
determine if the turbocharger is a wastegated or Is the turbocharger a variable geometry 5D

variable geometry turbocharger. turbocharger?
YES
Is the turbocharger a variable geometry 5F

turbocharger?
NO
STEP 5D: Check the variable geometry actuator rod for correct travel.
Condition:
Engine OFF.
Turn keyswitch ON.
Verify air tanks are fully charged.
perform the turbocharger actuator test using the Does the turbocharger actuator rod extend 5E
insite electronic service tool. between 10.2 and 11.8 mm [0.402 and 0.465
Adjust the delay timer in the Turbocharger in]?
Actuator Test so rod movement can be YES
observed.
Select the Retract Actuator position with
INSITE. Does the turbocharger actuator rod extend 5D-1
Mark or scribe the VG actuator rod at the between 10.2 and 11.8 mm [0.402 and 0.465
base of the actuator. in]?
Select the Extend Actuator position with NO
INSITE.
Measure the rod travel by measuring the
distance from the base of the turbocharger
actuator to the scribe mark.
NOTE: The turbocharger actuator should move
quickly and crisply. If the actuator rod movement
is slow, there could be a problem with the air
supply, a faulty ground connection on the engine
or chassis, or mechanical problems with the
variable geometry turbocharger assembly.
STEP 5D-1: Check for air leaks and inspect air lines.
Condition:
Engine OFF.
Turn keyswitch ON.
Verify vehicle air tanks are fully charged.
perform the turbocharger actuator test using the Air leaks found in the system? Repair
insite electronic service tool. select the extend YES complete
actuator position.
Repair:
Listen for air leaks at the following components:
Repair air leaks.
Turbocharger control valve
Turbocharger control shutoff valve inlet
connection Air leaks found in the system? 5D-2
Turbocharger control shutoff valve outlet NO
connection
Turbocharger control valve inlet connection
Turbocharger control valve outlet connection
Turbocharger actuator
All air lines, including the OEM supply line to
the turbocharger control shutoff valve,
turbocharger control shutoff valve to the
turbocharger control valve, and turbocharger
control valve to the turbocharger actuator.
STEP 5D-2: Check the engine and vehicle grounds.

Condition:
Turn keyswitch OFF.
check for loose or corroded engine, chassis, or Are all grounds present, properly grounded, 5D-3
battery ground connections. free of corrosion, and tight?
Check the battery terminal connections.
NO
Repair:
Replace, clean, or tighten the ground.
Condition:
Engine OFF.
Turn keyswitch ON.
perform the turbocharger actuator test using the Is vehicle air tank pressure present at the 5D-4
insite electronic service tool. select the retract turbocharger control valve outlet?
actuator position. YES
Remove the air line connection at the outlet of the
turbocharger control valve. Is vehicle air tank pressure present at the 5D-6
Install an M12 Compucheck fitting, Part Number turbocharger control valve outlet?
3824843, at the outlet of the turbocharger control NO
valve.
Install an air pressure gauge that is capable of
reading at least 1034 kPa [150 psi]
Perform the Turbocharger Actuator Test using
the INSITE electronic service tool. Select the
Condition:
Engine OFF.
Turn keyswitch ON.
perform the turbocharger actuator test using the Does the pressure gauge read more than 15 Repair
insite electronic service tool. select the retract psi after 5 minutes? complete
actuator position. YES
Remove the air line connection at the outlet of the Repair:
turbocharger control valve.
Install an M12 Compucheck fitting at the outlet
of the turbocharger control valve. Refer to Procedure 019-388 in the
Install an air pressure gauge that is capable of System, Signature Engines, Bulletin
reading at least 1034 kPa [150 psi]. 4021334.
Does the pressure gauge read more than 15 5D-5

psi after 5 minutes?
NO
STEP 5D-5: Check for correct turbocharger actuator travel.

Condition:
Engine OFF.
Turn keyswitch ON.
remove the variable geometry actuator from the Does the turbocharger actuator rod travel at Repair
turbocharger. least 12 mm [0.472 in]? complete
Refer to Procedure 010-113. YES
NOTE: Damage to the turbocharger may result if Repair:
the proper removal procedure is not followed. Replace the turbocharger assembly.
Perform the Turbocharger Actuator Test using Refer to Procedure 010-033.
the INSITE electronic service tool. Select the
Does the turbocharger actuator rod travel at Repair
least 12 mm [0.472 in]? complete
NO
Repair:
Replace the turbocharger actuator.
STEP 5D-6: Check for air pressure at the turbocharger control shutoff valve outlet.
Condition:
Engine OFF.
Turn keyswitch ON.
use insite to start the turbocharger actuator test. Can air be heard escaping from the Repair
Loosen the air line connection at the turbocharger control shutoff valve outlet? complete
turbocharger control shutoff valve outlet. YES
Repair:
4021334.
Can air be heard escaping from the 5D-7

turbocharger control shutoff valve outlet?
NO
STEP 5D-7: Check for air pressure at the turbocharger control shutoff valve inlet.
Condition:
Engine OFF.
Turn keyswitch ON.
verify the oem air supply line is connected to the Can air be heard escaping from the 5D-8
correct port on the turbocharger control shutoff turbocharger control shutoff valve inlet?
valve. YES
turbocharger control shutoff inlet. Can air be heard escaping from the Repair
turbocharger control shutoff valve inlet? complete
NO
Repair:
Repair the air supply from the OEM air tanks.
STEP 5D-8: Check for plugged turbocharger control shutoff valve filter.
Condition:
Remove the turbocharger control shutoff valve filter.
Turn keyswitch ON.
Connect the INSITE electronic service tool.
use insite to start the turbocharger actuator test. Is an air leak present at the turbocharger Repair
Listen for an air leak at the turbocharger control
shutoff valve filter head. YES
Repair:
valve filter.
Is an air leak present at the turbocharger Repair

NO
Repair:
valve.
4021334.
STEP 5E: Perform the INSITE EGR Valve/Turbocharger Operational Test.

Condition:
Turn keyswitch ON.
select the egr/vgt operational test using the Does the Turbocharger Operational Test 6A
insite electronic service tool. pass?
Choose the Turbocharger Actuator option under YES
Test Choices.
Does the Turbocharger Operational Test 5E-1
pass?
NO
STEP 5E-1: Check the engine and vehicle grounds.

Condition:
Turn keyswitch OFF.
check for a loose or corroded engine, chassis, or Are all grounds present, properly grounded, Repair
battery ground connection. free of corrosion, and tight? complete
Replace the variable geometry turbocharger.

NO
Repair:
Replace, clean, or tighten the ground.
STEP 5F: Inspect the wastegate actuator hose.

Condition:
Engine OFF.
Remove the turbocharger if wastegate actuator is inaccessible.
inspect the integral wastegate actuator hose for Are holes or cracks found in the wastegate Repair
cracks or holes. actuator hose? complete
YES
Repair:
Replace the wastegate actuator hose.
Are holes or cracks found in the wastegate 5G

actuator hose?
NO
STEP 5G: Inspect the wastegate actuator rod for travel.

Condition:
Engine OFF.
Remove the wastegate actuator hose from the wastegate actuator.
apply a regulated air supply of 310 kpa [45 psi] Does the wastegate actuator rod move? 5H
to the actuator and check for actuator movement. YES
Does the wastegate actuator rod move? 5G-1

NO
STEP 5G-1: Inspect the wastegate actuator rod for travel.

Condition:
Engine OFF.
Remove the e-clip from the wastegate pin and disconnect the actuator rod.
apply a regulated air supply of 310 kpa [45 psi] Does the wastegate actuator rod move? Repair
to the actuator and check for actuator movement. YES complete
Repair:
Move the wastegate lever on the
turbocharger back and forth and check for
smooth operation. Replace the turbocharger
assembly if the wastegate is seized.
Does the wastegate actuator rod move? Repair

NO complete
Repair:
Replace the wastegate actuator.
STEP 5H: Measure the resistance of the four-stage wastegate controllers, if equipped.
Condition:
Engine OFF.
Disconnect the ring terminals from the four-stage wastegate controllers, if equipped.
measure the resistance from the wastegate Are the wastegate controller solenoid 5I
controller post to engine block ground. resistances between 7.0 and 8.0 ohms?
NOTE: The wastegate controller solenoids YES
must be between 20C and 26C [68F and 78
F] before using the resistance specifications Are the wastegate controller solenoid Repair
listed. resistances between 7.0 and 8.0 ohms? complete
NO
Repair:
Replace the failed wastegate controller.
STEP 5I: Inspect the four-stage wastegate controller, if equipped.

Condition:
Engine OFF.
Remove the four-stage wastegate controllers.
check the valve disc, valve seat, and actuator Damage or debris found on the valve disc, Repair
disc for dirt, metal, debris, bonding separation, valve seat, or actuator disc? complete
Repair:
Replace or clean failed components.
Damage or debris found on the valve disc, 6A

NO
STEP 6: Base engine checks.

STEP 6A: Verify the overhead adjustments are correct.
Condition:
Turn keyswitch OFF.
Remove valve cover.
measure the overhead settings. Are the overhead settings within the reuse 6B
limits?
Valve Lash Reuse Limits:
YES
Intake valve lash: 0.102 mm [0.004 in] to 0.483
mm [0.019 in]
Exhaust valve lash: 0.508 mm [0.020 in] to Are the overhead settings within the reuse Repair
0.813 mm [0.032 in]. limits? complete
NO
Repair:
STEP 6B: Verify the dipstick calibration.

Condition:
Turn keyswitch OFF.
verify the dipstick calibration. Is the dipstick calibrated properly? 6C

Drain, remove, clean, and install the lubricating YES
oil pan. Refer to Procedure 007-025.
Check the calibration of the lubricating oil Is the dipstick calibrated properly? Repair
dipstick. Refer to Procedure 007-009. NO complete
Repair:
Calibrate the lubricating oil dipstick.
STEP 6C: Analyze the engine oil.

Condition:
Turn keyswitch OFF.
take an engine oil sample. Does the engine oil analysis show any signs Repair
of wear metals or contaminates? complete
YES
Does the engine oil analysis show any signs 6D

of wear metals or contaminates?
NO
Repair:
Locate and replace the worn component or
remove the source of contaminate and repair
the engine as necessary.
STEP 6D: Check for internal engine damage.

Condition:
Turn keyswitch OFF.
remove the oil filter. Is any foreign material found in the oil filter? Repair
YES complete
Inspect the oil filter for foreign material. Refer to Repair:
Procedure 007-002. Locate the source of foreign material and
repair the engine as necessary.
Is any foreign material found in the oil filter? Return to the

NO troubleshooti
ng steps or
contact a
local
Cummins
Authorized
Repair
Location, if
all steps
have been
completed
and checked
again.
Fuel Economy Troubleshooting Tree


This symptom tree is to be used to troubleshoot fuel economy complaints. This tree is used along with the Fuel
Consumption - Customer Complaint Form and the Driveability Low Power/Excessive Fuel - Consumption Checklist to
help isolate engine, chassis, or driver issues associated with excessive fuel consumption.
Shop Talk:
The Fuel Consumption - General Information section of this manual and Troubleshooting Excessive Fuel
Consumption, Bulletin 3666094, should be referenced prior to any troubleshooting being performed on a customer's
engine.
The cause of excessive fuel consumption is difficult to diagnose and correct because of the potential number of factors
Engine factors
Vehicle factors and specifications
Environmental factors
Driver technique and operating practices
Fuel system factors
Low power or driveability problems.
Form is a valuable list of questions that can be used to assist the service technician in determining the cause of the
problem. Complete the form before troubleshooting the complaint. The following are some of the factors that must
be considered when troubleshooting fuel consumption complaints.
Excessive idling time: Idling the engine can use from 0.5 to 1.5 gallons per hour depending on the engine idle
speed.
Vehicle Aerodynamics: The largest single power requirement for a truck is the power needed to overcome air
resistance. As a general rule, each 10 percent reduction in air resistance results in a 5 percent increase in mile per
gallon.
Rolling Resistance: Rolling resistance is the second largest consumer of power on a truck. The type of tire and
Environmental and Seasonal Weather Changes: There can be as much as 1 to 1.5 mile per gallon difference in fuel
consumption, depending on the season and the weather conditions.
Truck Route and Terrain: East and west routes experience almost continual crosswinds and head winds. Less fuel
can be used on north and south routes where parts of the trip are not only warmer, but have less wind resistance.
Driver Technique and Operating Practices: A 1 mile per hour increase in road speed equals a 0.1 mile per gallon
increase in fuel consumption. This means that increasing road speed from 50 to 60 mph will result in a loss of fuel
mileage of 1 mpg.
Result of a Low Power or Driveability Problem: An operator will change driving style to compensate for a low power
or driveability problem. Some things the driver is likely to do are (a) shift to a high engine rpm or (b) run on the
droop curve in a lower gear instead of upshifting to drive at part-throttle conditions. These changes in driving style
will increase the amount of fuel used.
Additional vehicle factors, vehicle specifications and axle alignment, can also affect fuel consumption. For additional
Bulletin 3387245.

STEP 1A: Fill out the Fuel Consumption -
Customer Complaint Form.
STEP 2B: Confirm Features and
Parameters.
STEP 2C: Check the ECM calibrations.
STEP 2D-1: Inspect the engine and
chassis grounds.
STEP 3: Engine performance.
STEP 3A: Engine performance
troubleshooting.

STEP 1A: Fill the Fuel Consumption - Customer Complaint Form.
Condition:
Fill out the Fuel Consumption - Customer Is the problem caused by vehicle factors, Repair
Complaint Form in the Troubleshooting and environmental factors, or driver technique? complete
Repair Manual, ISC, QSC8.3, ISL and QSL9 YES
Is the problem caused by vehicle factors, 1B
environmental factors, or driver technique?
NO

Condition:
Fill out the Driveability/Low Power/Excessive Taking into consideration the adverse effect 2A
Fuel Consumption - Checklist in Troubleshooting of ambient conditions, does the VE/VMS fuel
and Repair Manual. economy conflict with the customer's current
fuel economy?
Use the data gathered to run VE/VMS or provide
the data to the appropriate support personnel to YES
run VE/VMS.
NOTE: VE/VMS does not account for adverse Taking into consideration the adverse effect Repair
ambient conditions. of ambient conditions, does the VE/VMS fuel complete
economy conflict with the customer's current
fuel economy?
NO
Repair:
Explain to the customer the effects of driving
habits on fuel consumption.

Condition:
Turn keyswitch ON.
Using INSITE, read the fault codes. Are there any active or high counts of inactive Troubleshoot
fault codes? fault codes
YES
Are there any active or high counts of inactive 2B

fault codes?
NO
STEP 2B: Confirm Features and Parameters.

Condition:
Turn keyswitch ON.
Confirm the Programmable Features and Are the Features and Parameters set 2C
Parameters are set correctly. correctly?
YES
Are the Features and Parameters set Repair

correctly? complete
NO
Repair:
Reset the Features and Parameters to their
appropriate values.

Condition:
Turn keyswitch ON.
Compare the ECM code with the engine rating Is the calibration correct? 2D
and CPL. Verify the calibration is correct. YES
Is the calibration correct? Repair

NO complete
Repair:
Recalibrate the ECM with the correct ECM
code.

Condition:
Turn keyswitch ON.
With INSITE, monitor Vehicle Speed while the Does vehicle speed read 0 when the vehicle 3A
vehicle is not moving. is not moving?
YES
Does vehicle speed read 0 when the vehicle 2D-1

is not moving?
NO
STEP 2D-1: Inspect the engine and chassis grounds.

Condition:
Turn keyswitch OFF.
Check for loose or corroded engine, chassis, or Are all grounds present, properly grounded, Repair
battery ground connection. free of corrosion, and tight? complete
Check the engine ground connection YES
Check the chassis ground connections
Check the VSS and the VSS circuit.

NO
Repair:
Replace, clean, or tighten the grounds.
STEP 3: Engine performance.

STEP 3A: Engine performance troubleshooting.
Condition:
Perform the Fuel System Checks, Air Handling Poor fuel economy complaint still exists? Repair
Checks, and Base Engine Checks in the Engine YES complete
Performance Troubleshooting Tree.
Repair:
Perform the Fuel System Checks, Air
Handling Checks, and Base Engine Checks
in the Engine Performance Troubleshooting
Tree.
Poor fuel economy complaint still exists? Repair

NO complete
Vibration Excessive Signature, ISX, and QSX15 Eng [...]
Vibration Excessive
Vibration excessive
Cab noise due to vibration

This symptom tree can be used to troubleshoot all vibration-based symptoms listed above. Start by performing Step
1 troubleshooting. Step 2 will ask a series of questions and will provide a list of troubleshooting steps to perform,
depending on the symptoms. Perform the list of troubleshooting steps in the sequence shown in the Specifications/
Repair section of the tree.
Shop Talk:
Vibration Troubleshooting Documentation Information Questions
1) What is the OEM make/model?
2) What are the mileage/hours?
3) Has there been any recent repair and/or maintenance history?
Any engine/clutch/transmission rebuild, removal, and installation?
History of repeatedly broken brackets and/or capscrews (alternator, fan, exhaust, etc.)?
Structural modifications to the vehicle from OEM built?
4) Description of vibration?
What is shaking (mirror, seat, steering wheel, cab/dash, etc.)?
Is there excessive noise in the cab during the vibration?
5) What are the conditions when the complaint occurs?
Power take-off (PTO)?
Power output (hard pull, during lug down, etc.)?
During acceleration and/or deceleration?
At idle?
With or without a trailer?
Does vibration increase with engine speed?
Does vibration increase with road speed?
Is the vibration at a certain engine RPM?
6) Has the vibration been present since new? (From new, recent repair, modification to equipment)
7) Can the vibration be easily duplicated?
8) Do you have another piece of equipment with the same specification which exhibits the same complaint? (If yes,
get the engine serial number (ESN) and possibly test the vehicle)
9) Are you the only operator of the equipment? (If no, are the symptoms noticed by other operators)?
General Information
Vibration complaints can be very difficult to troubleshoot and understand the root cause. This troubleshooting
document was designed to help guide you through the logical steps of identifying the source. Vibration acceptance
is very subjective; what is objectionable to one person can possibly be acceptable to another.
Vibration complaints can be caused by many parts in the system (system includes the engine, driven component,
mounts, and equipment). The cause can be transmitted or generated from a remote point that is not readily apparent.
Cummins Inc. experience has shown that the engine is rarely the cause of an operator complaint. The majority of the
time, it is the engine mounts or design of the various components on the equipment. The engine is only at fault if
there is a misfire or an engine component that is out of balance.
Vibration complaints that occur only at idle speed are most likely caused by the engine mounts. If the engine mount
natural frequency is close to the engine firing frequency, the engine will cause the mounts to amplify the normal
vibration on an engine idling and cause the adjacent components to vibrate excessively.
Natural Frequency
Natural frequency, as the name implies, is the frequency at which an object wants to naturally vibrate. The frequency
is primarily dependent on mass and elasticity.
Types of Vibration
Signature, ISX, and QSX15 Eng [...] Vibration Excessive
1) Linear
a) Rotating components
b) Torque reaction
Caused by unbalanced rotating components and cylinder firing impulses.
Can be felt and observed visibly.
When excessive, can cause operator discomfort and destruction of components.
2) Torsional - twisting stresses
Cyclic speeding and slowing of rotating components.
Controlled by flywheel mass and vibration damper.
Can NOT be felt by the operator.
Can damage gears and splines.
3) Resonant - component excited at natural frequency
Is actually linear vibration.
Resonant vibration occurs when a system or component is excited by linear vibration at its natural frequency.
Vibration will increase in amplitude as the system's natural frequency is approached. Amplitude will decrease as
the exciting forces (engine firing frequency) increase in frequency beyond the system's natural frequency.
Resonant vibration can be many times larger in amplitude than the exciting force.
Vibration must be controlled by design of mounts (engine and cab) and components.
Engine and Cab Mounts
The mounts must be designed to isolate or reduce the transmission of engine and equipment component vibrations.
For maximum isolation, it is desired that the natural frequency of the mount be as low as possible.
Good engine mounts will reduce the amount of engine vibration transmitted to the chassis frame by at least 50
percent at idle.
Hard engine mounts will give little or no isolation, and can actually magnify the vibration transmitted to the chassis.
Stiffness (durometer) and size of the isolator, along with the weight of the engine or component applied are the
determining factors when designing a mounting system. An isolator that is correct for one engine, can possibly
not be right for another. Likewise, because of weight differential, a particular isolator designed for the rear of an
engine, probably will not be ideal for the front.

STEP 1: Perform the basic troubleshooting procedures.
STEP 1A: Document the information Documentation completed?
questions in the Shop Talk
section of this tree.
STEP 1B: Duplicate the complaint based Can the customer's complaint be
on the customer description. duplicated?
STEP 1C: Check for active fault codes or Active fault codes or high counts
codes.
STEP 1D: Perform the basic Are all steps verified to be
troubleshooting checks. correct?
STEP 1E: Determine if the engine is Is the engine running rough?
running rough.
STEP 1F: Perform a visual inspection of Is there visible engine mount
the engine mounts (without damage?
removal).
STEP 1G: Check for an engine mounted Engine mounted components
component contacting the frame touching the frame or body?
or body.
STEP 1H: Marine application. Is the engine installed in a
marine application?
STEP 1I: Do an engine RPM sweep. Is the vibration present
stationary below 1050 RPM?
STEP 1J: Do an engine RPM sweep. Is the vibration present
stationary above 1050 RPM?
STEP 1K: Check the vibration engine Is the vibration speed range
speed range. greater than 300 to 400 RPM?
STEP 2: Perform low RPM checks.
STEP 2A: Check that the accessory load is Are all steps verified to be
not excessive for the idle speed correct?
setting.
STEP 2B: Check that the Fast Idle Warm- Is the Fast Idle Warm-Up feature
Up feature is activating (if inactive?
applicable).
STEP 2C: Check that the Alternator Failure Is the Alternator Failure Warning
Warning feature is activating (if feature inactive?
applicable).
STEP 2D: Check for malfunctioning belt Did the vibration go away with
driven accessories. the drive belts removed?
STEP 2E: Check for equipment structural Are any structural modifications
modifications. to the equipment present?
STEP 2F: Check the engine mount Does the vibration go away
transmissibility for the rear during the test condition?
mount.
STEP 2F-1: Check the engine mount Does the vibration go away
transmissibility for all during the test condition?
mounts.
STEP 2G: Inspect the engine mounts. Are all steps verified to be
correct?
STEP 2H: Complaint since new. Has the problem been occurring
since the equipment was new?
STEP 3: Perform higher RPM checks.
STEP 3A: Inspect the engine mounts. Are all steps verified to be
correct?
STEP 3B: Check for malfunctioning belt Did the vibration go away with
driven accessories. the drive belts removed?
STEP 3C: Check for a damaged vibration Is the vibration damper damaged
damper. or out of specification?
STEP 3D: Check the air compressor Is the air compressor timing
timing. correct?
STEP 3E: Check the overhead Are the overhead adjustments
adjustments. correct?
STEP 3F: Check for malfunctioning gear Did the vibration go away?
driven components.
STEP 3G: Check for a damaged PTO. Did the vibration go away?
STEP 3H: Check for a malfunctioning Does the internal balancer meet
engine internal balancer specification?
assembly (4 cylinder B-Series
only).
STEP 3I: Check the clutch or torque Did engaging and disengaging
converter for vibration. the clutch affect the vibration?
STEP 3J: Check for a loose or damaged Does the flywheel meet
flywheel or flex plate. specifications?
STEP 3K: Check the flywheel housing for Does the flywheel housing meet
correct alignment. specifications?
STEP 3L: Check to see if the crankshaft Is the crankshaft balanced?
has been balanced.
STEP 3M: Check for internal engine Is there internal engine damage?
damage.
STEP 4: Operate the mobile equipment.
STEP 4A: Perform a diagnostic road test. Is the vibration present during a
diagnostic road test?
STEP 4A-1: Perform a diagnostic road Is the vibration present with the
test. transmission in neutral, under
the road speed conditions,
where the vibration was
duplicated driving?
STEP 4B: Inspect the engine mounts. Are all steps verified to be
correct?
STEP 4C: Check for drive train Are all steps verified to be
components that are worn, correct?
unbalanced, malfunctioning, or
are not correct.
STEP 5: Marine applications.
STEP 5A: Check the gear ratio and Are the gear ratio and the
propeller configuration. propeller incorrectly matched to
the engine power?
STEP 5B: Check for the correct engine Are the engine mount isolators
mounting isolators and for correct and installed correctly?
proper installation
requirements.
STEP 5C: Check for damaged engine Are the engine mounts and
mounts and isolators. isolators in good condition?
STEP 5D: Check the exhaust system. Is the exhaust system deficient?
STEP 5E: Check the engine driven Is an engine driven accessory
accessories. malfunctioning?
STEP 5F: Check the shaft coupling to gear Is the shaft coupling to gear
coupling alignment. coupling misaligned?
STEP 5G: Check the propeller shaft for Is the propeller shaft installed
proper installation. correctly?
STEP 5H: Check the propeller shaft for Is the propeller shaft
straightness. straightness within the OEM
specification?
STEP 5I: Isolate the engine. Does the engine vibration
persist?
STEP 5J: Check for strut/cutlass bearing Is the strut/cutlass bearing
misalignment. misaligned or strut mounting not
secure?
STEP 5K: Check the propeller. Is the propeller out of balance or
not fitted properly to the shaft?
STEP 5L: Check the V-angle on the V- Does the V-angle on the V-strut
strut. match the angle of the blade on
the prop?
STEP 5M: Check the propeller tunnels. Does the entry and exit of the
propeller tunnel match with the
propeller blades?
STEP 5N: Check the engine to Is the torsional coupling
transmission torsional coupling. incorrect or worn?
STEP 5O: Check the rudder. Does the rudder have excessive
play in the rudder post?
STEP 5P: Check the engine flywheel Is the flywheel housing
housing to cylinder block alignment incorrect?
alignment.
STEP 1: Perform the basic troubleshooting procedures.

STEP 1A: Document the information questions in the Shop Talk section of this tree.
Condition:
None
Perform the basic troubleshooting questionnaire. Documentation completed? 1B

Complete the vibration troubleshooting YES
documentation information questions contained
in the Shop Talk section of this procedure. Documentation completed? 1A
NO
Repair:
Complete the documentation.
STEP 1B: Duplicate the complaint based on the customer description.

Condition:
None.
Operate the equipment based on the description Can the customer's complaint be duplicated? 1C
from the customer to duplicate the complaint. YES
Can the customer's complaint be duplicated? Repair

NO complete
STEP 1C: Check for active fault codes or high counts of inactive fault codes.
Condition:
Turn keyswitch ON.
Check the fault codes. Active fault codes or high counts of inactive Repair
Use INSITE electronic service tool to read the fault codes? complete
fault codes. YES
Repair:
See the corresponding Electronic Control
System Troubleshooting and Repair manual
for the engine being serviced.
Active fault codes or high counts of inactive 1D

fault codes?
NO
STEP 1D: Perform the basic troubleshooting checks.

Condition:
As required.
Check or verify the following items before Are all steps verified to be correct? 1E
continuing. YES
Battery voltage is low (engine running)
External fuel leak Are all steps verified to be correct? Repair
Engine idle speed is set too low NO complete
Engine idle speed is set too high
Throttle lever or pedal, return spring, or air
throttle damaged or improperly adjusted (use
INSITE electronic service tool for electronic
engines)
Air in the fuel
Fuel pressure
Inlet restriction.
STEP 1E: Determine if the engine is running rough.

Condition:
Engine running at idle speed (less than 900 RPM).
Accessories off (air conditioning, fan, PTO).
Engine at operating temperature (greater than 338C [170F]).
Determine if the engine is running rough at Is the engine running rough? Complete
engine idle. YES Engine Runs
Refer to the Engine Runs Rough symptom tree Rough
Repair: troubleshooti
in Section TS or the Engine Performance
Refer to the Engine Runs Rough symptom ng tree
Troubleshooting Tree in Section TT.
tree.
Is the engine running rough? 1F

NO
STEP 1F: Perform a visual inspection of the engine mounts (without removal).
Condition:
Engine not running.
Engine mounts installed.
Perform a visual inspection of the engine Is there visible engine mount damage? Repair
mounts. YES complete
Look for obvious damage or something shorting Repair:
against the mounts, preventing isolation.
Repair or replace the engine mounts. Refer
Note: A more detail inspection will be carried out to Procedure 016-010 in Section 16 in the
later in the procedure. appropriate service manual.
Is there visible engine mount damage? 1G

NO
STEP 1G: Check for an engine mounted component contacting the frame or body.
Condition:
Engine not running.
Engine mounts installed.
Check for an engine mounted component Engine mounted components touching the Repair
touching the frame or body. frame or body? complete
Inspect the engine and engine mounted YES
components to make sure none of them are Repair:
touching the frame and/or body.
Correct the mounting of the engine mounted
Including but not limited to the following: component.
Clamps
Mounting hardware Engine mounted components touching the 1H
Exhaust system frame or body?
Air intake piping
Cooling package support NO
Etc.
STEP 1H: Marine application.

Condition:
None
Is this engine in a marine application? Is the engine installed in a marine 5A

application?
YES
Is the engine installed in a marine 1I

application?
NO
STEP 1I: Do an engine RPM sweep.

Condition:
Engine running.
INSITE electronic service tool connected.
0 vehicle speed.
Perform a slow (at 100 RPM per second) RPM Is the vibration present stationary below 1050 2A
sweep and note where the vibration occurs. RPM?
Note the engine speed at which any usual YES
vibration or vibration related noise occurs
(mirrors, panels, doors, seat, etc.). Note any Is the vibration present stationary below 1050 1J
speed points or ranges with excessive vibration. RPM?
If a resonance is passed through quickly in NO
getting up to the operating speed range and
doesn't exist in the idle speed or peak operating
range, it represents no major problem.
STEP 1J: Do an engine RPM sweep.

Condition:
Engine running.
0 vehicle speed.
Perform a slow (at 100 RPM per second) RPM Is the vibration present stationary above 1050 1K
sweep and note where the vibration occurs. RPM?
Does the vibration increase progressively from YES
idle to maximum speed? If so, rotating or
reciprocating unbalance is the source. This can Is the vibration present stationary above 1050 4A
be caused by any rotating components or engine RPM?
mount isolation.
NO
STEP 1K: Check the vibration engine speed range.

Condition:
Engine running.
0 vehicle speed.
Perform a slow (at 100 RPM per second) RPM Is the vibration speed range greater than 300 3A
sweep and note where the vibration occurs. to 400 RPM?
This step is to identify if the vibration YES
progressively increases with engine speed or if it
starts and stops within a slow engine RPM band. Is the vibration speed range greater than 300 2A
If the vibration progressively increases with to 400 RPM?
engine speed and has a peak band greater than
300 RPM, this can indicate a rotating component NO
that is out of balance.
If the vibration peak is in a tight band of
approximately 300 to 400 RPM or less, this
indicates that a structural component of the
engine or equipment is going into resonance
because its natural frequency is close to or the
same as the engine firing frequency.
STEP 2: Perform low RPM checks.

STEP 2A: Check that the accessory load is not excessive for the idle speed setting.
Condition:
Engine running at idle speed (less than 900 RPM).
Accessories off (air conditioning, fan, and PTO).
Engine at operating temperature (greater than 77C [170F]).
Disable all engine driven accessories and PTOs Are all steps verified to be correct? 2B
to make sure they are not applying excessive YES
load to the engine.
Are all steps verified to be correct? Repair
NO complete
Repair:
Repair as required.
STEP 2B: Check that the Fast Idle Warm-Up feature is activating (if applicable).
Condition:
Turn keyswitch ON.
Check the Fast Idle Warm-Up status. Is the Fast Idle Warm-Up feature inactive? 2C
Use INSITE electronic service tool Data YES
Monitor/Logger to check the status of the Fast
Idle Warm-Up feature. Is the Fast Idle Warm-Up feature inactive? Repair
NO complete
Repair:
Disable the Fast Idle Warm-Up feature and
retest for the customer's complaint.
STEP 2C: Check that the Alternator Failure Warning feature is activating (if applicable).
Condition:
Turn keyswitch ON.
Check to see if the Alternator Failure Warning Is the Alternator Failure Warning feature 2D
feature is active. inactive?
Use INSITE electronic service tool Data YES
Monitor/Logger to check that the Alternator
Failure Warning feature is active. Is the Alternator Failure Warning feature Repair
inactive? complete
NO
Repair:
Disable the Alternator Failure Warning
feature and retest for the customer's
complaint.
STEP 2D: Check for malfunctioning belt driven accessories.

Condition:
Drive belt(s) removed.
Remove the drive belt(s) and operate the engine Did the vibration go away with the drive belts Repair
under the conditions where the vibration occurs. removed? complete
Caution: For engines with a belt driven water YES
pump, do not allow the engine to overheat Repair:
during the test. Engine damage will occur.
Repair or replace the malfunctioning belt
driven component.
Did the vibration go away with the drive belts 2E

removed?
NO
STEP 2E: Check for equipment structural modifications.

Condition:
Visual inspection.
Check for any structural modifications to the Are any structural modifications to the Repair
equipment. equipment present? complete
Check for any structural modifications to the YES
equipment in the engine area that were Repair:
completed by the OEM after equipment
manufacture. Contact the equipment manufacturer. If
possible, remove or isolate the structural
Snow plows, frame rail extensions, front modification.
bumpers, etc.
Structural modifications can change the natural Are any structural modifications to the 2F
frequency of the frame and engine mounting equipment present?
system, which can result in a vibration complaint.
NO
STEP 2F: Check the engine mount transmissibility of the rear mount.
Condition:
Loosen the front engine mount capscrews.
Engine running at the documented RPM where the complaint occurs.
Check the engine mounts. Does the vibration go away during the test 2G
This step is checking to see if the engine mounts condition?
are amplifying the firing frequency of the engine, YES
since the vibration only occurs in a low engine
RPM range. Does the vibration go away during the test 2F-1
Loosen only the isolator capscrews for the condition?
front engine mount(s) and run the engine at NO
idle.
STEP 2F-1: Check the engine mount transmissibility for all mounts.
Condition:
Loosen ALL engine mount capscrews.
Engine running at the documented RPM where the complaint occurs.
Check the engine mounts. Does the vibration go away during the test 2G
condition?
This step is checking to see if the engine mounts
are amplifying the firing frequency of the engine, YES
since the vibration only occurs in a low engine
RPM range. Does the vibration go away during the test 2G
Loosen the isolator capscrews for ALL of the condition?
engine mounts and run the engine at idle. NO
STEP 2G: Inspect the engine mounts.

Condition:
Engine not running.
Remove engine mount isolators.
This step is a detailed inspection of the engine Are all steps verified to be correct? 2H
mount brackets, isolators, and mounting YES
hardware.
Check the engine mount isolators for
installation damage. Are all steps verified to be correct? Repair
Check the alignment of the engine mount NO complete
brackets.
Repair:
Check for premature wear on the engine
mount isolators and mounting hardware. Repair or replace the damaged components.
STEP 2H: Complaint since new.

Condition:
Record the odometer/hour meter.
Review the troubleshooting documentation information questions.
Check the equipment. Has the problem been occurring since the Contact a
equipment was new? Cummins
Check the equipment mileage/hours and
compare to the vibration customer interview form YES Technical
Support
completed in Step 1A. Repair: Specialist or
Low mileage is an indication that the complaint The engine mounts are not the right the OEM
has been present since the equipment was specification for the application, or a
new.
structural resonance exists.
Complaints on new equipment are typically
due to a manufacturing defect in the system or
an inadequate engine mounting design. Has the problem been occurring since the Contact a
equipment was new? Cummins
NO Technical
Support
Repair: Specialist or
Recheck for shorts, a rough running engine, the OEM
or malfunctioning engine mounts.
STEP 3: Perform higher RPM checks.

STEP 3A: Inspect the engine mounts.
Condition:
Engine not running.
Remove the engine mount isolators.
Inspect the engine mount brackets, isolators, and Are all steps verified to be correct? 3B
mounting hardware. YES
installation damage.
Check the alignment of the engine mount Are all steps verified to be correct? Repair
brackets. NO complete
Repair:
mount isolators and mounting hardware.
Repair or replace the malfunctioning
components. Refer to Procedure 016-010 in
Section 16 in the appropriate service manual.
STEP 3B: Check for malfunctioning belt driven accessories.

Condition:
Remove the drive belts.
Check the belt driven accessories. Did the vibration go away with the drive belts Repair
removed? complete
Remove the drive belts and operate the engine
under the conditions where the vibration occurs. YES
Caution: For engines with a belt driven water Repair:
pump, do not allow the engine to overheat Repair or replace the malfunctioning belt
during the test. Engine damage will occur. driven accessory.
Did the vibration go away with the drive belts 3C

removed?
NO
STEP 3C: Check for a damaged vibration damper.

Condition:
Engine not running.
Remove and visually inspect the vibration Is the vibration damper damaged or out of Repair
damper. specification? complete
Use Procedure 001-052 in the appropriate YES
service manual for vibration damper inspection Repair:
specifications.
Replace the vibration damper. Reference the
appropriate service manual.
Is the vibration damper damaged or out of 3D

specification?
NO
STEP 3D: Check the air compressor timing.

Condition:
Engine not running.
Air compressor removed.
Check the air compressor timing. Is the air compressor timing correct? 3E
Reference Procedure 012-014 in the appropriate YES
service manual.
Is the air compressor timing correct? Repair
NO complete
Repair:
Correct the air compressor timing and retest
for the vibration complaint. Reference
manual.
STEP 3E: Check the overhead adjustments.

Condition:
Engine not running.
Rocker lever cover removed.
Measure and adjust the overhead settings. Are the overhead adjustments correct? 3F
Check the overhead components for damage. YES
Reference Procedure 003-004 in the appropriate
service manual. Are the overhead adjustments correct? Repair
NO complete
Repair:
Repair or adjust the overhead. Reference
manual.
STEP 3F: Check for malfunctioning gear driven components.

Condition:
None.
Check the hydraulic pump and air compressor. Did the vibration go away? Repair
If possible, isolate any gear-driven accessories YES complete
and check for vibration. Repair:
Repair or replace the gear driven
components.
Did the vibration go away? 3G

NO
STEP 3G: Check for a damaged PTO.

Condition:
Disconnect the PTO.
Check the PTO for damage and correct Did the vibration go away? Repair
installation. YES complete
Refer to the OEM service manual. Repair:
Repair the PTO. Refer to the OEM service
manual.
Did the vibration go away? 3H

NO
STEP 3H: Check for a malfunctioning engine internal balancer assembly (4 cylinder B-Series only).
Condition:
None.
Inspect the engine internal balancer assembly. Does the internal balancer meet 3I
Reference Procedure 001-004 in the appropriate specification?
service manual. YES
Note: This applies to 4 cylinder B-Series engines
only. Does the internal balancer meet Repair
specification? complete
NO
Repair:
Repair the internal balancer. Reference
manual.
STEP 3I: Check the clutch or torque converter for vibration.

Condition:
Engine running.
With engine running in the operating condition of Did engaging and disengaging the clutch Repair
the vibration, disengage and engage the clutch affect the vibration? complete
serval times. YES
If there is a significant vibration reduction, clutch Repair:
plate(s) balance is the source.
Repair or replace the clutch. Refer to the
OEM service manual.
Did engaging and disengaging the clutch 3J

affect the vibration?
NO
STEP 3J: Check for a loose or damaged flywheel or flex plate.

Condition:
Transmission removed.
Check the flywheel. Does the flywheel meet specifications? 3K

Check the flywheel bore and face run out. YES
Check the flywheel for damage.
Reference Procedure 016-005 in the appropriate Does the flywheel meet specifications? Repair
service manual. complete
NO
Repair:
Repair or replace the flywheel or flexplate.
Reference Procedure 016-005 in the
STEP 3K: Check the flywheel housing for correct alignment.

Condition:
Transmission removed.
Flywheel/flexplate removed.
Check the flywheel housing bore and face Does the flywheel housing meet 3L
alignment. specifications?
service manual.
Does the flywheel housing meet Repair
specifications? complete
NO
Repair:
Repair or replace the flywheel housing.
STEP 3L: Check to see if the crankshaft has been balanced.

Condition:
Engine not running.
Lubricating oil pan removed.
Remove the lubricating oil pan. Is the crankshaft balanced? 3M

service manual.
Check the crankshaft to see if it has been Is the crankshaft balanced? Repair
balanced. Reference Procedure 001-016 in the NO complete
Repair:
Note: This step only applies if the complaint has
been present since the engine was new or after Replace the crankshaft. Contact a Cummins
a crankshaft replacement. Technical Support/Warranty specialist
before proceeding with the repair.
ISX engines built after 01-November-2008 have
a marking on the crankshaft to indicate if it
passed the balancing step in the manufacturing
process. Refer to Procedure 001-016 in Section
1 of the ISX service manual.
STEP 3M: Check for internal engine damage.

Condition:
None.
Contact a support specialist. Is there internal engine damage? Contact

YES Technical
At this point, a significant amount of labor has
been invested in the repair. Before Support
disassembling the engine, seek troubleshooting
assistance. Contact the appropriate Technical Is there internal engine damage? Contact
Support Channel for your facility. They will NO Technical
provide the necessary guidance and schedule Support
on-site support, if deemed necessary.
Camshaft journals and number 1 camshaft
bushing are severely damaged
Gear train backlash is excessive or the gear
teeth are damaged
Idler gear bushing damaged or worn
Main or connecting rod bearing damage
Gears out of balance or gear bushing damage
Connecting rod damage.
STEP 4: Operate the mobile equipment.

STEP 4A: Perform a diagnostic road test.
Condition:
Diagnostic road test.
Perform a diagnostic road test, observing where Is the vibration present during a diagnostic 4A-1
the vibration occurs. road test?
If the vibration can be duplicated on the road, YES
place the transmission in neutral and allow the
engine speed to drop to idle under the road Is the vibration present during a diagnostic No repair
speed conditions of the vibration. road test?
NO
STEP 4A-1: Perform a diagnostic road test.

Condition:
Diagnostic road test.
Perform a diagnostic road test, observing where Is the vibration present with the transmission 4C
the vibration occurs. in neutral, under the road speed conditions,
where the vibration was duplicated driving?
If the vibration can be duplicated on the road,
place the transmission in neutral and allow the YES
engine speed to drop to idle under the conditions
of the vibration. Is the vibration present with the transmission 4B
in neutral, under the road speed conditions,
where the vibration was duplicated driving?
NO
STEP 4B: Inspect the engine mounts.

Condition:
Engine not running.
Remove the engine mount isolators.
This step is a detailed inspection of the engine Are all steps verified to be correct? 4C
mount brackets, isolators, and mounting YES
hardware.
installation damage. Are all steps verified to be correct? Repair
Check the alignment of the engine mount NO complete
brackets.
Repair:
mount isolators and mounting hardware. Repair or replace damaged components.
If the equipment is new, check for the proper
mount specification.
Reference Procedure 016-010 in the appropriate
service manual.
STEP 4C: Check for drive train components that are worn, unbalanced, malfunctioning, or are not
correct.
Condition:
None.
Compare the drive train components to the Are all steps verified to be correct? Contact
engine and equipment specifications. YES Cummins
Isolate the drive train components and check for Technical
Support and
vibrations. Refer to the OEM service manual.
the OEM
Are all steps verified to be correct? Contact

NO Cummins
Technical
Support and
the OEM
STEP 5: Marine applications.

STEP 5A: Check the gear ratio and propeller configuration.
Condition:
Turn keyswitch OFF.
Check for an incorrect matching of the gear ratio Are the gear ratio and the propeller Repair
and propeller to the engine power. incorrectly matched to the engine power? complete
YES
Repair:
Contact a Cummins Distributor or a Marine
District Field Service Manager.
Are the gear ratio and the propeller 5B

incorrectly matched to the engine power?
NO
STEP 5B: Check for the correct engine mounting isolators and for proper installation requirements.
Condition:
None.
Check for the correct engine mount isolators and Are the engine mount isolators correct and 5C
for propeller installation requirements. installed correctly?
YES
Are the engine mount isolators correct and Repair

installed correctly? complete
NO
Repair:
Check for proper isolator installation
requirements. Replace and repair vibration
isolators as needed. Reference Procedure
016-026 in the appropriate service manual
and Engine Mounting/Drive Systems section
in the Marine Recreational Installation
Directions, Bulletin 3884649. If the isolators
are not manufactured by Cummins Inc., refer
to the OEM service manual.
STEP 5C: Check for damaged engine mounts and isolators.

Condition:
None.
Inspect the engine mount and isolators for Are the engine mounts and isolators in good 5D
damage. condition?
YES
Are the engine mounts and isolators in good Repair

condition? complete
NO
Repair:
Remove and replace the engine mount
isolators. Reference Procedure 016-026 in
the appropriate service manual and Engine
Mounting/Drive Systems section in the
Marine Recreational Installation Directions,
Bulletin 3884649. If the isolators are not
manufactured by Cummins Inc., refer to the
OEM service manual.
STEP 5D: Check the exhaust system.

Condition:
None.
Check for exhaust system deficiencies. Is the exhaust system deficient? Repair
YES complete
Repair:
Repair or replace as needed. See the
Exhaust System section in the Marine
Recreational Installation Directions, Bulletin
3884649, and the OEM service manual.
Is the exhaust system deficient? 5E

NO
STEP 5E: Check the engine driven accessories.

Condition:
Turn keyswitch ON.
Turn keyswitch OFF.
Check for engine driven accessory malfunctions. Is an engine driven accessory Repair
Isolate or disconnect the accessories and malfunctioning? complete
check for vibration. YES
Do not operate the engine if the sea water
pump is disconnected. Repair:
Determine the cause of the malfunctioning
accessories and correct the problem. See the
Exhaust System section in the Marine
Recreational Installation Directions, Bulletin
3884649, and the OEM service manual.
Is an engine driven accessory 5F

malfunctioning?
NO
STEP 5F: Check the shaft coupling to gear coupling alignment.

Condition:
Turn keyswitch OFF.
Check the shaft coupling to gear coupling Is the shaft coupling to gear coupling Repair
alignment. misaligned? complete
YES
Repair:
Repair or replace as needed. Reference
manual and the Engine Mounting/Drive
Systems section in the Marine Recreational
Installation Directions, Bulletin 3884649, and
the gear manufacturer's recommendations.
Is the shaft coupling to gear coupling 5G

misaligned?
NO
STEP 5G: Check the propeller shaft for proper installation.

Condition:
None.
Check the propeller shaft for proper installation. Is the propeller shaft installed correctly? 5H
YES
Is the propeller shaft installed correctly? Repair

NO complete
Repair:
Repair or replace as needed. Reference
manual and the Engine Mounting/Drive
Systems section in the Marine Recreational
Installation Directions, Bulletin 3884649, and
the gear manufacturer's recommendations.
STEP 5H: Check the propeller shaft for straightness.

Condition:
None.
Check the propeller shaft for straightness. Is the propeller shaft straightness within the 5I
OEM specification?
YES
Is the propeller shaft straightness within the Repair

OEM specification? complete
NO
Repair:
Repair or replace the propeller shaft as
needed. Refer to an Authorized OEM Service
Location.
STEP 5I: Isolate the engine.

Condition:
Disconnect the drive shaft.
Run the engine without the drive shaft attached Does the engine vibration persist? Repair
at the coupler. YES complete
Repair:
Check the engine vibration damper for
damage. Repair or replace as needed.
Does the engine vibration persist? 5J

NO
STEP 5J: Check for strut/cutlass bearing misalignment.

Condition:
Turn keyswitch OFF.
Check for strut/cutlass bearing misalignment or Is the strut/cutlass bearing misaligned or Repair
strut mounting is not secure. strut mounting not secure? complete
YES
Repair:
Check the strut for mounting stiffness. Repair
or replace as necessary. Refer to an
Authorized OEM Service Location.
Is the strut/cutlass bearing misaligned or 5K

strut mounting not secure?
NO
STEP 5K: Is the propeller out of balance or not fitted properly to the shaft?
Condition:
None.
Check for propeller out-of-balance or propeller Is the propeller out of balance or not fitted Repair
not fitted properly to shaft. properly to the shaft? complete
YES
Repair:
Check the propeller for accuracy. Repair or
replace as needed. Refer to an Authorized
OEM Service Location.
Is the propeller out of balance or not fitted 5L

properly to the shaft?
NO
STEP 5L: Check the V-angle on the V-strut.

Condition:
None.
Check to see if the V-angle on the V-strut does Does the V-angle on the V-strut match the 5M
not match the angle of the blade on the propeller. angle of the blade on the prop?
YES
Repair or replace as needed. Refer to an Repair

Authorized OEM Service Location. complete
NO
Repair:
Does the V-angle on the V-strut match the
angle of the blade on the prop?
STEP 5M: Check the propeller tunnels.

Condition:
None.
Check if the propeller tunnels are properly Does the entry and exit of the propeller tunnel 5N
matched with the propellers. match with the propeller blades?
YES
Does the entry and exit of the propeller tunnel Repair

match with the propeller blades? complete
NO
Repair:
Repair or replace as needed. Refer to an
STEP 5N: Check the engine to transmission torsional coupling.

Condition:
None.
Check the engine to transmission torsional Is the torsional coupling incorrect or worn? Repair
coupling. YES complete
Repair:
Replace the coupling. Refer to an Authorized
Is the torsional coupling incorrect or worn? 5O

NO
STEP 5O: Check the rudder.

Condition:
None.
Check the rudder for excessive play in the rudder Does the rudder have excessive play in the Repair
post. rudder post? complete
YES
Repair:
Repair or replace as needed. Refer to an
Does the rudder have excessive play in the 5P

rudder post?
NO
STEP 5P: Check the engine flywheel housing to cylinder block alignment.
Condition:
None.
Check the engine flywheel housing to cylinder Is the flywheel housing alignment incorrect? Repair
block alignment. YES complete
Repair:
Align the flywheel housing to cylinder block.
Is the flywheel housing alignment incorrect? Repair

NO complete
Repair:
The engine can possibly have internal
damage that has not been detected. Analyze
the oil and inspect the filters to locate an area
of probable damage. Reference Procedure
007-083 in the appropriate service manual.
The engine can possibly need to be rebuilt.
Reference Procedure 000-001 and the
engine rebuild specifications in the
appropriate service manual. If the engine is
not damaged, the problem can possibly be
the vessel design. Refer to an Authorized
Section 0 - Complete Engine - Group 00 Page 0-a
Section 0 - Complete Engine - Group 00

Section Contents
Page
Engine Installation ............................................................................................................................................0-7
Finishing Steps.................................................................................................................................................0-9
All Applications..............................................................................................................................................0-9
Install................................................................................................................................................................0-7
Automotive and Industrial...............................................................................................................................0-7
Power Generation..........................................................................................................................................0-8
Engine Removal ................................................................................................................................................0-2
Preparatory Steps.............................................................................................................................................0-2
All Applications..............................................................................................................................................0-2
Remove............................................................................................................................................................0-3
Automotive and Industrial...............................................................................................................................0-3
Power Generation..........................................................................................................................................0-5
Engine Storage - Long Term ...........................................................................................................................0-11
General Information.........................................................................................................................................0-11
Service Tools ....................................................................................................................................................0-1
Engine Removal and Installation.......................................................................................................................0-1
Page 0-b Section 0 - Complete Engine - Group 00

Signature, ISX, and QSX15 Eng [...] Service Tools
Section 0 - Complete Engine - Group 00 Page 0-1
Service Tools
Engine Removal and Installation
The following special tools are recommended to perform procedures in this section. The use of these tools
is shown in the appropriate procedure. These tools can be purchased from a local Cummins Authorized
Repair Location.
Tool No. Tool Description Tool Illustration

Engine Lifting Fixture
Used with a hoist to lift the engine.
3162871
Engine Removal Signature, ISX, and QSX15 Eng [...]
Page 0-2 Section 0 - Complete Engine - Group 00
Engine Removal (000-001)

Preparatory Steps
All Applications
Place a tag on all hoses, lines, linkages, and electrical
connections as they are removed to identify their locations
on the engine.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To
reduce the possibility of arcing, remove the negative
(-) battery cable first and attach the negative (-) battery
cable last.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50C
[120F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Disconnect the battery cables.
Drain the engine coolant. Refer to Procedure 008-018.
WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.
WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
Drain the lubricating oil. Refer to Procedure 007-037.
Disconnect the starting motor cable, the engine ground
straps, the cab- or chassis-to-engine hoses, the tubing, the
electrical wires, and the hydraulic lines.
Signature, ISX, and QSX15 Eng [...] Engine Removal
Remove
Automotive and Industrial
Disconnect the intake and the exhaust air pipes.
Disconnect all chassis-mounted, engine-driven
accessories.
Disconnect the drive units from the flywheel.
Disconnect the OEM wiring harness from the electronic

control module (ECM). Refer to Procedure 019-071 in the
Troubleshooting and Repair Manual CM870 Electronic
Control Systems Signature and ISX Engines, Bulletin
4021334.
NOTE: If the rear engine mounts are attached to the

transmission, it will possibly be necessary to remove the
engine and the transmission as an assembly.
Most cab-over configuration vehicles will have the
Cummins factory-installed rear engine lifting bracket still
installed.
WARNING
If a liquid refrigerant system (air conditioning) is used,
wear eye and face protection, and wrap a cloth around
the fittings before removing. Liquid refrigerant can
cause serious eye and skin injury.
WARNING
To protect the environment, liquid refrigerant systems
must be properly emptied and filled using equipment
that prevents the release of refrigerant gas into the
atmosphere. Federal law requires capturing and
recycling the refrigerant.
Remove all chassis components necessary to remove the

engine.
WARNING
The engine lifting equipment must be designed to lift
the engine and the transmission as an assembly
without causing personal injury.
WARNING
This component weighs 23 kg [50 lb] or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift this component.
Use a correctly rated hoist, and attach the engine lifting
fixture, Part Number 3162871, to the engine-mounted
lifting brackets to remove the engine.
If the transmission is not removed, place a support under
the transmission to prevent it from falling.
Remove the engine.
Cover all engine openings to prevent dirt and debris from

entering the engine.
Place the engine on suitable engine support stands.
Remove and use all remaining accessories and brackets

with the replacement engine.
Power Generation
accessories.

Troubleshooting and Repair Manual Electronic Control
System Signature, ISX and QSX15 Engines, Bulletin
3666259.

engine.
WARNING
WARNING
Remove the engine.


Signature, ISX, and QSX15 Eng [...] Engine Installation
Engine Installation (000-002)

Install
Install all accessories and brackets that were removed
from the previous engine.
If the rear engine mounts are attached to the transmission,

it will possibly be necessary to install the engine and the
transmission as an assembly.
WARNING
WARNING
Use a correctly rated hoist, and attach engine lifting
lifting brackets to install the engine.
CAUTION
Make sure all lines, hoses, and tubes are correctly
routed and fastened to prevent damage.
Align the engine in the chassis, and tighten the engine
mounting capscrews. Refer to the equipment
manufacturer's torque specifications.
Connect all engine and chassis-mounted accessories that
were removed.
Engine Installation Signature, ISX, and QSX15 Eng [...]
Connect the OEM wiring harness to the ECM. Refer to

Procedure 019-071 in the Troubleshooting and Repair
Manual CM870 Electronic Control Systems Signature and
ISX Engines, Bulletin 4021334.
Power Generation

WARNING
WARNING
CAUTION
were removed.
Connect the OEM wiring harness to the ECM. Refer

Manual Electronic Control System Signature, ISX and
Finishing Steps
All Applications
Fill and prime the engine with clean 15W-40 lubricating oil.
Refer to the equipment manufacturer's specifications for

radiator and system capacity.
Fill the cooling system. Refer to Procedure 008-018.
Make a final inspection to make sure all hoses, wires,

linkages, and components have been correctly installed
and tightened.
WARNING
Operate the engine at low idle for 2 to 3 minutes.
Stop the engine and wait 15 minutes for the oil to drain to
the oil pan.
Check the oil and the coolant levels again.
Fill the engine to the correct coolant level, if necessary.

Fill the engine to the correct oil level, if necessary. Refer
Operate the engine for 8 to 10 minutes to check for correct

engine operation, unusual noises, and coolant, fuel, or
lubricating oil leaks.
Repair all leaks and component problems. Refer to the
appropriate sections.
Signature, ISX, and QSX15 Eng [...] Engine Storage - Long Term
Engine Storage - Long Term (000-005)

General Information
CAUTION
After 24 months in storage, the engine cooling system must be drained and flushed with a suitable solvent
or a hot, lightweight mineral oil. Repeat flushing procedure a second time before being put back into service.
WARNING
Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50C [120
F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
WARNING
Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local
This procedure describes the proper method for the long term storage of an engine.
Operate the engine at high idle until the coolant temperature is 71C [160F].
Turn the engine OFF.
Drain the oil
Install the drain plugs.
Use Tectyl 910 E or equivalent, preservative oil. This will provide long term engine rust protection.1
Disconnect the fuel lines to the engine fuel filter and the injector return line.
Use Daubert Chemical Nox-Rust No. 518, or an equivalent preservative oil.2
Fill one container with diesel fuel, and the second container with preservative oil. Put both fuel lines in the container
of diesel fuel.3
Start the engine. Run for 25 minutes to distribute the preservative oil.4
After the engine is operating smoothly, transfer the fuel supply line to the container of preservative oil.
Operate the engine until the preservative oil flows out of the injector return line.
Turn the engine OFF.
Connect the fuel lines to the filtration system before the fuel enters the engine fuel system and the injector return
line.
Drain the preservative oil from the engine oil pan sump, the air compressor (if applicable) and the oil filters.
Drain the engine coolant and cover all cooling system openings with Plastic and tape.5
Remove the intake and exhaust manifolds.
Spray preservative oil into the intake and exhaust ports in the cylinder heads and in the manifolds.
Remove the rocker lever covers.
Spray the rocker levers, valve stems, valve springs, valve guides, crossheads, and push rods with preservative
oil. Coat the flywheel, flywheel housing and all other unpainted machined surfaces with preservative oil
Install the rocker lever covers. Install intake and exhaust manifolds.
Remove the exhaust aftertreatment components (if applicable) and cover all component openings and engine
openings with plastic and tape to prevent dirt and moisture from entering the engine
CAUTION
Put a warning tag on the engine.
Do not operate the engine
Do not bar the crankshaft
The engine has been treated with preservatives
The coolant has been removed
The date of treatment.
The engine can be stored in an area that is dry and has a uniform temperature.
Engine Storage - Long Term Signature, ISX, and QSX15 Eng [...]
NOTE: 1The preservative oil must meet Military Specification MIL-PRF-21260, Type P-10, Grade 2, SAE 30. Ex.
Tectyl 910 E or equivalent.
NOTE: 2The preservative oil must meet Military Specification MIL-L-644 Type P9. Ex Nox-Rust 501, Tectyl 981,
or equivalent.
NOTE: 3Do not follow this step for Natural Gas, Propane, or Diesel Engines with a High Pressure Common Rail fuel
system.
NOTE: 4If the engine cannot be started remove an oil rifle plug. Use a hand pump to pump the preservative oil through
the engine. Pump the oil then rotate the engine 90 degrees. Repeat for 3 revolutions of the engine.
NOTE: 5If the engine is not being removed from chassis and the engine has an extended life coolant with a rust
inhibitor, the coolant does not need to be drained.
To remove the engine from long term storage
Use clean diesel fuel. Refer to Bulletin Number 3379001, Fuels for Cummins Engines. Flush the fuel system until
all of the preservative oil is removed.
Remove the plug from the main oil rifle. Use a hot, lightweight, mineral oil.
Flush all of the preservative oil from the engine.
Bar the engine crankshaft three to four revolutions during the flushing procedure.
Fill the oil pan sump, oil filters, and fuel filters.
Fill the cooling system with coolant.
Install the exhaust aftertreatment components (if applicable).
Prime the lubricating system. Refer to the Engine Run-in (Engine Dynamometer) procedure in the corresponding
Base Troubleshooting and Repair Manual or Service Manual for the engine being serviced.
For engines with exhaust aftertreatment, force an active regeneration of the regeneration system.
Adjust the injector (if applicable) and valve clearance. Refer to the Overhead Set procedure in the corresponding
Base Troubleshooting and Repair Manual or Service Manual for the engine being serviced.
Tighten the intake manifold mounting capscrews.
Section DS - Engine Disassembly Group 00 Page DS-a
Section DS - Engine Disassembly Group 00

Section Contents
Page
Aftertreatment Adapter Pipe ........................................................................................................................DS-26
Remove........................................................................................................................................................DS-26
Aftertreatment Fuel Injector .........................................................................................................................DS-27
Remove........................................................................................................................................................DS-27
Aftertreatment Fuel Shutoff Manifold ..........................................................................................................DS-23
Remove........................................................................................................................................................DS-23
Aftertreatment Injector Lines .......................................................................................................................DS-19
Remove........................................................................................................................................................DS-19
Air Compressor .............................................................................................................................................DS-62
Remove........................................................................................................................................................DS-62
Air Compressor Coolant Lines .....................................................................................................................DS-62
Finishing Steps.............................................................................................................................................DS-62
Remove........................................................................................................................................................DS-62
Air Intake Connection ...................................................................................................................................DS-18
Remove........................................................................................................................................................DS-18
Automotive with CM870.............................................................................................................................DS-18
Automotive With CM871............................................................................................................................DS-18
Automotive, Industrial with CM570 and Power Generation without CM570................................................. DS-18
Alternator ......................................................................................................................................................DS-52
Remove........................................................................................................................................................DS-52
Driven by Cooling Fan Drive Belt...............................................................................................................DS-52
Alternator/Refrigerant Compressor Mounting Bracket ................................................................................DS-53
Remove........................................................................................................................................................DS-53
Bearings, Connecting Rod ...........................................................................................................................DS-74
Remove........................................................................................................................................................DS-74
Bearings, Main ..............................................................................................................................................DS-83
Remove........................................................................................................................................................DS-83
Bearings, Thrust ...........................................................................................................................................DS-82
Remove........................................................................................................................................................DS-82
Belt Tensioner, Automatic (Water Pump) ......................................................................................................DS-9
Remove.........................................................................................................................................................DS-9
Drives Alternator..........................................................................................................................................DS-9
Automotive Applications............................................................................................................................ DS-10
Industrial and Power Generation................................................................................................................DS-10
Belt Tensioner, Refrigerant Compressor, Automatic ..................................................................................DS-13
Remove........................................................................................................................................................DS-13
With Water Pump and Refrigerant Compressor Belt Routing......................................................................DS-13
Block Stiffener Plate .....................................................................................................................................DS-71
Remove........................................................................................................................................................DS-71
Coolant Filter ..................................................................................................................................................DS-7
Remove.........................................................................................................................................................DS-7
Coolant Thermostat ......................................................................................................................................DS-51
Remove........................................................................................................................................................DS-51
Coolant Thermostat Housing .......................................................................................................................DS-49
Remove........................................................................................................................................................DS-49
Single Thermostat.....................................................................................................................................DS-49
Dual Thermostat........................................................................................................................................DS-49
Cooling System ..............................................................................................................................................DS-1
Drain..............................................................................................................................................................DS-1
Crankcase Breather (External) .....................................................................................................................DS-14
Remove........................................................................................................................................................DS-14
Crankshaft .................................................................................................................................................... DS-82
Page DS-b Section DS - Engine Disassembly Group 00
Remove........................................................................................................................................................DS-82
Crankshaft Seal, Front ................................................................................................................................. DS-61
Remove........................................................................................................................................................DS-61
Crankshaft Seal, Rear ...................................................................................................................................DS-76
Measure.......................................................................................................................................................DS-77
Remove........................................................................................................................................................DS-76
Cylinder Head ...............................................................................................................................................DS-69
Remove........................................................................................................................................................DS-69
Cylinder Liner ...............................................................................................................................................DS-84
Remove........................................................................................................................................................DS-84
Drive Belt, Cooling Fan ..................................................................................................................................DS-9
Remove.........................................................................................................................................................DS-9
Drives Alternator..........................................................................................................................................DS-9
Drive Belt, Refrigerant Compressor .............................................................................................................DS-13
Remove........................................................................................................................................................DS-13
ECM Cooling Plate, Fuel Cooled ..................................................................................................................DS-19
Remove........................................................................................................................................................DS-19
EGR Connection Tubes ................................................................................................................................DS-43
Remove........................................................................................................................................................DS-43
EGR Cooler ...................................................................................................................................................DS-45
Remove........................................................................................................................................................DS-45
EGR Cooler Coolant Lines ............................................................................................................................DS-38
Remove........................................................................................................................................................DS-38
EGR Mixer .....................................................................................................................................................DS-17
Remove........................................................................................................................................................DS-17
EGR Valve .....................................................................................................................................................DS-40
Remove........................................................................................................................................................DS-40
EGR Valve Coolant Lines .............................................................................................................................DS-40
Remove........................................................................................................................................................DS-40
EGR Valve Mounting Bracket .......................................................................................................................DS-41
Remove........................................................................................................................................................DS-41
Engine Base Timing ..................................................................................................................................... DS-63
Remove........................................................................................................................................................DS-63
Engine Lifting Brackets ................................................................................................................................DS-48
Remove........................................................................................................................................................DS-48
Engine Removal ..............................................................................................................................................DS-2
Remove.........................................................................................................................................................DS-2
Automotive and Industrial............................................................................................................................DS-2
Power Generation........................................................................................................................................DS-5
Engine Support Bracket, Front ....................................................................................................................DS-70
Remove........................................................................................................................................................DS-70
Exhaust Gas Pressure Sensor Adapter ....................................................................................................... DS-42
Remove........................................................................................................................................................DS-42
All Applications..........................................................................................................................................DS-42
Exhaust Gas Pressure Sensor Tube ............................................................................................................DS-42
Remove........................................................................................................................................................DS-42
Exhaust Manifold, Dry ..................................................................................................................................DS-43
Remove........................................................................................................................................................DS-43
Fan Hub, Belt Driven ....................................................................................................................................DS-11
Remove........................................................................................................................................................DS-11
Industrial CM570 and Power Generation without CM570............................................................................DS-12
Fan Support ..................................................................................................................................................DS-12
Remove........................................................................................................................................................DS-12
Flywheel ........................................................................................................................................................DS-76
Remove........................................................................................................................................................DS-76
Flywheel Housing .........................................................................................................................................DS-78
Remove........................................................................................................................................................DS-78
Flywheel Housing, REPTO ...........................................................................................................................DS-79
Remove........................................................................................................................................................DS-79
Section DS - Engine Disassembly Group 00 Page DS-c
Fuel Filter (Spin-On Type) ..............................................................................................................................DS-8

Remove.........................................................................................................................................................DS-8
Gear Cover, Lower .......................................................................................................................................DS-62
Remove........................................................................................................................................................DS-62
Gear Cover, Upper ........................................................................................................................................DS-60
Remove........................................................................................................................................................DS-60
Automotive Applications............................................................................................................................DS-60
Gear Housing, Front .....................................................................................................................................DS-81
Remove........................................................................................................................................................DS-81
Heat Shield ...................................................................................................................................................DS-37
Remove........................................................................................................................................................DS-37
Idler Gear, Lower Scissor .............................................................................................................................DS-70
General Information......................................................................................................................................DS-70
Idler Pulley, Refrigerant Compressor ..........................................................................................................DS-13
Remove........................................................................................................................................................DS-13
Injector ..........................................................................................................................................................DS-57
Remove........................................................................................................................................................DS-57
Integrated Fuel System Module (IFSM) ........................................................................................................DS-24
Remove........................................................................................................................................................DS-24
Lubricating Oil Cooler ..................................................................................................................................DS-47
Remove........................................................................................................................................................DS-47
All Applications..........................................................................................................................................DS-47
Lubricating Oil Dipstick Tube ......................................................................................................................DS-17
Remove........................................................................................................................................................DS-17
Lubricating Oil Fill Tube ...............................................................................................................................DS-15
Remove........................................................................................................................................................DS-15
Lubricating Oil Filter (Spin-On) ......................................................................................................................DS-7
Remove.........................................................................................................................................................DS-7
Lubricating Oil Pan .......................................................................................................................................DS-70
Remove........................................................................................................................................................DS-70
Lubricating Oil Pump ....................................................................................................................................DS-82
Remove........................................................................................................................................................DS-82
Lubricating Oil Suction Tube (Block-Mounted) ...........................................................................................DS-71
Remove........................................................................................................................................................DS-71
Lubricating Oil System ...................................................................................................................................DS-2
Drain..............................................................................................................................................................DS-2
Overhead Camshaft, Injector .......................................................................................................................DS-68
Remove........................................................................................................................................................DS-68
Overhead Camshaft, Valve ...........................................................................................................................DS-67
Remove........................................................................................................................................................DS-67
Piston and Connecting Rod Assembly ........................................................................................................DS-72
Remove........................................................................................................................................................DS-72
Piston Cooling Nozzle ..................................................................................................................................DS-71
Remove........................................................................................................................................................DS-71
Piston Rings .................................................................................................................................................DS-75
Remove........................................................................................................................................................DS-75
Articulated Piston......................................................................................................................................DS-75
Single-Piece Piston....................................................................................................................................DS-75
Refrigerant Compressor ...............................................................................................................................DS-13
Remove........................................................................................................................................................DS-13
Sanden......................................................................................................................................................DS-13
Climate Control Incorporated.....................................................................................................................DS-14
Refrigerant Compressor Mounting Bracket .................................................................................................DS-53
Remove........................................................................................................................................................DS-53
Sanden......................................................................................................................................................DS-53
Page DS-d Section DS - Engine Disassembly Group 00
Climate Control Incorporated.....................................................................................................................DS-54

Automotive, Industrial with CM570 and Power Generation without CM570.................................................DS-54
Rocker Lever Assembly ...............................................................................................................................DS-56
Remove........................................................................................................................................................DS-56
Rocker Lever Cover ........................................................................................................................................DS-8
Remove.........................................................................................................................................................DS-8
Starting Motor .................................................................................................................................................DS-9
Remove.........................................................................................................................................................DS-9
All Except 50MT With Aluminum Flywheel Housing.....................................................................................DS-9
50MT With Aluminum Flywheel Housing......................................................................................................DS-9
Turbocharger ................................................................................................................................................DS-29
Clean...........................................................................................................................................................DS-30
Inspect for Reuse.........................................................................................................................................DS-31
Remove........................................................................................................................................................DS-29
Turbocharger Air Shutoff Valve Filter .........................................................................................................DS-24
Remove........................................................................................................................................................DS-24
Variable Geometry.....................................................................................................................................DS-24
Turbocharger Control Shutoff Valve Filter Head .........................................................................................DS-25
Remove........................................................................................................................................................DS-25
Turbocharger Coolant Hoses .......................................................................................................................DS-28
Remove........................................................................................................................................................DS-28
Turbocharger, Variable Geometry Actuator ................................................................................................DS-27
Remove........................................................................................................................................................DS-27
Turbocharger, Variable Geometry Actuator Air Supply Line ......................................................................DS-26
Remove........................................................................................................................................................DS-26
Turbocharger, Variable Geometry Control Valve Air Supply Line ..............................................................DS-25
Remove........................................................................................................................................................DS-25
Vibration Damper, Viscous ..........................................................................................................................DS-58
Remove........................................................................................................................................................DS-58
Automotive Applications............................................................................................................................DS-58
Industrial and Power Generation with Crank-Driven Fan or PTO.................................................................DS-58
Industrial and Power Generation without Crank-Driven Fan or PTO............................................................DS-59
Water Inlet Connection .................................................................................................................................DS-54
Remove........................................................................................................................................................DS-54
Water Pump ..................................................................................................................................................DS-54
Remove........................................................................................................................................................DS-54
Industrial CM570 and Power Generation without CM570............................................................................DS-55
Signature, ISX, and QSX15 Eng [...] Cooling System
Section DS - Engine Disassembly Group 00 Page DS-1
Cooling System (008-018)

Drain
Position the equipment on level ground.
WARNING
Remove the radiator cap after the engine has cooled down
ad adequately.
WARNING
Do not allow the cooling system to dry out.
If the coolant is to be reused, the holding container must
be free of oil and dirt. Before pouring coolant back into the
engine, it must be tested for SCA (Supplemental Coolant
Additive) concentration.
For automotive applications, use the Signature and ISX
Operation and Maintenance Manual, Bulletin 3666251.
Refer to Procedure 018-004 in Section V.
For industrial applications, use the Industrial and Power
Generation QSX15 Engines Operation and Maintenance
Manual, Bulletin 3666423. Refer to Procedure 018-004 in
Section V.
Open the radiator draincocks.
Remove the lower radiator hose(s).
Do not remove the coolant filter.
Page DS-2 Section DS - Engine Disassembly Group 00
Lubricating Oil System (007-037)

Drain
WARNING
WARNING
Operate the engine until the water temperature reaches
60C [140F].
Shut off the engine.
Remove the oil drain plug.
Drain the oil immediately to make sure all the oil and
suspended contaminants are removed from the engine.
If lubricating oil element failure occurs resulting in
contamination of the lubricating oil, the following is
recommended:
Inspect the lubricating oil filter by cutting it open and
inspecting for debris. Refer to Procedure 007-083.
If debris is not found, drain the lubricating oil and
remove the lubricating oil pan. Clean and reinstall
the lubricating oil pan. Refer to Procedure 007-025.
Remove the valve cover and clean the contaminated
lubricating oil from the cylinder head cavities. This
can be done using a siphoning device. Refer to
Procedure 003-011.
If debris is found, refer to the Cummins Warranty
Administration Manual, Bulletin 4021290.
Engine Removal (000-001)

Remove
accessories.

Troubleshooting and Repair Manual CM870 Electronic
Control Systems Signature and ISX Engines, Bulletin
4021334.
NOTE: If the rear engine mounts are attached to the

transmission, it will possibly be necessary to remove the
engine and the transmission as an assembly.
Most cab-over configuration vehicles will have the
Cummins factory-installed rear engine lifting bracket still
installed.
WARNING
If a liquid refrigerant system (air conditioning) is used,
wear eye and face protection, and wrap a cloth around
the fittings before removing. Liquid refrigerant can
cause serious eye and skin injury.
WARNING
To protect the environment, liquid refrigerant systems
must be properly emptied and filled using equipment
that prevents the release of refrigerant gas into the
atmosphere. Federal law requires capturing and
recycling the refrigerant.

engine.
WARNING
WARNING
If the transmission is not removed, place a support under
the transmission to prevent it from falling.
Remove the engine.


Power Generation
accessories.

Troubleshooting and Repair Manual Electronic Control
System Signature, ISX and QSX15 Engines, Bulletin
3666259.

engine.
WARNING
WARNING
Remove the engine.


Signature, ISX, and QSX15 Eng [...] Coolant Filter
Lubricating Oil Filter (Spin-On)

(007-013)
Remove
WARNING
WARNING
NOTE: If the lubricating oil filter head adapter comes off
during the removal of the lubricating oil filter, then reinstall
the oil filter head adapter. Use a small amount of Loctite
on the threads of the oil filter head adapter and tighten.
Refer to Procedure 007-018 (Lubricating Oil Filter Head
Adaptor) in Section 7.
Use oil filter wrench, Part Number 3375049, 3397929, or
3400157 to remove the oil filter.
Coolant Filter (008-006)

Remove
WARNING
Remove the cooling system pressure cap.
WARNING
Turn the coolant on/off valve to the OFF position.
Do not use force to open or close the on/off valve. If the
valve does not turn freely, refer to Procedure 008-082.
Remove and discard the coolant filter. Clean the gasket
surface on the filter head.
Rocker Lever Cover Signature, ISX, and QSX15 Eng [...]
Fuel Filter (Spin-On Type) (006-015)

Remove
With Pressurized Fuel Filtering
WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot
lights, arcing equipment, and switches out of the work
area and areas sharing ventilation to reduce the
possibility of severe personal injury or death when
working on the fuel system.
Clean the area around the fuel filter head and filter.
Remove the fuel filter with filter wrench, Part Number
3400157.
With Vacuum Fuel Filtering
WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot
lights, arcing equipment, and switches out of the work
area and areas sharing ventilation to reduce the
possibility of severe personal injury or death when
working on the fuel system.
Disconnect the wiring harness from the water-in-fuel
sensor, if equipped.
3400158.
Rocker Lever Cover (003-011)

Remove
NOTE: Engines built before September 7, 2006, and have
a the separate cover and separate gasket.
Remove the eight capscrews and isolator assemblies from
the rocker lever cover.
Remove the cover and gasket from the head separately.
The rocker lever cover gasket is reusable. Do not damage
the gasket when removing or cleaning.
NOTE: Engines built after September 7, 2006, or engines

that have the cover gasket embedded in the rocker lever
cover.
Completely loosen the eight capscrews and isolator
assemblies.
Remove the rocker lever cover, the cover gasket and the
isolators all together as an assembly.
The cover gasket is reusable. Do not damage the cover
gasket when removing the cover or when setting the
assembly aside during repair.
Signature, ISX, and QSX15 Eng [...] Belt Tensioner, Automatic (Water Pump)
Starting Motor (013-020)

Remove
All Except 50MT With Aluminum Flywheel Housing
Remove the three capscrews, starting motor, and starting
motor spacer (if used).
50MT With Aluminum Flywheel Housing

Remove the three mounting capscrews, starting motor,
and starting motor spacer (if used), as well as the
necessary starting motor brackets.
Drive Belt, Cooling Fan (008-002)

Remove
Drives Alternator
CAUTION
The belt tensioner is spring loaded and must be
pivoted away from the drive belt. Pivoting in the
wrong direction can result in damage to the belt
tensioner or cause personal injury.
Pivot the automatic tensioner down to relieve tension on
the belt.
Remove the belt.
Belt Tensioner, Automatic (Water

Pump) (008-080)
Remove
Drives Alternator
Remove the mounting capscrew and the belt tensioner
from the bracket.
Belt Tensioner, Automatic (Water Pump) Signature, ISX, and QSX15 Eng [...]
Automotive Applications
NOTE: Different engine configurations utilize different belt
tensioner bracket and belt tensioner arrangements.
For the low-mount belt tensioner:
Remove the belt tensioner mounting capscrew and belt
tensioner from the bracket.
Remove the belt tensioner bracket from the water pump.
For the mid-mount belt tensioner:

Remove the belt tensioner mounting capscrew and the
belt tensioner from the bracket.
The mid-mount aluminum belt tensioner/idler bracket is
part of the water pump removal and installation because
of common capscrew usage. Refer to Procedure 008-062.
Industrial and Power Generation

For the low-mount (small version) belt tensioner:
Remove the belt tensioner bracket from the front engine

support.
Signature, ISX, and QSX15 Eng [...] Fan Hub, Belt Driven
For the low-mount (large version) belt tensioner:

Remove the belt tensioner bracket from the front engine

support.
Fan Hub, Belt Driven (008-036)

Remove
WARNING
Remove the mounting capscrews and the fan hub
assembly.
WARNING
This assembly weighs 23 kg [50 lb] or more. To reduce
the possibility of personal injury, use a hoist or get
assistance to lift this assembly.
Remove alternator belt tensioner and bracket.
Remove the capscrews and the fan hub assembly.
Fan Support Signature, ISX, and QSX15 Eng [...]
Industrial CM570 and Power Generation without

CM570
Remove the fan hub mounting capscrews.
Remove the fan hub from the fan support.
Fan Support (008-088)

Remove
Remove the belt tensioner support bracket from the fan
support.
Remove two capscrews and install two guide studs.

Remove the remaining six capscrews.
Remove the fan support and guide studs.

Signature, ISX, and QSX15 Eng [...] Refrigerant Compressor
Drive Belt, Refrigerant Compressor

(009-052)
Remove
With Water Pump and Refrigerant Compressor Belt
Routing
CAUTION
Pivot the automatic tensioner counterclockwise to
relieve tension on the belt.
Remove the belt.
Idler Pulley, Refrigerant Compressor

(009-054)
Remove
Routing
Remove the pulley mounting capscrew.
Remove the refrigerant compressor idler pulley.
Belt Tensioner, Refrigerant

Compressor, Automatic (009-053)
Remove
Routing
Remove the mounting capscrew and the refrigerant
compressor belt tensioner from the bracket.
Refrigerant Compressor (009-051)

Remove
Sanden
Remove the four refrigerant compressor mounting
capscrews.
Remove the refrigerant compressor.
Crankcase Breather (External) Signature, ISX, and QSX15 Eng [...]
Climate Control Incorporated

Remove the four refrigerant compressor mounting
capscrews.
Remove the refrigerant compressor and bracket
assembly.
Crankcase Breather (External)

(003-001)
Remove
Remove the breather tube and rubber grommet from
engine.
Remove the four p-clips securing the hose to the front

cover and block.
Disassemble the breather tube.

Signature, ISX, and QSX15 Eng [...] Lubricating Oil Fill Tube

Disconnect the wiring connector from the breather
pressure sensor.
Loosen the two hose clamps on the inlet hose.
Disconnect hose from breather. Loosen outlet hose
clamp.
Disconnect the outlet hose.
Disconnect the breather oil drain line.
Remove the drain line inline with the connection nipple,
do not bend.
Remove the four mounting capscrews from the crankcase
breather element housing to the breather housing bracket
and remove the housing assembly.
Lubricating Oil Fill Tube (007-065)

Remove
CAUTION
Removal of the oil fill tube without loosening the tube
brace capscrew is likely to cause fill tube thread
breakage.
Loosen the tube brace capscrew (1).
Remove the tube brace capscrew from the gear cover (2).
Remove the oil fill tube (1) and the tube brace (2) from the
oil fill tube connection (3).
A smooth, rounded end bar can be used for leverage to

rotate the oil fill tube connection.
Rotate the oil fill tube connection counterclockwise to
remove.
Lubricating Oil Fill Tube Signature, ISX, and QSX15 Eng [...]
Remove the ring seals from the oil fill connection, the oil
fill tube, and the oil fill tube cap.
Discard the ring seals.
Ring seals:
1. Oil fill connection ring seal
2. Oil fill tube ring seal
3. Oil fill cap ring seal.
CAUTION
Removal of the oil fill tube without loosening the tube
brace capscrew is likely to cause fill tube thread
breakage
Remove the tube brace capscrews from the gear cover.
Remove the oil fill tube from the oil fill tube connection.
Rotate the oil fill tube connection counterclockwise to

remove. A smooth, rounded end, bar can be used for
leverage to rotate the oil fill tube connection.
Signature, ISX, and QSX15 Eng [...] EGR Mixer
Remove the ring seals from the oil fill connection, the oil
fill tube, and the oil fill tube cap.
Discard the ring seals.
Ring seals:
1. Oil fill connection ring seal
2. Oil fill tube o-rings
3. Oil fill cap ring seal.
Lubricating Oil Dipstick Tube

(007-011)
Remove
Remove the dipstick tube clamp capscrew, nut, and
clamp.
Remove the dipstick and dipstick tube.

Remove the dipstick tube clamp capscrew, nut, and
clamp.
Remove the dipstick and dipstick tube.
EGR Mixer (011-021)

Remove
Do not remove the EGR inlet pipe into the EGR mixer.
This is a precision interface and performance will be
affected if disturbed. There is no service procedure for this
and none is required.
Remove the capscrews at the four-bolt flange between the
EGR mixer and the air intake horn.
Air Intake Connection Signature, ISX, and QSX15 Eng [...]
Air Intake Connection (010-080)

Remove
Remove the four capscrews holding the air intake
connection to the cylinder head.
Remove and discard the gasket.

Remove the four capscrews that hold the air intake
connection to the cylinder head.
Cover all open points on the air intake connection and

cylinder head with caps and heavy tape from the Air
Handling Clean Care Kit or heavy tape.

Remove the four mounting capscrews, air inlet
connection, and gasket.
Signature, ISX, and QSX15 Eng [...] Aftertreatment Injector Lines
ECM Cooling Plate, Fuel Cooled

(006-006)
Remove
Disconnect the ECM cooling plate fuel supply line (bottom)
from the integrated fuel system module and the ECM
cooling plate.
Disconnect the ECM cooling plate fuel return line (top)
from the fuel pump and the ECM cooling plate.
Remove the five ECM mounting capscrews and the ECM.

Remove the six cooling plate mounting capscrews and
washers.
Remove the cooling plate and gasket.
Remove five insulating washers and the one ground

washer from the cooling plate mounting holes.
Aftertreatment Injector Lines

(011-051)
Remove
Disconnect the aftertreatment injector coolant supply line
at the inlet to the aftertreatment injector.
at the EGR cooler.
Remove the aftertreatment injector coolant supply line.
Aftertreatment Injector Lines Signature, ISX, and QSX15 Eng [...]
Disconnect the aftertreatment injector coolant return line

at the aftertreatment injector.
at the oil cooler.
Remove the aftertreatment injector coolant return line.
WARNING
Depending on the circumstance, diesel fuel is
flammable. When inspecting or performing service or
repairs in the fuel system, to reduce the impossibility
of fire and resulting severe personal injury, death or
property damage, never smoke or allow sparks or
flames (such as pilot lights, electrical switches, or
welding equipment) in the work area.
3375249.
Disconnect the wiring harness from the shut off valve, fuel
drain valve, and pressure sensor.
Disconnect the aftertreatment injector fuel supply line

from the supply outlet of the fuel rifle.
Disconnect the aftertreatment injector fuel supply line at
the inlet to the fuel shutoff manifold.
Remove the aftertreatment injector fuel supply line.
For access lower the fuel shutoff manifold by removing the

two mounting capscrews.
Disconnect the fuel return line from the fuel shutoff

manifold and the fuel control module.

the outlet of the fuel shutoff manifold.
Disconnect the fuel lines from the union fitting, located just
above the EGR valve.
the inlet to the aftertreatment injector, use a 9/16 inch
wrench. In some applications, access to the
aftertreatment injector is difficult and requires removal of
the exhaust adapter pipe. Refer to Procedure 011-043 in
Section 11.

at the inlet to the aftertreatment injector.
at the coolant heater housing.
Remove the aftertreatment injector coolant supply line.

at the aftertreatment injector.
at the coolant return manifold.
Remove the aftertreatment injector coolant return line.
Disconnect the aftertreatment injector fuel supply line

from the supply outlet of the fuel rifle.
the inlet to the fuel shutoff manifold.
Remove the aftertreatment injector fuel supply line.
Disconnect the fuel return line from the fuel shutoff

manifold and the fuel return tee fitting, located in front of
the engine control module.
Remove the P-clips.

the outlet of the fuel shutoff manifold.
the inlet to the aftertreatment injector. In some
applications, access to the aftertreatment injector is
difficult and requires removal of the exhaust adapter pipe.
Signature, ISX, and QSX15 Eng [...] Aftertreatment Fuel Shutoff Manifold
Aftertreatment Fuel Shutoff Manifold

(011-052)
Remove
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Fuel Shutoff Manifold - Make sure the area around the fuel
shutoff manifold is clear of debris.
Use compressed air to clean the area and remove any
loose dirt particles.
Remove the two mounting capscrews.

Remove the fuel shutoff manifold.
Remove the aftertreatment fuel shutoff valve (1),

aftertreatment fuel drain valve (2), and aftertreatment
pressure sensor (3) with a 1-1/8 inch open end wrench.
WARNING
personal injury.
Fuel Shutoff Manifold - Make sure the area around the fuel
shutoff manifold is clear of debris.
Use compressed air to clean the area and remove any
loose dirt particles.
Turbocharger Air Shutoff Valve Filter Signature, ISX, and QSX15 Eng [...]

Remove the fuel shutoff manifold.
Remove the aftertreatment fuel shutoff valve (1),

aftertreatment fuel drain valve (2), and aftertreatment
pressure sensor (3) with a 1-1/8 inch open end wrench.
Integrated Fuel System Module (IFSM)

(005-073)
Remove
WARNING
This component or assembly weighs greater than 23
kg [50 lb]. To prevent serious personal injury, be sure
to have assistance or use appropriate lifting
equipment to lift this component or assembly.
Remove two mounting capscrews from the IFSM.
Install two guide studs.
Remove the remaining capscrews, IFSM, and gasket.
Discard the gasket, if damaged.
Turbocharger Air Shutoff Valve Filter

(010-114)
Remove
Variable Geometry
Use filter wrench and remove the air filter from the
turbocharger control shutoff valve.
Signature, ISX, and QSX15 Eng [...] Turbocharger Control Shutoff Valve Filter Head
Turbocharger, Variable Geometry

Control Valve Air Supply Line
(010-121)
Remove
CAUTION
The turbocharger control valve is very sensitive to
contamination. Failure to prevent contamination from
entering the turbocharger control valve air lines will
cause damage to the turbocharger control valve.
Make sure the keyswitch is in the OFF position.
Bleed the air from the control valve air supply line.
Disconnect the air line at the turbocharger control valve.
Mask the end of the air line and turbocharger control valve
to prevent contamination.
Remove the p-clips holding the air line to the engine.
Disconnect the air line from the turbocharger control
shutoff valve.
Remove the turbocharger control valve air supply line.

Mask the end of the air line and turbocharger control
shutoff valve to prevent contamination.
Turbocharger Control Shutoff Valve

Filter Head (010-115)
Remove
Variable Geometry
Remove the turbocharger control shutoff valve filter head.
Aftertreatment Adapter Pipe Signature, ISX, and QSX15 Eng [...]

Actuator Air Supply Line (010-120)
Remove
CAUTION
Make sure the keyswitch is in the OFF position.
Disconnect the air line at the turbocharger actuator.
Mask the end of the air line and turbocharger actuator to
prevent contamination.
Remove the p-clip at the thermostat housing.

Disconnect the air line from the turbocharger control
valve.
Mask the end of the air line and turbocharger control valve
to prevent contamination.
Remove the turbocharger control valve air line.
Aftertreatment Adapter Pipe (011-043)

Remove
Remove the V-band clamp between the exhaust adapter
pipe and the turbocharger.
Remove the V-band clamp between the exhaust adapter
pipe and the OEM exhaust down-pipe.
Remove the adapter pipe assembly from engine.
Remove the gasket from each end and discard. Do not use
a screwdriver or other sharp tool to remove the gaskets.
This will damage the gasket seating area.
Remove the aftertreatment injector from the adapter pipe.
Signature, ISX, and QSX15 Eng [...] Turbocharger, Variable Geometry Actuator
Aftertreatment Fuel Injector (011-042)

Remove
Remove the adaptor tube gasket.
Remove the capscrews holding the injector.

Remove the injector assembly.
Cut the EZ tie holding the injector harness to the heat
shield.
Discard the metal gasket.
Discard the fibrous insulator.
Remove the capscrew spacers.

Actuator (010-113)
Remove
Variable Geometry
CAUTION
The keyswitch must be in the OFF position to make
sure no air pressure is present at the actuator.
Remove the capscrew holding the actuator rod to the
turbocharger cross-shaft.
Remove the snap ring from the cross-shaft.
WARNING
Keep fingers and hands away from the actuator link to
reduce the possibility of personal injury as a result of
sudden movement when air is supplied.
Loosen the two capscrews holding the actuator to the
turbocharger bearing housing.
Use coupling, Part Number 3824843, to apply 414 kPa [60
psi] regulated air pressure to the actuator air inlet, to
reduce the spring load at the linkage.
Remove the two loosened capscrews and actuator.
Turbocharger Coolant Hoses Signature, ISX, and QSX15 Eng [...]
Turbocharger Coolant Hoses (010-041)

Remove
Use a second wrench to hold the coolant hose coupling
while loosening the line.
Remove the turbocharger coolant supply line from the
bottom of the turbocharger and the lubricating oil filter
head.

Remove the turbocharger coolant return line from the top
of the turbocharger and the thermostat housing.

Remove the turbocharger coolant supply hose from the
lubricating oil filter head (1).
Remove the smaller banjo bolt from the turbocharger
electric actuator coolant inlet port (2) and the large banjo
bolt from the turbocharger bearing housing coolant inlet
port (3).

Remove the turbocharger bearing housing coolant return
hose from the top of the turbocharger and the thermostat
housing (1).
Remove the turbocharger actuator coolant return hose
from the top of the turbocharger and the thermostat
housing (2).
Signature, ISX, and QSX15 Eng [...] Turbocharger
Turbocharger (010-033)
Remove
WARNING
Automotive, Industrial, and Power Generation with
CM570
Remove the oil supply, oil drain tube, and brace (if
equipped) from the turbocharger.
Remove the intake and exhaust pipes from the

turbocharger.
Remove the charge-air cooler piping from the discharge
elbow.
Remove the clamp, o-ring, and discharge elbow from the

turbocharger.
Discard the o-ring.
NOTE: In some applications, the turbocharger will not

clear the lubricating oil cooler assembly during removal
and installation. It will, perhaps, be necessary to remove
the exhaust manifold and turbocharger together, and then
separate the two components. If the two components
must be removed together for the removal and installation
of the exhaust manifold. Refer to Procedure 011-007 in
Section 11.
If the turbocharger mounting nuts do not loosen freely,
split the nuts to avoid breaking a mounting stud.
Remove the four turbocharger mounting nuts.
Remove the turbocharger and discard the gasket.
Turbocharger Signature, ISX, and QSX15 Eng [...]
Clean
Turbine Housing Cleaning for ISX Automotive with
CM570, QSX15 with CM570, and Power Generation
with CM570
The turbocharger turbine housing surface adjacent to
the turbine compressor wheels must be clean,
smooth, and free from deposits.
Inspect the components to detect signs of burning and
other conditions, in order to obtain as much
information as possible before washing.
NOTE: This procedure applies ONLY to Automotive with
CM570, QSX15 with CM570, and Power Generation with
CM570. Do NOT disassemble variable geometry
turbochargers (VGT).
CAUTION
non-corrosive metal cleaner.
Soak the turbocharger turbine housing in a non-corrosive,
low flash point metal cleaner to loosen deposits.
CAUTION
personal injury.
Scale-like deposits, if any, must be removed by using a
non-metallic bristle brush. After removing the deposits,
wash and dry the components.
Dry the components with compressed air.
CAUTION
personal injury.
NOTE: Do not bead blast aluminum and cast iron
components together.
NOTE: To prevent bead spray impinging directly on the
clamp plate and turbine flange threads, mask and plug off
all items.
NOTE: Prevent the bead spray impinging directly on the
wastegate valve spindle, as beads can penetrate the
spindle bore, and lead to spindle seizure.
It is permissible to bead blast the turbocharger turbine
housing if chemical and brush cleaning is not effective.
After removing the deposits, wash and dry the

components.
Inspect for Reuse

ISX Automotive with CM570, QSX15 with CM570 and
Power Generation with CM570
Clean the retaining nut mating surfaces of the
turbocharger and the exhaust manifold.
Clean the mating surfaces with Scotch-Brite 7448
abrasive pad.
The surface under the mounting nuts must be free of
dirt, rust, or any other debris, before applying anti-
seize compound, Part Number 3823097.
Inspect the wastegate actuator. Refer to Procedure

Inspect the turbocharger casings.
Replace the housing if through cracks are found in the
outer walls.
Cracking in the turbine housing inlet flange and the inlet

duct generally requires replacement of the turbine
housing. Acceptance and rejection guidelines are shown
in these illustrations. If an exhaust gasket is available,
always make certain that cracks do not exist within the
sealing area.
Check the turbine housing inlet flange flatness. It must be
within 0.1 mm [0.004 in] to be acceptable for reuse.
Flange Fasteners - Clearance Holes

Check the fastener hole diameter. It must not be more
than 1.5 mm [0.006 in] larger than the maximum thread
diameter of the fastener.
CAUTION
If external cracks are found on the turbine housing,
the turbine housing must be replaced.
CAUTION
Turbine blades can be easily damaged and care is
required for the turbine housing installation process.
Cracking of the internal wall at the entry to the turbine
wheel (tongue) is acceptable as a service condition, and
the turbine housing can be re-used.
Inspect the turbocharger compressor v-band outlet and

the discharge elbow v-band connection for dents or
fretting.
Replace the turbocharger or discharge elbow, if damaged,
to prevent compressed air leaks.
Use dial depth gauge, Part Number ST-537.

Push the rotor assembly away from the gauge.
Set the gauge to zero (0).
Push the rotor assembly toward the gauge and record the
reading.
Turbocharger Axial Clearance

mm in
0.025 MIN 0.001
0.127 MAX 0.005
If the turbocharger axial clearance is not within
specifications, the turbocharger must be replaced.
Use a dial indicator to check radial movement at the

compressor impeller nose.
Push the impeller away from the gauge and set the
indicator to zero. Push the impeller toward the gauge and
record the reading.
Turbocharger Radial Bearing Clearance

mm in
0.406 MIN 0.016
0.610 MAX 0.024
If the turbocharger radial clearance is not within
If the engine experiences a turbocharger malfunction or

any other occasion where oil or debris is put into the
charge-air system, the charge-air system must be
inspected and cleaned. Refer to Procedure 010-027 in
Section 10.

Inspect for cracks in the turbocharger and compressor
casings.
Replace the turbocharger if through cracks in the outer
walls are found.
Inspect for cracks on the turbine inlet and exhaust
mounting flanges. Replace the turbocharger if any cracks
are found.
Clean the retaining nut mating surfaces of the

turbocharger and the exhaust manifold.
abrasive pad.
The surface under the mounting nuts must be free of dirt,
rust, or any other debris before applying anti-seize
compound, Part Number 3823097.

fretting.
Inspect the compressor wheel for signs of rubbing against
the compressor cover. Replace the turbocharger if
rubbing evidence is seen.
Use light finger pressure to push the compressor wheel.
If the compressor wheel contacts the cover, replace the
turbocharger.
Section 10.
Check the axial movement of the turbocharger wheels and

shaft.

mm in
0.025 MIN 0.001
0.127 MAX 0.005
Check the radial movement of the turbocharger wheels

and shaft.
Use light finger pressure to push the compressor wheel
toward the side of the compressor housing.
Repeat the procedure for the turbine wheel and housing.
Replace the turbocharger if either wheel contacts the
housing.

Inspect the variable geometry actuator and mechanism for
proper operation. Refer to Procedure 010-134 in Section
10.
Inspect for cracks in the turbocharger and compressor

casings.
Replace the turbocharger if through cracks in the outer
walls are found.
Inspect for cracks on the turbine inlet and exhaust
mounting flanges. Replace the turbocharger if any cracks
are found.
NOTE: All openings on the turbocharger, including the

turbine inlet connection, must be plugged with caps from
the Air Handling and Vehicle Air Plumbing Clean Care
Kits, Part Numbers 4919403, and 4919425 respectively,
during flange cleaning.
Clean the turbocharger and exhaust manifold where the
retaining nut contacts the turbocharger and exhaust
manifold.
abrasive pad.
After abrasive cleaning, wipe debris from both surfaces
with a clean shop towel.
The surface under the mounting nuts must be free of dirt,
rust, or any other debris, before applying anti-seize
compound, Part Number 3823097.
Replace turbocharger if any leaks are found.

Check for evidence of coolant in the oil supply and oil drain
fittings.

fretting.
Inspect the compressor wheel for signs of rubbing against
the compressor cover. Replace the turbocharger if
rubbing evidence is seen.
Use light finger pressure to push the compressor wheel.
If the compressor wheel contacts the cover, replace the
turbocharger.
Section 10.
Signature, ISX, and QSX15 Eng [...] Heat Shield
Check the axial movement of the turbocharger wheels and

shaft.

mm in
0.051 MIN 0.002
0.152 MAX 0.006
Check the radial movement of the turbocharger wheels

and shaft.
Use light finger pressure to push the compressor wheel
toward the side of the compressor housing.
Repeat the procedure for the turbine wheel and housing.
Replace the turbocharger if either wheel contacts the
housing.
Heat Shield (011-032)

Remove
Remove the three mounting capscrews from the EGR
valve.
Remove the heat shield.

Remove the four EGR valve heat shield mounting
capscrews from the EGR valve.
Remove the heat shield.
EGR Cooler Coolant Lines Signature, ISX, and QSX15 Eng [...]
EGR Cooler Coolant Lines (011-031)

Remove
Disconnect the EGR cooler coolant vent line from the EGR
cooler coolant return line and the EGR cooler.
Remove the two mounting capscrews from the EGR cooler

coolant return line.
Disconnect the EGR cooler coolant return line from the
EGR cooler and the elbow connection on the thermostat
housing.
CAUTION
Be sure all the components are clean and free of
debris that can cause damage to o-ring seals.
Disconnect the EGR cooler coolant vent line from the
thermostat housing and the EGR cooler.
Remove the two EGR cooler coolant return tube mounting

capscrews.
Signature, ISX, and QSX15 Eng [...] EGR Cooler Coolant Lines
Remove the EGR cooler coolant return jumper tube from

the EGR cooler.
Remove the EGR cooler coolant supply tube mounting

capscrew.
Slide the EGR cooler coolant supply jumper tube all the
way rearward inside the EGR cooler coolant supply tube.
Remove the EGR cooler coolant supply tube retaining
clamp capscrew from the water pump housing.
Slide the EGR cooler coolant supply tube rearward until

the EGR cooler coolant supply tube is disengaged from
the water pump outlet.
Remove the EGR cooler coolant supply tube from the
engine.
Remove and discard all three o-rings.
EGR Valve Signature, ISX, and QSX15 Eng [...]
Remove the nuts from the EGR cooler coolant supply tube
mounting bracket.
EGR Valve Coolant Lines (011-030)

Remove
Disconnect the EGR valve coolant supply (bottom) and
return (top) lines.
EGR Valve (011-022)

Remove
Loosen the v-band clamp connecting the EGR valve to the
exhaust manifold.
Loosen the v-band clamp connecting the EGR valve to the
EGR cooler connection.
Remove the EGR valve and v-band clamps.

Remove and discard the gaskets.
Signature, ISX, and QSX15 Eng [...] EGR Valve Mounting Bracket

Disconnect the EGR valve electrical connector.
Make sure to support the EGR valve by hand before

removing the mounting capscrews. If the EGR valve is
not supported, it can fall off of the engine, causing
damage to the EGR valve and actuator.
Loosen and remove the four EGR valve mounting

capscrews.
Remove the EGR valve from the EGR valve support
bracket.
The EGR valve will need to be moved at an angle forward
and downward in order to disengage it from the EGR valve
support bracket.
Use protective caps from the Air Handling Clear Care Kit
to cover open points on the EGR valve and bracket.
EGR Valve Mounting Bracket (011-044)

Remove
Remove one of the EGR valve bracket rear support
mounting capscrews (2) from the EGR valve mounting
bracket and cylinder head.
Remove the remaining two EGR valve mounting bracket
capscrews (1).
Exhaust Gas Pressure Sensor Adapter Signature, ISX, and QSX15 Eng [...]
Use protective caps from the Air Handling Clean Care Kit
to cover open points.
Exhaust Gas Pressure Sensor Tube

(011-027)
Remove
Loosen the tube nuts at the exhaust manifold and at the
sensor adapter.
Remove the tube.
Exhaust Gas Pressure Sensor Adapter

(011-033)
Remove
All Applications
Remove the p-clamp mounting capscrew and remove the
adapter.
Signature, ISX, and QSX15 Eng [...] EGR Connection Tubes
Exhaust Manifold, Dry (011-007)

Remove
WARNING
Remove two mounting capscrews and install two guide
studs.
Remove the remaining mounting capscrews, the spacers,
the exhaust manifold assembly and the gaskets.
Discard the gaskets.
Cover open points on the exhaust manifold and cylinder
head using heavy tape.
EGR Connection Tubes (011-025)

Remove
WARNING
The EGR connection tubes can be hot. To reduce the
possibility of personal injury, allow the engine to cool
before removing.
Loosen all hose clamps on the EGR connection tubes and
remove the two p-clip mounting capscrews or nuts
(depending on the vintage of the engine) on the front EGR
connection tube.
If the M10 stud comes out upon removal of the nut, install
the M10 stud into the block until the stud bottoms out.
Remove the one capscrew and one nut or the two nuts
that attach the rear section of the connection tube to the
cylinder block.
If the M10 stud comes out upon removal of the nut, install
the M10 stud into the block until the stud bottoms out.
Remove the front EGR connection tube.
Remove the one capscrew and one nut that attach the rear
section of the connection tube to the cylinder block.
Remove the rear EGR connection tube from the EGR
cooler.
EGR Connection Tubes Signature, ISX, and QSX15 Eng [...]
WARNING
The EGR connection tubes can be hot. To reduce the
possibility of personal injury, allow the engine to cool
before removing.
Loosen the hose clamps on the front EGR connection tube
and remove the hose.
Remove the two retaining capscrews on the lower portion
of the tube at the EGR valve housing outlet.
Remove the front EGR connection tube and hose.
Discard the hose.
Use protective caps from the Air Handling Clean Care Kit,
Part Number 4919403 and Part Number 4919425, to cover
the open points on all components.
Remove the three EGR venturi mounting capscrews.

Remove the EGR venturi.
Cover the irregular openings on the venturi and air intake

connections with protective caps from the Air Handling
Clean Care Kit, Part Number 4919403 and Part Number
4919425.
Signature, ISX, and QSX15 Eng [...] EGR Cooler
Remove the two rear EGR connection capscrews from the

EGR cooler.
Loosen the hose clamp on the rear EGR connection tube.
Pull the EGR cooler outlet connection tube from the EGR
cooler.
Part Number 4919403 and Part Number 4919425, to cover
the open points on all components.
EGR Cooler (011-019)

Remove
Loosen the v-band clamp between the EGR cooler and the
EGR cooler connection.
Loosen the hose clamps at the rear EGR connection tube.

Remove and discard the EGR hose.
EGR Cooler Signature, ISX, and QSX15 Eng [...]
CAUTION
The straps on the EGR cooler are not serviceable.
Adjusting or removing the straps can damage the EGR
cooler.
Remove the four capscrews that attach the EGR cooler to
the block.
Remove the four nuts that attach the EGR cooler to the
lubricating oil cooler assembly.
Remove the EGR cooler assembly from the engine.
Remove the coolant supply and vent jumper tubes if they
remain in the block after the cooler is removed.

Loosen the v-band clamp between the EGR cooler and the
exhaust manifold. In order to prevent damage to the EGR
cooler bellows, place the v-band clamp over the exhaust
manifold flange.
Loosen the rear EGR connection tube retaining

capscrews at the EGR cooler gas outlet.
Part Number 4919403, to cover the open points on both
the EGR cooler and EGR plumbing.
Remove the four capscrews that attach the EGR cooler to

the block.
Remove the four nuts that attach the EGR cooler to the
lubricating oil cooler assembly.
Remove the EGR cooler bracket clamping plates from the
EGR cooler.
Remove the EGR cooler assembly from the engine.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Cooler
Use protective caps from the Air Handling Clean Care Kit
to cover the open ports on the EGR cooler and exhaust
manifold.
Lubricating Oil Cooler (007-003)

Remove
All Applications
Remove two oil cooler mounting capscrews and install the
guide pins.
Clean the area above the oil cooler to prevent debris entry
into the oil passages.
WARNING
Remove the remaining 18 capscrews, oil cooler, and
gasket. Discard the gasket.
Engine Lifting Brackets Signature, ISX, and QSX15 Eng [...]
CAUTION
Immediately upon removal of the lubricating oil cooler
assembly, a plug must be inserted into the housing
and cylinder block oil passage drillings. Failure to
insert the oil passage plug can result in a bearing
failure, crankshaft failure, or both.
The reusable plugs, Part Numbers 4918322, 4918324,
and 4918340, are included in protective plug kit, Part
Number 4918319. These plugs are necessary to prevent
debris from entering the lubrication system during the
repair.
Plug the oil cooler housing filtered oil passage with plug,
Part Number 4918323, the block filtered oil passage with
plug, Part Number 4918340, and the block oil pump
passage with plug, Part Number 4918322.
Firmly push the plugs into the oil passages to prevent all
debris from entering the lubrication system when cleaning
the gasket surface.
Engine Lifting Brackets (016-001)

Remove
NOTE: Newer models use three mounting capscrews.
Remove the four capscrews and the rear lifting bracket.
Remove the four capscrews and the front lifting bracket.

Signature, ISX, and QSX15 Eng [...] Coolant Thermostat Housing
Coolant Thermostat Housing (008-014)

Remove
Single Thermostat
Remove the four thermostat housing cover capscrews.
Remove the thermostat cover and gasket.
Discard the gasket.
Remove the thermostat from the thermostat housing

cover.
Remove the three thermostat housing capscrews.

Remove the thermostat housing and gasket.
Discard the gasket.
Dual Thermostat
Remove the upper radiator hose from the thermostat
housing cover.
Coolant Thermostat Housing Signature, ISX, and QSX15 Eng [...]
Disconnect vent line, if required.

Disconnect the coolant sensor connector.
Remove the four capscrews that attach the thermostat

housing cover to the thermostat housing.
Remove the thermostat housing cover and gasket from
the thermostat housing.
Discard the gasket.
Remove the thermostats from the thermostat housing

cover.
Remove the two capscrews that attach the thermostat

housing to the cylinder head.
Remove the thermostat housing and gasket from the
cylinder head.
Discard the gasket.
Signature, ISX, and QSX15 Eng [...] Coolant Thermostat
Coolant Thermostat (008-013)

Remove
Remove the upper radiator hose from the thermostat
housing cover.
Disconnect vent line.

Disconnect the coolant sensor connector.
Remove the four capscrews that attach the thermostat

housing cover to the thermostat housing.
Remove the thermostat housing cover and gasket from
the thermostat housing. Discard the gasket.
Remove the thermostats from the thermostat housing

cover.
Alternator Signature, ISX, and QSX15 Eng [...]
Alternator (013-001)
Remove
Driven by Cooling Fan Drive Belt
Remove the four alternator mounting capscrews.
Remove the alternator from the alternator spacers.

Loosen the alternator support link capscrews.
Remove the support link capscrew from the alternator.
Remove alternator to alternator support capscrews, nut,

washer, and alternator.
Signature, ISX, and QSX15 Eng [...] Refrigerant Compressor Mounting Bracket
Alternator/Refrigerant Compressor
Mounting Bracket (009-056)
Remove
Disconnect the wire harness jumper from the EGR valve
motor, EGR valve position sensor and the main engine
wire harness.
Remove the five mounting capscrews from the alternator/
refrigerant compressor mounting bracket.
Gently pry out the bracket from the gear housing.
The split washers will create a slight friction fit between
the bracket and the gear housing.
Remove the wire harness jumper from the alternator/

Remove the six mounting capscrews from the alternator/
Gently pry out the bracket from the gear housing.
The split washers will create a slight friction between the
bracket and the gear housing.
Refrigerant Compressor Mounting

Bracket (009-055)
Remove
Sanden
Remove the mounting capscrew from each refrigerant
compressor bracket.
Remove the refrigerant compressor brackets.
Water Pump Signature, ISX, and QSX15 Eng [...]

Remove the four mounting capscrews from the refrigerant
compressor bracket.
Remove the refrigerant compressor bracket from the
refrigerant compressor.

Remove the two bracket mounting capscrews and the
bracket.
Remove the support links from the bracket.
Water Inlet Connection (008-082)

Remove
Remove the coolant hoses.
Remove the four capscrews, water inlet connection,
gasket, and o-ring.
Water Pump (008-062)

Remove
Remove two water pump mounting capscrews and install
two guide studs.
Signature, ISX, and QSX15 Eng [...] Water Pump
Remove the remaining three capscrews, the water pump,

and the o-ring seal.
Discard the o-ring seal.

Remove two water pump capscrews and install guide
studs.
Remove remaining three capscrews, water pump, and
water inlet o-ring seal.
Discard the o-ring seal.

CM570
Remove the pulley (1), pilot adapter (2), and belt tensioner
bracket (3).
Remove the remaining water pump capscrews, and water

inlet o-rings.
Discard the o-ring seals.
Rocker Lever Assembly Signature, ISX, and QSX15 Eng [...]
Rocker Lever Assembly (003-009)

Remove
There are four rocker lever shafts:
Front - valve and brake rocker lever shaft
Rear - valve and brake rocker lever shaft
Front - injector rocker lever shaft
Rear - injector rocker lever shaft.
CAUTION
Some valves will not be loose. Do not tighten or
bottom adjusting screw against lever. Engine damage
can occur.
Loosen the valve and injector adjusting screw locknuts on
each rocker lever.
Turn the adjusting screws counterclockwise until the
rocker levers are loose.
CAUTION
Use care when handling shafts. Rocker levers can fall
off the shaft during removal and damage the levers.
Remove the valve and brake, rocker lever shaft
capscrews, and the rocker lever shaft assemblies.
Remove the injector, rocker lever shaft capscrews, and
the rocker lever shaft assemblies.
Remove the valve crossheads.
To prevent increased wear, mark each crosshead and
rocker lever shaft assembly as it is removed so it can be
installed back in its original location.
Remove the rocker levers and brake levers from the

shafts.
Remove the rocker lever spacers from the shaft.
Remove the locknuts and the adjusting screws from the
rocker levers.
To prevent increased wear, mark each adjusting screw as
it is removed so it can be installed back in its original
rocker lever.
Signature, ISX, and QSX15 Eng [...] Injector
Injector (006-026)
Remove
CAUTION
Do not bottom out adjusting screws. Engine damage
can occur if adjusting screws are bottomed out.
Remove only the valve and injector shaft for the injector
(s) being removed.
Loosen the injector rocker lever adjusting screws.
Remove the six capscrews and injector rocker lever shaft.
Do not let the rocker levers come off of the shaft during
removal.
Rotate the engine to the valve set mark for the injector
being removed. Refer to Procedure 003-004 in Section 3.
Loosen and back off the valve lash adjusting screws

counterclockwise to allow the intake and exhaust valve
crossheads to be removed.
Remove the intake crosshead.
Mark the crossheads to make certain they are installed in
the same position.
Position the exhaust valve crosshead toward the exhaust

side of the engine to allow the injector to be removed.
Vibration Damper, Viscous Signature, ISX, and QSX15 Eng [...]
Loosen the injector clamp capscrew.

Use a small magnet to remove the injector clamp
capscrew and washer.
Remove the injector clamp capscrew and washer.
CAUTION
Do not use a heel bar to pry the injector loose from
the cylinder head. Damage to the injector can occur.
Use injector puller, Part Number 3823579, to remove the
injectors.
If the injector spring does come loose from the spring
retainer, it can be reassembled by using a screwdriver to
compress the spring back under the retainer.
Vibration Damper, Viscous (001-052)

Remove
CAUTION
Do not use a hammer or a screwdriver to remove the
vibration damper(s). These tools can damage the
vibration damper(s).
Remove two of the vibration damper(s) and crankshaft
pulley retaining capscrews.
Install two guide studs into the holes.
Remove the remaining 10 capscrews.
Remove the pulley and vibration damper(s).
Industrial and Power Generation with Crank-Driven

Fan or PTO
Remove the crankshaft adapter (1) from the pulley (2).
Signature, ISX, and QSX15 Eng [...] Vibration Damper, Viscous
Remove two pulley capscrews.

CAUTION
vibration damper. These tools can damage the
vibration damper.
Remove the remaining four capscrews.
Remove the pulley (4), vibration damper (3), mounting
spacer (2) and second vibration damper (1).
Remove the guide studs from the crankshaft nose.
Industrial and Power Generation without Crank-Driven

Fan or PTO
Remove two of the pulley capscrews.
Gear Cover, Upper Signature, ISX, and QSX15 Eng [...]
CAUTION
vibration damper.
spacer (2), and second vibration damper (1).
Gear Cover, Upper (001-079)

Remove
WARNING
The component weighs 23 kg [50 lb] or more. To
reduce the possibility of injury, use a hoist or get
assistance to lift the component.
Remove 16 capscrews and the upper gear cover.
Discard the strip seal.

Some industrial applications use a stamped steel cover
with a clamping plate.
Remove two capscrews and install two guide pins.
Remove the 14 vibration isolator capscrew assemblies.
Signature, ISX, and QSX15 Eng [...] Crankshaft Seal, Front
WARNING
or get assistance to lift the component.
Remove the clamping plate and upper gear cover.
Crankshaft Seal, Front (001-023)

Remove
Remove the eight mounting nuts from the gear cover
studs.
Position the replacer plate (1) over the crankshaft end and
against the crankshaft seal. The large notch between the
teeth needs to bridge the raised gear cover surface.
Make certain that the alignment of the three welded nuts
on the crankshaft seal are positioned into the counterbore
slots of the replacer plate (1).
Install a capscrew (4) with a flat washer (5) in the upper
slot of the replacer plate to hold it in position
CAUTION
Tighten the capscrews by hand until a slight
resistance is felt. Do not overtighten the capscrews or
the seal nuts can break off causing damage to the seal
and leading to front cover damage.
Use a small allen wrench to thread the removal tool
capscrews (2) through the replacer plate and into the seal
nuts.
Tighten the socket head capscrews (2) clockwise into the
three seal removal nuts that are welded on the crankshaft
seal until a slight resistance is felt.
Remove the capscrew in the upper slot of the replacer
plate (1).
Air Compressor Signature, ISX, and QSX15 Eng [...]
Install the replacer screw (3) into the replacer plate (1).
Turn the screw (3) clockwise until the crankshaft seal is
removed from the crankshaft.
Gear Cover, Lower (001-080)

Remove
NOTE: If the gear cover contains an o-ring seal groove for
the crankshaft seal and the seal needs to be replaced, the
lower gear cover must also be replaced. The new
crankshaft seal has the o-ring incorporated into the seal.
Remove the 15 capscrews and the lower gear cover.
Air Compressor Coolant Lines

(012-004)
Remove
Remove the coolant lines from the air compressor.
Air Compressor (012-014)

Remove
Remove the air connections from the air compressor.
Remove or disconnect the air governor. Refer to the OEM
service manual.
Signature, ISX, and QSX15 Eng [...] Engine Base Timing
Remove the air compressor support bracket and

capscrews.
Remove the four mounting capscrews and the air
compressor.
Discard the gasket.
Engine Base Timing (001-088)

Remove
Valve Camshaft Gear
The injector camshaft scissor gear must be unloaded
during removal of the valve camshaft gear. To unload the
gear, two of the gear screws must be backed out far
enough to allow the teeth on the scissor gear to be aligned.
Unload the injector camshaft scissor gear.
Remove the valve camshaft gear mounting capscrew and
washer.
Early production engines were not equipped with puller

holes in the valve camshaft gear. A 3-jaw gear puller
must be used for gears that do not have puller holes. The
injector and valve gear puller, Part Number 3163069, can
be used for gears that have puller holes.
Install the gear puller, Part Number 3163069.
Install the valve camshaft gear mounting capscrew
completely.
Loosen the capscrew two turns.
Use the gear puller to remove the valve camshaft gear
from the camshaft nose.
Remove the puller.

Do not completely remove the camshaft gear mounting
capscrew when the 3-jaw puller is used. The capscrew
serves as a safety catch by preventing the gear from
shooting off of the camshaft nose.
Remove the valve camshaft gear mounting capscrew,
spacer, and valve camshaft gear.
Engine Base Timing Signature, ISX, and QSX15 Eng [...]
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
Some solvents are flammable and toxic. Read the
manufacturer's instructions before using.
Use a lint free cloth and solvent to clean the Loctite
residue from the nose of the camshaft.
Injector Camshaft Scissor Gear
CAUTION
Remove the rear injector camshaft cover plate before
removal of the injector camshaft gear or camshaft.
The force required to remove the camshaft gear
creates sufficient backwards movement of the
camshaft to crack the rear cover plate.
Remove the injector camshaft rear cover plate.
Remove the injector camshaft scissor gear mounting

Install gear puller, Part Number 3163069.
Install the injector camshaft scissor gear mounting
capscrew. Loosen the capscrew one turn.
Use the gear puller to force the injector camshaft scissor

gear off the camshaft taper.
Remove the gear puller.
Remove the capscrew.
Remove the injector camshaft scissor gear.
WARNING
WARNING
Injector Camshaft Non-Scissor Gear
CAUTION
Remove the injector camshaft gear mounting capscrew

and washer.
Install the injector camshaft gear mounting capscrew.
Loosen the capscrew one turn.
Use the gear puller to force the injector camshaft gear off
the camshaft taper.
Remove the injector camshaft gear.
WARNING
WARNING
Adjustable Idler Gear

The adjustable idler gear shaft can fall out when the
adjustable idler gear is removed.
Remove the retainer capscrews, retainer, gear, and
adjustable idler gear shaft.
Remove the mounting spacer.
Lower Idler Scissor Gear

The lower idler scissor gear must be unloaded during
removal. To unload the gear, two of the gear screws
must be backed out far enough to allow the teeth on the
scissor gear to be aligned.
Unload the lower idler scissor gear.
Remove the idler scissor gear capscrews.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft, Valve
Remove the retainer, gear, shaft, and thrust bearing.
Lower Idler Non-Scissor Gear

Remove the idler non-scissor gear capscrews and
retainer.
Remove the gear, shaft, and thrust bearing.
Overhead Camshaft, Valve (002-024)

Remove
Remove the retainer capscrews, retainer, seal, and o-ring.
Discard the seal and o-ring.
Overhead Camshaft, Injector Signature, ISX, and QSX15 Eng [...]
CAUTION
Use caution when removing the camshaft to avoid
damaging the camshaft bushings.
Remove the valve camshaft.
Overhead Camshaft, Injector (002-025)

Remove
Remove the injector camshaft cover plate capscrews.
Remove the injector cover plate and gasket.
Discard the gasket.
Remove the two capscrews and the injector camshaft

retainer plate and o-rings.
Discard the o-rings.
CAUTION
Use caution when removing the camshaft to avoid
Remove the injector camshaft.
Signature, ISX, and QSX15 Eng [...] Cylinder Head
Cylinder Head (002-004)

Remove
WARNING
Use a chip vacuum to remove the excess oil from the top
of the cylinder head.
Remove the cylinder head capscrews.
Use engine lifting fixture, Part Number 4919360 or
equivalent, to lift the cylinder head.
Remove the cylinder head. Remove and discard the
gasket.
Remove the fire rings from the cylinder liners, if equipped.
NOTE: This step is not applicable if the engine has flat-

top liners and a single-piece head gasket, or when
upgrading from grooved-top liners and a 13-piece gasket
to flat-top liners and a single-piece gasket.
Prior to removing the cylinder head gasket and sealing
rings (if installed), examine the gasket for carbon tracks
across the sealing ring.
The pressure of carbon indicates a combustion leak.
Remove the cylinder head gasket.

Make sure the cylinder liner recession or protrusion
(based on liner style) is within specification.
Lubricating Oil Pan Signature, ISX, and QSX15 Eng [...]
Engine Support Bracket, Front

(016-002)
Remove
WARNING
Remove the two capscrews that attach the support to the
equipment frame.
Use the hoist to lift the weight of the engine off the front
support.
Remove the six mounting capscrews and the front engine

support.
Remove the rubber engine mounts.
Idler Gear, Lower Scissor (001-076)

General Information
Before installation or removal of any gears, read Engine
Base Timing. Refer to Procedure 001-088 in Section 1.
Lubricating Oil Pan (007-025)

Remove
Remove the oil pan mounting capscrews, oil pan, and
gasket.
Discard the oil pan gasket.
Signature, ISX, and QSX15 Eng [...] Piston Cooling Nozzle
Lubricating Oil Suction Tube (Block-

Mounted) (007-035)
Remove
Remove the lubricating oil suction tube capscrews,
suction tube, and o-ring. Discard o-ring.
Block Stiffener Plate (001-089)

Remove
Remove the 10 capscrews and the block stiffener plate.
Piston Cooling Nozzle (001-046)

Remove
The crankshaft must be rotated to allow access to remove
all the nozzles.
Remove the piston cooling nozzle capscrews and nozzles.
Piston and Connecting Rod Assembly Signature, ISX, and QSX15 Eng [...]
Piston and Connecting Rod Assembly

(001-054)
Remove
WARNING
cleaning, following the manufacturer's
recommendations for use. Wear goggles and
protective clothing to reduce the possibility of
personal injury.
WARNING
CAUTION
Do not use emery cloth or sandpaper to remove
carbon from the cylinder liners. Aluminum oxide or
silicon particles from emery cloth or sandpaper can
cause serious engine damage. Do not use any
abrasives in the ring travel area. The cylinder liner can
be damaged.
Use a fine fibrous, abrasive pad such as Scotch-Brite
7448, Part Number 3823258, or equivalent, and solvent to
remove the carbon.
Install two connecting rod guide pins, Part Number

3376038.
Use a T-handle piston pusher to push the connecting rod
away from the crankshaft.
Push the connecting rod until the piston rings are outside
of the top of the cylinder liner.
Remove the upper connecting rod bearing.

Mark the cylinder number and the letter U (upper) on the
flat surface of the bearing tang.
Signature, ISX, and QSX15 Eng [...] Piston and Connecting Rod Assembly
Use both hands to remove the piston and connecting rod

assembly.
The piston and connecting rod assemblies must be
installed in the same cylinder they were removed from to
provide for proper fit of worn mating surfaces if parts are
reused.
Use a tag to mark the cylinder number from which each
piston and connecting rod assembly was removed.
CAUTION
To reduce the possibility of engine damage all pistons
within a given engine must be of the same design - all
are to be either the articulated design or the single-
piece design. Do not mix piston designs in the same
engine. Single-piece pistons must have drilled rods
and connecting rod bearings. Articulated pistons can
use either drilled or non-drilled rods and bearings.
Place the connecting rod and piston assemblies in a

container to protect them from damage.
A unique number (not cylinder number) is stamped on the

connecting rod and matching connecting rod cap. When
the connecting rods and connecting rod cap are installed
in the engine, the numbers on the connecting rod and cap
must match and be installed on the same side (the
exhaust side) of the engine.
Bearings, Connecting Rod Signature, ISX, and QSX15 Eng [...]
Bearings, Connecting Rod (001-005)

Remove
Rotate the crankshaft so that two of the connecting rods
are at bottom dead center.
Do not remove the capscrews at this time.

Loosen the connecting rod capscrews.
Hit the connecting rod capscrews with a rubber hammer
to loosen the rod caps from the dowels.
Remove the capscrews and the rod cap.

Remove the bearing shell from the rod cap and mark the
cylinder number and the letter "L on the flat surface of
the bearing tangs.
Install two guide pins, Part Number 3163097, in the

connecting rod.
Push the rod up far enough to allow the upper bearing
shell to be removed. Use a T-handle piston pusher.
Remove the bearing shell and mark the cylinder number
and the letter "U" on the flat surface of the bearing tangs.
Signature, ISX, and QSX15 Eng [...] Piston Rings
Piston Rings (001-047)

Remove
Articulated Piston
Remove the piston rings.
Place a tag on the rings, and record the cylinder number

of the piston on the tag for future reference, if required.
Single-Piece Piston
CAUTION
Do not over-expand the second piston ring on single-
piece pistons.
Use a universal ring expander to remove the second
piston ring on single-piece pistons.

Crankshaft Seal, Rear Signature, ISX, and QSX15 Eng [...]
Flywheel (016-005)
Remove
WARNING
Use two M6 x 1.5 guide studs to prevent the flywheel from
rotating. Remove two capscrews and install the guide
studs.
Use a hoist, two t-handles, and a lifting sling. Install the
tee-handles. Remove the remaining ten capscrews.
Remove the flywheel.
Use a soft faced mallet to tap the flywheel from the
crankshaft, if necessary. Damage to the clutch surface
can occur if a hard faced hammer is used.
Remove the pilot bearing spacer from the rear of the

crankshaft.
Use a mandrel and hammer to remove the pilot bearing
from the flywheel.
Crankshaft Seal, Rear (001-024)

Remove
The rear crankshaft seal requires the rear crankshaft seal
replacer kit, Part Number 3164780, for the seal removal
and installation.
1 Replacer plate
2 Pilot drill
3 Replacer screw
4 Self-tapping screw x 10
5 Stud x 3
6 Hex nut x 3.
Signature, ISX, and QSX15 Eng [...] Crankshaft Seal, Rear
Use three flywheel mounting capscrews to secure the

replacer plate (1) to the crankshaft.
Install a pilot drill (2) into one of the holes in the rear
crankshaft seal tool and drill a hole through the seal
casing.
Remove the pilot drill (2) and repeat the procedure for at
least two more evenly spaced holes of the rear crankshaft
seal tool. As many as six holes may be drilled to assist in
removing the rear crankshaft seal.
NOTE: Three stud screws (3) and three hex nuts (4) are
required for some engines with flywheel mounting
capscrews that are too short to mount the replacer plate
(1) to the crankshaft.
NOTE: Three guide pins, Part Number 3164765, are
required on REPTO applications to support the REPTO
crankshaft gear and the replacer plate.
Install at least three self-tapping screws (1) into the

replacer plate (2).
Remove the flywheel capscrews from the rear crankshaft
seal tool.
Install the replacer screw (3) into the center hole of the
replacer plate and turn clockwise to remove the seal.
Measure
Measure the protrusion of the outer rubber portion (A) of
the seal relative to the inner metal portion of the seal (B).
Set the dial indicator to zero on the inner metal portion of
the seal.
Measure and record the protrusion of the outer rubber
portion of the seal. Repeat the measurement in four
locations equally spaced around the crankshaft seal.
The protrusion measurement at each location must be
within +/- 1 mm [+/- 0.04 in]. The difference between any
of the four protrusion measurements must be within +/-
0.5 mm [0.02 in].
If either of these conditions are not met, the rear
crankshaft seal must be removed and a new seal
installed.
Flywheel Housing Signature, ISX, and QSX15 Eng [...]
Flywheel Housing (016-006)

Remove
Remove the two top exterior capscrews from the flywheel
housing.
WARNING
avoid personal injury, use a hoist or get assistance.
Use a hoist and lifting sling. Install the lifting sling around
both sides of the upper housing. Adjust the hoist until
there is tension in the lifting sling. Remove the remaining
capscrews.
Use a mallet to tap the flywheel housing off the two

locating dowels.
Remove two capscrews, cover plate, and gasket. Discard

the gasket.
Signature, ISX, and QSX15 Eng [...] Flywheel Housing, REPTO
CAUTION
Immediately upon removal of the flywheel housing
assembly, a plug must be inserted into the cylinder
block oil passage drillings. Failure to insert the oil
passage plug can result in a bearing failure,
crankshaft failure, or both.
The reusable plug, Part Number 4918321, is included in
Protective Plug Kit, Part Number 4918319. This plug is
necessary to prevent debris from entering the lubrication
system during the repair.
Plug the block oil passage with plug Part Number
4918321.
Firmly push plug into oil passage to prevent all debris from
entering the lubricating system when cleaning the gasket
surface.
Flywheel Housing, REPTO (016-007)

Remove
Remove the three capscrews from the rear of the oil pan.
WARNING
Remove the 10 10-mm capscrews from the hydraulic
housing.
Remove the hydraulic housing from the REPTO flywheel
housing.
Remove the spray nozzle from the oil supply line hole.
Remove the 12 capscrews (1) from the seal carrier.

Remove the seal carrier (2) from the REPTO flywheel
housing.
Remove oil seal (4) and discard. Refer Procedure 001-024
(Crankshaft Seal, Rear) in Section 1.
Remove the o-ring (3) from the groove on the REPTO
flywheel housing.
Flywheel Housing, REPTO Signature, ISX, and QSX15 Eng [...]
Remove the four plugs (1) and o-rings (2) from the REPTO
flywheel housing.
Remove the crankshaft gear.

Remove the idler gear shaft capscrew and washer.
Remove the three guide pins.
If the idler gear shaft can not be removed with the handle,
a slide hammer similar to Snap-On, Part Number CJ114,
can be used.
Position the replacer idler plate, Part Number 3164762, on
the idler gear shaft. Install and tighten the two idler gear
capscrews. Install the handle, Part Number 3163089.
Torque Value: 14 Nm [ 124 in-lb ]
Remove the idler shaft, idler gear, and bearing from the
REPTO flywheel housing.
Remove two capscrews from the REPTO flywheel

housing.
Install the two guide pins, Part Number 3164764.
Signature, ISX, and QSX15 Eng [...] Gear Housing, Front
Install the two eye bolts, Part Number 3164767, on the top
of the REPTO flywheel housing. Install the lifting slings to
the eye hooks. Adjust the hoist until there is tension in the
lifting sling.
Remove the remaining capscrews.
WARNING
Use a mallet to tap the REPTO flywheel housing off the
two locating dowels. Remove and discard the gasket.
CAUTION
Immediately upon removal of the flywheel housing
assembly, a plug must be inserted into the cylinder
block oil passage drillings. Failure to insert the oil
passage plug can result in a bearing failure,
crankshaft failure, or both.
Protective Plug Kit, Part Number 4918319. This plug is
Plug the block oil passage with plug Part Number
4918321.
Firmly push the plug into the oil passage to prevent all
debris from entering the lubricating system when cleaning
the gasket surface.
Gear Housing, Front (001-033)

Remove
WARNING
Remove two capscrews and install two guides.
Bearings, Thrust Signature, ISX, and QSX15 Eng [...]

Remove the housing and gasket.
Discard the gasket.
Remove the guide studs.
Lubricating Oil Pump (007-031)

Remove
CAUTION
Do not discard shims, if equipped. They must be
installed in the original location. Failure to do so can
result in engine damage.
Remove four capscrews, oil pump, and shims if equipped.
When installing a new oil pump, new shims will possibly
be needed to acquire acceptable lash.
Crankshaft (001-016)
Remove
WARNING
Use a lifting strap that will not damage the crankshaft.
Use a hoist and a sling that to remove the crankshaft.
Bearings, Thrust (001-007)

Remove
Remove the thrust bearings from the number four main
bearing cap.
Mark the thrust bearings as being lower, and front or rear
bearings.
Signature, ISX, and QSX15 Eng [...] Bearings, Main
CAUTION
To reduce the possibility of damage to the crankshaft,
use care when removing the upper thrust bearings.
Use a blunt tool to remove the upper thrust bearings.
Mark these bearings as being upper, and front or rear
bearings.
Bearings, Main (001-006)

Remove
CAUTION
Mark any unmarked bearing caps before removing
them from the cylinder block. Do not remove main
bearing capscrews until the main bearing cap is
pulled, or the cap could fall out, causing personal
injury and parts damage.
If the crankshaft is not going to be removed, replace the
main bearings one at a time.
Loosen the main bearing cap capscrews.
Use the main bearing cap puller, Part Number ST-1178,
to remove the cap. The tool must be centered on the cap.
Remove the main bearing capscrews and cap.
Mark the bearing shells with the journal number from

which they were removed.
Remove the lower main bearing shell from the cap.
Cylinder Liner Signature, ISX, and QSX15 Eng [...]
Rotate the crankshaft with the air compressor drive or a

barring device to remove the main bearing shell.
Mark each main bearing for location if they are to be
installed again in the engine.
Cylinder Liner (001-028)

Remove
The cylinder liners can be removed by using either:
Cylinder liner puller (universal), Part Number 3163745
and puller plate (S600), Part Number 3162462.
Cylinder liner puller (universal), Part Number 3376015.
CAUTION
The cylinder puller must be installed and used as
described to reduce the possibility of damage to the
cylinder block. The puller plate must be parallel to the
main bearing saddles and must not overlap the
cylinder liner outside diameter.
Insert the cylinder liner puller onto the top of the cylinder
block.
The cylinder liner puller must be centered on the top of

the cylinder block.
Turn the puller jackscrew clockwise to loosen the cylinder
liner from the cylinder block.
Use both hands to remove the cylinder liner.
Remove and discard the o-ring seals.
Signature, ISX, and QSX15 Eng [...] Cylinder Liner
Use Dykem, or equivalent, to place a mark on the intake

air side of the cylinder liner to show cylinder liner
orientation.
Use Dykem, or equivalent, to mark the cylinder number on

each cylinder liner.
Notes
Section AS - Engine Assembly - Group 00 Page AS-a
Section AS - Engine Assembly - Group 00

Section Contents
Page
Aftertreatment Adapter Pipe ......................................................................................................................AS-122
Install.........................................................................................................................................................AS-122
Aftertreatment Fuel Injector .......................................................................................................................AS-122
Install.........................................................................................................................................................AS-122
Aftertreatment Fuel Shutoff Manifold ........................................................................................................AS-126
Install.........................................................................................................................................................AS-126
Aftertreatment Injector Lines .....................................................................................................................AS-127
Install.........................................................................................................................................................AS-127
Air Compressor .............................................................................................................................................AS-57
Install...........................................................................................................................................................AS-57
Air Compressor Coolant Lines .....................................................................................................................AS-58
Finishing Steps.............................................................................................................................................AS-60
Install...........................................................................................................................................................AS-58
Air Intake Connection .................................................................................................................................AS-131
Install.........................................................................................................................................................AS-131
Automotive, Industrial with CM570 and Power Generation without CM570................................................AS-131
Automotive with CM870...........................................................................................................................AS-131
Automotive With CM871...........................................................................................................................AS-131
Alternator ......................................................................................................................................................AS-92
Install...........................................................................................................................................................AS-92
Driven by Cooling Fan Drive Belt...............................................................................................................AS-92
Automotive with CM870.............................................................................................................................AS-92
Alternator/Refrigerant Compressor Mounting Bracket ................................................................................AS-91
Install...........................................................................................................................................................AS-91
Bearings, Thrust .............................................................................................................................................AS-9
Install.............................................................................................................................................................AS-9
Bearings, Connecting Rod ........................................................................................................................... AS-36
Install...........................................................................................................................................................AS-36
Bearings, Main ................................................................................................................................................AS-4
Install.............................................................................................................................................................AS-4
Belt Tensioner, Automatic (Water Pump) ..................................................................................................AS-140
Install.........................................................................................................................................................AS-140
Drives Alternator......................................................................................................................................AS-140
Automotive Applications...........................................................................................................................AS-140
Industrial and Power Generation..............................................................................................................AS-141
Belt Tensioner, Refrigerant Compressor, Automatic ................................................................................AS-137
Install.........................................................................................................................................................AS-137
With Water Pump and Refrigerant Compressor Belt Routing....................................................................AS-137
Block Stiffener Plate .....................................................................................................................................AS-42
Install...........................................................................................................................................................AS-42
Coolant Filter ..............................................................................................................................................AS-147
Install.........................................................................................................................................................AS-147
Coolant Thermostat ......................................................................................................................................AS-92
Install...........................................................................................................................................................AS-92
Coolant Thermostat Housing ....................................................................................................................... AS-94
Install...........................................................................................................................................................AS-94
Single Thermostat......................................................................................................................................AS-94
Dual Thermostat........................................................................................................................................AS-95
Cooling System ...........................................................................................................................................AS-153
Fill..............................................................................................................................................................AS-153
Crankcase Breather (External) ...................................................................................................................AS-135
Install.........................................................................................................................................................AS-135
Crankshaft .....................................................................................................................................................AS-10
Page AS-b Section AS - Engine Assembly - Group 00
Install...........................................................................................................................................................AS-10
Crankshaft Seal, Front ..................................................................................................................................AS-61
Install...........................................................................................................................................................AS-61
Crankshaft Seal, Rear ...................................................................................................................................AS-31
Install...........................................................................................................................................................AS-31
Measure.......................................................................................................................................................AS-32
Cylinder Head ...............................................................................................................................................AS-44
Install...........................................................................................................................................................AS-44
Cylinder Liner .................................................................................................................................................AS-1
Install.............................................................................................................................................................AS-1
Measure.........................................................................................................................................................AS-2
Drive Belt, Cooling Fan ..............................................................................................................................AS-142
Install.........................................................................................................................................................AS-142
Drives Alternator......................................................................................................................................AS-142
Drive Belt, Refrigerant Compressor ...........................................................................................................AS-137
Install.........................................................................................................................................................AS-137
ECM Cooling Plate, Fuel Cooled ................................................................................................................AS-130
Install.........................................................................................................................................................AS-130
EGR Connection Tubes ..............................................................................................................................AS-101
Install.........................................................................................................................................................AS-101
EGR Cooler ...................................................................................................................................................AS-97
Install...........................................................................................................................................................AS-97
EGR Cooler Coolant Lines ..........................................................................................................................AS-109
Install.........................................................................................................................................................AS-109
EGR Mixer ...................................................................................................................................................AS-132
Install.........................................................................................................................................................AS-132
EGR Valve ...................................................................................................................................................AS-107
Install.........................................................................................................................................................AS-107
EGR Valve Coolant Lines ............................................................................................................................AS-108
Install.........................................................................................................................................................AS-108
EGR Valve Mounting Bracket .....................................................................................................................AS-106
Install.........................................................................................................................................................AS-106
Engine Base Timing ......................................................................................................................................AS-46
Adjust...........................................................................................................................................................AS-53
Install...........................................................................................................................................................AS-46
Engine Installation ......................................................................................................................................AS-148
Install.........................................................................................................................................................AS-148
Automotive and Industrial.........................................................................................................................AS-148
Power Generation....................................................................................................................................AS-149
Engine Lifting Brackets ................................................................................................................................AS-96
Install...........................................................................................................................................................AS-96
Engine Support Bracket, Front .................................................................................................................... AS-43
Install...........................................................................................................................................................AS-43
Exhaust Gas Pressure Sensor Adapter ......................................................................................................AS-106
Install.........................................................................................................................................................AS-106
All Applications........................................................................................................................................AS-106
Exhaust Gas Pressure Sensor Tube ..........................................................................................................AS-107
Install.........................................................................................................................................................AS-107
Exhaust Manifold, Dry ................................................................................................................................AS-103
Install.........................................................................................................................................................AS-103
Automotive with CM870 and CM871.........................................................................................................AS-103
Automotive, Industrial with CM570 and Power Generation without CM570................................................AS-104
Fan Hub, Belt Driven ..................................................................................................................................AS-139
Install.........................................................................................................................................................AS-139
Industrial CM570 and Power Generation without CM570..........................................................................AS-139
Fan Support ................................................................................................................................................AS-137
Install.........................................................................................................................................................AS-137
Industrial and Power Generation..............................................................................................................AS-137
Flywheel ........................................................................................................................................................AS-32
Install...........................................................................................................................................................AS-32
Section AS - Engine Assembly - Group 00 Page AS-c
Flywheel Housing .........................................................................................................................................AS-14

Install...........................................................................................................................................................AS-14
Measure.......................................................................................................................................................AS-15
Bore Alignment..........................................................................................................................................AS-15
Face Alignment..........................................................................................................................................AS-17
Flywheel Housing, REPTO ...........................................................................................................................AS-19
Install...........................................................................................................................................................AS-19
Measure.......................................................................................................................................................AS-27
Bore Alignment..........................................................................................................................................AS-27
Face Alignment..........................................................................................................................................AS-29
Fuel Filter (Spin-On Type) ..........................................................................................................................AS-144
Install.........................................................................................................................................................AS-144
Gear Cover, Lower ........................................................................................................................................AS-60
Install...........................................................................................................................................................AS-60
Gear Cover, Upper ........................................................................................................................................AS-64
Install...........................................................................................................................................................AS-64
Automotive Applications.............................................................................................................................AS-64
Industrial and Power Generation................................................................................................................AS-64
Gear Housing, Front .....................................................................................................................................AS-12
Install...........................................................................................................................................................AS-12
Heat Shield ..................................................................................................................................................AS-111
Install.........................................................................................................................................................AS-111
Idler Gear, Lower Scissor .............................................................................................................................AS-43
General Information......................................................................................................................................AS-43
Idler Pulley, Refrigerant Compressor .........................................................................................................AS-137
Install.........................................................................................................................................................AS-137
Injector ..........................................................................................................................................................AS-68
Install...........................................................................................................................................................AS-68
Integrated Fuel System Module (IFSM) ......................................................................................................AS-125
Install.........................................................................................................................................................AS-125
Lubricating Oil Cooler ..................................................................................................................................AS-97
Install...........................................................................................................................................................AS-97
All Applications..........................................................................................................................................AS-97
Lubricating Oil Dipstick Tube .....................................................................................................................AS-132
Install.........................................................................................................................................................AS-132
Lubricating Oil Fill Tube .............................................................................................................................AS-132
Install.........................................................................................................................................................AS-132
Lubricating Oil Filter (Spin-On) ..................................................................................................................AS-147
Install.........................................................................................................................................................AS-147
Lubricating Oil Pan .......................................................................................................................................AS-42
Install...........................................................................................................................................................AS-42
Lubricating Oil Pump ....................................................................................................................................AS-10
Install...........................................................................................................................................................AS-10
Lubricating Oil Suction Tube (Block-Mounted) ...........................................................................................AS-42
Install...........................................................................................................................................................AS-42
Lubricating Oil System ...............................................................................................................................AS-151
Fill..............................................................................................................................................................AS-152
Prime..........................................................................................................................................................AS-151
Overhead Camshaft, Injector .......................................................................................................................AS-45
Install...........................................................................................................................................................AS-45
Overhead Camshaft, Valve ...........................................................................................................................AS-46
Install...........................................................................................................................................................AS-46
Overhead Set ................................................................................................................................................AS-73
Adjust...........................................................................................................................................................AS-77
Measure.......................................................................................................................................................AS-73
General Information...................................................................................................................................AS-73
Page AS-d Section AS - Engine Assembly - Group 00
Piston and Connecting Rod Assembly ........................................................................................................AS-39

Install...........................................................................................................................................................AS-39
Piston Cooling Nozzle ..................................................................................................................................AS-41
Install...........................................................................................................................................................AS-41
Piston Rings ..................................................................................................................................................AS-34
Install...........................................................................................................................................................AS-34
Articulated Piston.......................................................................................................................................AS-34
Single-Piece Piston....................................................................................................................................AS-35
Refrigerant Compressor .............................................................................................................................AS-136
Install.........................................................................................................................................................AS-136
Sanden....................................................................................................................................................AS-136
Climate Control Incorporated...................................................................................................................AS-136
Refrigerant Compressor Mounting Bracket .................................................................................................AS-89
Install...........................................................................................................................................................AS-89
Sanden......................................................................................................................................................AS-89
Climate Control Incorporated.....................................................................................................................AS-90
Automotive, Industrial with CM570 and Power Generation without CM570..................................................AS-90
Rocker Lever Assembly ................................................................................................................................AS-69
Install...........................................................................................................................................................AS-69
Rocker Lever Cover ....................................................................................................................................AS-143
Install.........................................................................................................................................................AS-143
Starting Motor .............................................................................................................................................AS-142
Install.........................................................................................................................................................AS-142
All Except 50MT With Aluminum Flywheel Housing..................................................................................AS-142
50MT With Aluminum Flywheel Housing..................................................................................................AS-142
Turbocharger ..............................................................................................................................................AS-112
Assemble....................................................................................................................................................AS-112
Install.........................................................................................................................................................AS-113
Turbocharger Air Shutoff Valve Filter ........................................................................................................AS-124
Install.........................................................................................................................................................AS-124
Variable Geometry...................................................................................................................................AS-124
Turbocharger Coolant Hoses .....................................................................................................................AS-119
Install.........................................................................................................................................................AS-119
Turbocharger Control Shutoff Valve Filter Head .......................................................................................AS-123
Install.........................................................................................................................................................AS-123
Turbocharger, Variable Geometry Actuator ...............................................................................................AS-121
Install.........................................................................................................................................................AS-121
Turbocharger, Variable Geometry Actuator Air Supply Line ....................................................................AS-123
Install.........................................................................................................................................................AS-123
Turbocharger, Variable Geometry Control Valve Air Supply Line ............................................................AS-124
Install.........................................................................................................................................................AS-124
Vibration Damper, Viscous ...........................................................................................................................AS-65
Eccentricity Check........................................................................................................................................AS-68
Install...........................................................................................................................................................AS-65
Automotive Applications.............................................................................................................................AS-65
Industrial and Power Generation with Crank-Driven Fan or PTO.................................................................AS-66
Industrial and Power Generation without Crank-Driven Fan or PTO............................................................AS-67
Wobble Check..............................................................................................................................................AS-68
Water Inlet Connection .................................................................................................................................AS-89
Install...........................................................................................................................................................AS-89
Water Pump ..................................................................................................................................................AS-85
Install...........................................................................................................................................................AS-85
Industrial CM570 and Power Generation without CM570............................................................................AS-87
Automotive With CM871............................................................................................................................AS-89
Section AS - Engine Assembly - Group 00 Page AS-1

Install
CAUTION
Cylinder liners of different design can not be mixed
within an engine. All six cylinder liners must be of the
same design.
There are two different designs of cylinder liners used.
The design used in a particular engine is dependent on
the engine's production vintage.
Engines assembled prior to engine serial number
14022615 have groove-top cylinder liners. They are
characterized by a groove machined into the top surface
of the cylinder liner flange.
Engines with serial number 14022615 and after are
assembled with flat-top cylinder liners. They are
characterized by a cylinder liner flange that is flat, except
for the fire dam.
Make sure the cylinder block and all parts are clean before
assembly.
Lubricate the two cylinder liner o-ring seals with vegetable
oil prior to assembly.
Install the two o-ring seals onto the cylinder liner.
CAUTION
same design.
Install the cylinder liner into the cylinder block.
When acceptable and used cylinder liners are installed,
rotate the cylinder liner 90 degrees from its original
position in the engine. The thrust and anti-thrust surfaces
must face the front and back of the cylinder block.
Use cylinder liner installation kit, Part Number 3162461,
to seat the liner.
If the cylinder liner does not seat properly, remove it and
Inspect the cylinder liner bore seat and cylinder liner for
nicks, burrs, or dirt.
Install the cylinder liner again.
Page AS-2 Section AS - Engine Assembly - Group 00
Measure
Liner Protrusion
Because of design differences, the cylinder liner's position
(relative to the cylinder top deck) will be different.
For groove-top cylinder liners, a recession measurement
is taken. This measures the depth of the groove relative
to the cylinder block deck regardless of the flange or fire
dam height.
For flat-top cylinder liners, a cylinder liner protrusion

measurement is taken which is the height of the cylinder
liner flange above the cylinder block surface regardless of
the flange or fire dam height.
Regardless of the cylinder liner design, the measurement
technique will be the same.
The cylinder liner measurement must be checked before

installing the pistons and connecting rods.
The cylinder liner measurement must be made with the
cylinder liners in the clamped state.
Install and tighten the cylinder liner installation tool.
Torque Value: 68 Nm [ 50 ft-lb ]
Use depth gauge, Part Number 3823495, to measure the

clamped state at the intake side three times and average
the readings.
Measure the clamped state of the exhaust side three times
and average the readings.
Cylinder Liner Recession (Groove-Top Cylinder

Liners)
mm in
0.36 MIN 0.014
0.51 MAX 0.019
Cylinder Liner Protrusion (Flat-Top Cylinder Liners)

mm in
0.18 MIN 0.007
0.33 MAX 0.014
If the cylinder liner measurement on either the intake or
exhaust side is not within specifications, the cylinder liner
must be replaced.
For flat-top cylinder liners only:

The difference between the lowest cylinder liner and
the highest cylinder liner can not be greater than 0.102
mm [0.004 in].
The maximum allowable difference between adjacent
cylinders is 0.51 mm [0.002 in].
The protrusion must be within 0.0381 mm [0.0015 in]
around any cylinder.
Before installing the piston and connecting rod

assemblies, wipe the inside of the cylinder liners using a
clean cloth with 15W-40 oil.
Bearings, Main Signature, ISX, and QSX15 Eng [...]

Install
CAUTION
The cylinder block saddle and the cap mating surfaces
must be clean and dry when the bearing shells are
installed. Used bearings must be installed in their
original location or engine damage can occur.
CAUTION
The bearing tang must fit into the slot in the bearing
saddle or engine damage can occur.
CAUTION
Do not use a capscrew or any hard metal object to
install bearings, as this can damage the crankshaft
and cause an engine failure.
Use clean Lubriplate 105 multi-purpose lubricant, or its
equivalent, to lubricate the upper main bearing shell to
crankshaft journal mating surface.
Start the bearing into the upper saddle by hand. Slide the
bearing into position. Take care to not damage the
crankshaft journal while installing the bearing.

equivalent, to lubricate the inside diameter of the bearing
shells and the liner side of the upper thrust bearings.
Align the lower main bearing shell and push it into place.
CAUTION
Make sure the bevel side is toward the crankshaft
journal. Incorrect thrust bearing installation will result
in engine damage.
equivalent, to lubricate the liner side of the lower thrust
bearings.
Install the lower thrust bearings in the number four main
bearing cap as shown.
CAUTION
in engine damage.
Install the upper thrust bearings in the number four main
bearing saddle.
Push the crankshaft toward the rear of the engine to install
the front thrust bearing and toward the front of the engine
to install the rear thrust bearing.
CAUTION
Only use Loctite 518 thread sealant on the main cap
joint mating surface. Other sealants can become hard,
brittle, and allow oil and debris into the main bearing/
block joint, causing engine damage.
CAUTION
The bead must be 3 to 5 mm [0.12 to 0.20 in] wide and
must not enter the main bearing shell inside the main
bearing shell inside diameter. Sealant in the main
bearing can cause engine damage.
Apply a bead of Loctite 518 thread sealant to the two
main bearing cap surfaces on each main bearing cap as
shown.
Use clean 15W-40 engine oil to lubricate the capscrew

threads and flat washers (or the underside of the capscrew
heads if washers are not used).
Drain the excess oil from the capscrews before installing
them.
CAUTION
The main bearing caps are marked with a `V.' Position
the `V' mark so that it points to the front of the engine.
Incorrect positioning will result in severe engine
damage.
Align the capscrew holes in the cap with the holes in the
cylinder block. Make sure the lower bearing shell is in
position.
Install the capscrews through the cap and into the cylinder
block.
To reduce the possibility of bore size issues, clearance

issues, or both, the main bearing capscrews must be
tightened within 15 minutes of the Loctite 518 thread
sealant application.
Make sure the bearing shell does not move.

Tighten the capscrews in far enough to use a heel bar to
pry the caps into place.
Tighten both of the capscrews on a main bearing cap to

203 Nm [150 ft-lb].
Loosen both capscrews completely.
The remaining main bearings do not have thrust bearings.

It is recommended to use an air impact wrench and

socket, Tool Numbers 3163059 and 3163060, to rotate the
capscrews an additional 180 degrees.
Use the torque plus angle method to tighten the main
bearing capscrews in the sequence shown.
Torque Value: Step1 149 Nm [ 110 ft-lb ]
Step2 Rotate 180 degrees.
To measure the end clearance of the crankshaft, install a

dial indicator onto the oil pan flange.
Place the tip of the gauge against the crankshaft
counterweight.
Push the crankshaft toward the rear of the cylinder block.
Set the dial indicator at "0" (zero).

Push the crankshaft toward the front of the cylinder block.
If the end clearance is less than 0.10 mm [0.004 in], loosen

all main bearing capscrews one turn.
Push the crankshaft toward the front and then toward the
rear of the cylinder block.
Tighten the main bearing capscrews in sequence.

Torque Value:
Block Main Step1 149 Nm [ 110 ft-lb ]
Bearing
Capscrews
Measure the crankshaft end clearance.
Crankshaft End Clearance - New or Reground

mm in
0.10 MIN 0.004
0.50 MAX 0.020
Crankshafts that have been reground on the thrust

bearing surfaces are marked for oversize thrust bearings
on the rear crankshaft counterweight. If the crankshaft
counterweight is marked, check the thrust ring part
number to make sure the correct thrust ring size is used.
Example: F0.010 = front 0.25 mm [0.010 in]
Example: R0.020 = rear 0.51 mm [0.020 in]
If the crankshaft end play is more than 0.50 mm [0.020 in],

the engine must be removed to allow for replacement of
the crankshaft. Refer to Procedure 000-001 (Engine
Removal) in Section 0.
Signature, ISX, and QSX15 Eng [...] Bearings, Thrust

Install
Use Lubriplate 105, or equivalent, to coat the upper
thrust bearings.

the rear thrust bearing, and to the front of the engine to
install the front thrust bearing.
bearing saddle.
The bevel must be toward the crankshaft.
Use Lubriplate 105, or equivalent, to coat the lower thrust

bearings.
The bevel of the thrust bearing must be toward the
crankshaft.
Lubricating Oil Pump Signature, ISX, and QSX15 Eng [...]
Install
WARNING
CAUTION
Do not drop the crankshaft on the bearings.
Install the main bearings. Refer to Procedure 001-006 in
Section 1.
The end of the crankshaft with the smallest diameter
must point toward the front of the cylinder block.
Install the crankshaft.
Lubricating Oil Pump (007-031)

Install
Align dowels on oil pump with mounting holes in the
cylinder block.
Install the oil pump, shims (if they were removed), and the
four capscrews.
Tighten the capscrews.
Use a dial indicator, check the oil pump idler gear back
lash.
Oil Pump Idler Gear Backlash

mm in
0.18 MIN 0.008
0.46 MAX 0.018
0.32 NOM 0.013
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Pump
CAUTION
Improper gear lash can cause damage to the gear train
and the lubricating oil pump.
Shims will be available in six different thicknesses in order
to provide correct lash. The various thicknesses are
identified by the color of the shim. Identify the number
stamped on the pump (1) and the letter on the block (2).
Use the following table to determine which shim should be
used according to the stamped number and letter.
Gear Housing, Front Signature, ISX, and QSX15 Eng [...]
If a lube pump or cylinder block is replaced, the block and pump will not be stamped. In that instance, a shim must
be chosen and installed. The oil pump idler gear backlash must be checked. If the backlash is not within the
specification, choose another size shim and recheck the backlash. Do this until the backlash is within specification.
Block
Pump A B C D
1 0.000 mm [0.000 in]-None- 0.45 mm [0.018 in]-Black- 0.55 mm [0.022 in]- 0.35 mm [0.014 in]-
Purple- Yellow-
2 0.45 mm [0.018 in]-Black- 0.65 mm [0.026 in]-Red- 0.75 mm [0.030 in]-Blue- 0.55 mm [0.022 in]-Purple-
3 0.55 mm [0.022 in]-Purple- 0.75 mm [0.030 in]-Blue- 0.85 mm [0.033 in]-Green- 0.65 mm [0.026 in]-Red-
4 0.35 mm [0.014 in]-Yellow- 0.55 mm [0.022 in]- 0.65 mm [0.026 in]-Red- 0.45 mm [0.018 in]-Black-
Purple-
If the lubricating oil pump is not within specifications, the
shims must be changed to proper thickness to give proper
backlash.

Install
Remove the protective plug from the cylinder block oil
passage. Make sure no debris enters the lubrication
system. Use a clean shop towel, carefully wipe out the oil
passage and inspect to make sure no debris is left in the
passages.

Install a new gear housing mounting gasket.
The gear housing has the words Special Capscrew cast

into the housing at the number 1 mounting location (see
illustration). This capscrew must be the short head
capscrew to prevent contact between the capscrew and
the idler gear.
WARNING
Install the gear housing.
Install the 18 mounting capscrews.

Four different length capscrews are utilized on the front
gear housing. Use the table below to identify the
capscrews and their mounting locations.
Capscrew Mounting Location
Location Size Quantity
14 M10 x 1.5 x 93 1
18, 19, 20 M10 x 1.5 x 70 3
1 M10 x 1.5 x 21.8 (Special 1
Short Head)
All remaining M10 x 1.5 x 2.5 15
Remove the guide studs and install two capscrews.

Tighten the capscrews in the sequence shown.
Torque Value:
All Capscrews Step1 20 Nm [ 15 ft-lb ]
Except (1)
Step2 72 Nm [ 53 ft-lb ]
Torque Value:
Capscrew (1) Step1 20 Nm [ 15 ft-lb ]
Flywheel Housing (016-006)

Install
Remove the protective plug from the block oil passages.
Make sure debris does not enter the lubrication system.
Use a clean shop towel to carefully wipe out the oil
passage.
Install the cover plate and two capscrews. Tighten the

capscrews.
Install two guide studs into the cylinder block to help

support and align the housing during installation.
Position the flywheel housing gasket to the rear of the
engine block using the guide pins.
Install the flywheel housing over the guide studs.

Lubricate the threads and underneath the heads of the
capscrews with clean 15W-40 lubricating oil.
Install capscrews 1, 2, 3, and 4, and tighten in the
sequence shown.
Signature, ISX, and QSX15 Eng [...] Flywheel Housing
The flywheel housing is located on the block by two ring

dowels from the factory. If a flywheel housing is removed,
it can be reinstalled with the ring dowels in place, but
alignment must be checked with the following alignment
procedure.
If the alignment does not meet specification, the ring
dowels must be removed and the housing must be
realigned without the ring dowels.
CAUTION
The flywheel housing bore and surface must be in
alignment with the crankshaft to prevent possible
damage to the engine, the clutch, or the transmission.
Measure the flywheel housing alignment.
Measure
Bore Alignment
Attach a dial indicator to the crankshaft. Use mounting tool
Part Number ST-1325 and indicator Part Number
3376050.
The dial indicator can be mounted by any method that
holds the extension bar of the indicator rigid so it does
not sag. If the bar sags or the indicator slips, the readings
obtained will be inaccurate.
Position the indicator in the 6:00 o'clock position and the
gauge at zero.
Slowly rotate the crankshaft. Record the readings

obtained at the 9:00 o'clock, 12:00 o'clock, and 3:00
o'clock positions as (a), (b), and (c) in the concentricity
work sheet. Recheck zero at the 6:00 o'clock position.
The values for (a), (b), and (c) can be positive or negative.
Refer to the accompanying figure to determine the correct
sign when recording these values.
CAUTION
Do not force the crankshaft beyond the point where
the bearing clearance has been removed. Do not pry
against the flywheel housing. These actions can
cause false bearing clearance reading.
Rotate the crankshaft until the dial indicator is at the 12-
o'clock position and zero the gauge.
Use a pry bar to raise the rear of the crankshaft to its upper
limit. Record the value as (d) in the concentricity work
sheet. This is the vertical bearing clearance adjustment
and will always be positive.
Use the concentricity work sheet (see the accompanying

illustration) to determine the total vertical and horizontal
values.
The total horizontal is equal to the 9:00 o'clock reading (1)
minus the 3 :00 o'clock reading (c).
The total vertical is equal to the 12:00 o'clock reading (b)
plus the bearing clearance (d).
Example:
6:00 o'clock = reference = 0
9:00 o'clock = [a ] = 0.004
12:00 o'clock = [b ] = 0.003
3:00 o'clock =[c] = -0.002.
Using the work sheet and the numbers from the example,
the total horizontal value equals 0.006, and the total
vertical value equals 0.005.
Mark the total horizontal value on the horizontal side of the

chart and the total vertical on the vertical side of the chart.
Use a straightedge to find the intersection point of the total
horizontal and total vertical values. The intersection point
must fall within the shaded area for the flywheel housing
concentricity to be within specification.
Using the total horizontal and total vertical values from the
previous example, the intersection point falls within the
shaded area. Therefore, the flywheel housing
concentricity is within specification.
Use the accompanying chart for SAE 1, 2, and 3 flywheel
housings.
Signature, ISX, and QSX15 Eng [...] Flywheel Housing
Use the accompanying chart for SAE 0 and flywheel

housings.
Use the accompanying chart for SAE 00 flywheel

housings.
If the intersection point falls outside the shaded area, the

ring dowels must be removed and the housing
repositioned.
The ring dowels are not required to maintain concentricity
of the housing; the clamping force of the capscrews holds
the housing in place.
After the ring dowels are discarded, install the flywheel
housing on the engine.
To position the housing, tighten the capscrews enough to
hold the flywheel housing in place, but loose enough to
enable small movement when struck lightly with a mallet.
Recheck the concentricity. When concentricity is within
specification, tighten the capscrews to the specified value.
Face Alignment
CAUTION
The dial indicator tip must not enter the capscrew
holes, or the gauge will be damaged.
Install a dial indicator as illustrated.
The extension bar for the indicator must be rigid for an
accurate reading. It must not sag. Position the indicator
at the 12:00 o'clock position. Adjust the dial until the
needle points to zero.
Slowly rotate the crankshaft. Record the readings at the

3:00 o'clock, 6:00 o'clock, and 9:00 o'clock positions.
The crankshaft must be pushed toward the front of the
engine to remove the crankshaft end clearance each time
a position is measured.
Continue to rotate the crankshaft until the indicator is at

the 12:00 o'clock position. Check the indicator to make
sure that the needle points to zero. If it does not, the
readings will be incorrect.
Determine the total indicator runout.

Total Indicator Runout (Example)
Position Runout
12:00 o'clock 0.00 mm [0.000 in]
3:00 o'clock +0.08 mm [+0.003 in]
6:00 o'clock -0.05 mm [-0.002 in]
9:00 o'clock +0.08 mm [+0.003 in]
Total Indicator Runout = 0.13 mm [0.005 in]
The maximum allowable total indicator reading is

determined by the diameter of the housing bore. If out of
specifications, replace the housing.
SAE Bore Diameter Total Indicator
Number Runout Maximum
00 787.40 to 787.65 mm 0.30 mm [0.012 in]
[30.88 to 31.00 in]
0 647.70 to 647.95 mm 0.25 mm [0.010 in]
[25.50 to 25.51 in]
584.2 to 584.4 mm 0.25 mm [0.010 in]
[23.000 to 23.008 in]
1 511.18 to 511.30 mm 0.20 mm [0.008 in]
[20.125 to 20.130 in]
2 447.68 to 447.80 mm 0.20 mm [0.008 in]
[17.652 to 17.630 in]
3 409.58 to 409.70 mm 0.20 mm [0.008 in]
[16.125 to 16.130 in]
Install the remaining capscrews. Tighten all capscrews in

two steps using the sequence shown.
Step2 197 Nm [ 145 ft-lb ]
Flywheel Housing, REPTO (016-007)

Install
Remove the protective plug from the block oil passages.
Make sure no debris enters the lubrication system.
Use a clean shop towel to carefully wipe out the oil
passage.
Install the two guide pins (3), Part Number 3164764, into
the cylinder block.
Position the flywheel housing gasket to the rear of the
cylinder block using guide pins.
WARNING
Install the two eye hooks (4) in the top of the REPTO
flywheel housing. Install the lifting slings to the eye hooks
and push the REPTO flywheel housing onto the two
guides pins (3).
Install the six short capscrews (2) and four long capscrews
(1) in the locations shown.
Remove the two guide pins and install the two other long
capscrews.
Tighten capscrews (1), (2), (9) and (10).

Tighten the remaining capscrews in the sequence shown.
CAUTION
The REPTO flywheel housing bore and face must be
in alignment with the crankshaft to prevent possible
damage to the engine, the clutch, or the transmission.
Use the measure step in this procedure to align the
housing.

Step2 197 Nm [ 145 ft-lb ]
Install the three oil pan capscrews.
Install the large o-ring seal (1) and the small o-ring seal (2)
onto the idler shaft.
Assemble the replacer idler shaft plate and handle.

Install the two capscrews in the idler shaft holes and
tighten.
Use clean 15W-40 oil to lubricate the idler shaft.
The two cones (2) are loose and will fall out if not
contained.
Make sure the gear (4), two bearing snap rings (1), and the
two cups (3) are pressed in place before inserting the
assemblies through the center or sides of the REPTO
flywheel housing openings.
Use clean 15W-40 oil to lubricate the bearing snap rings,
cones, cups, idler shaft, and gear.
Make sure the idler shaft plug (1) is facing upward when
installing it into the bore.
Install the gear and bearing assembly through the center
or sides of the REPTO flywheel housing holes. Position
the bearing races together and insert the idler shaft with
the tool through the first bear bore. The running clearance
is 0 to 0.025 mm [0.000 to 0.001 in].
Make sure the idler shaft is properly aligned and seated
against the shoulder of the internal bore.
Repeat the procedure if installing a second gear.

Remove the two capscrews, replacer idler plate, and
handle from the idler shaft.
Lubricate the threads and under the capscrew head with
clean 15W-40 oil.
Install the washer and capscrew and tighten capscrew.
A second idler gear can be installed or an insert shaft can

be used without the idler gear and roller.
Install the o-rings onto the insert shaft. Lubricate the o-
rings with clean 15W-40 oil.
Install the insert shaft into the flywheel housing hole where
the cover plate will be installed (opposite pump location).
Align the hole with the tapped hole in the block.
Lubricate the threads and under the capscrew head with
clean 15W-40 oil.
Install the washer and capscrew and tighten capscrew.
Install the three guide pins, Part Number 3164765, equally

spaced through the crankshaft gear and into the
crankshaft.
Rotate the idler gears, as necessary, to mesh the
crankshaft gear with the idler gear(s).
Install the crankshaft gear.
Make sure the o-rings are properly seated into the groove
before installation.
Use clean 15W40 oil to lubricate the o-rings.
Install four plugs (1) with o-rings (2) into the REPTO
flywheel housing holes.
Install the o-ring in the REPTO flywheel housing groove.

Install the seal carrier over the two dowels pins on the
REPTO flywheel housing.
Install the 12 capscrews.

Tighten the capscrews in the sequence shown to secure
the seal carrier.
Install the three flywheel mounting capscrews and

spacers. Tighten the flywheel mounting capscrews.
Remove the three flywheel mounting capscrews and
spacers.
CAUTION
The rear crankshaft seal must be pressed evenly into
the bore. If the crankshaft and crankshaft seal is not
pressed evenly into the bore, the oil seal can cause
equipment damage.
Install the rear crankshaft oil seal over the rear crankshaft
seal replacer, Part Number 3164780, and onto the three
guide pins.
Install three flywheel mounting capscrews (without the
washers) through the three holes in the rear crankshaft
seal replacer.
CAUTION
To reduce the possibility of damage to the oil seal and
crankshaft, never use a hammer or mallet to install the
rear crankshaft oil seal.
Do not use lubricants during the installation process.
Apply a 10 percent soap solution to the outer ribbed
surface of the rear crankshaft oil seal.
Tighten the flywheel mounting capscrews no more than
revolution at a time, alternating capscrews in a
clockwise pattern, until the rear crankshaft seal replacer,
Part Number 3164780, seats against the REPTO flywheel
housing.
Remove the rear crankshaft seal replacer and the three

flywheel mounting capscrews.
Install the flywheel. Refer to Procedure 016-005 (Flywheel)
in Section 16.
If one side of the REPTO flywheel housing cover access

hole does not use a hydraulic housing, the opening
must be covered in conjunction with the oil supply line
hole and plugging the straight thread plug hole.
Install the 1/8-inch pipe plug (1) into the oil supply line
hole. Make sure the pipe plug is flush with the mounting
surface.
Install the straight thread plug (2) into the flywheel housing
hole. Make sure pipe plug is flush with the mounting
surface.
Install the diamond seal (1) on the REPTO flywheel

housing cover access hole.
Apply a small amount of RTV on the two ends (2) where
the diamond seal comes together and a small amount of
15W-40 oil on the diamond seal.
Install the cover plate to the REPTO flywheel housing
cover access hole. Install the 10 capscrews and tighten.
Make sure the idler gear is locked in position. Use a dial

gauge to check the backlash.
Idler Gear to Crankshaft Gear Backlash

mm in
0.15 MIN 0.006
0.28 MAX 0.011
If the backlash is not within specifications, replace the
idler gear, REPTO hub gear, or both.
NOTE: The spray nozzle and diamond seal are only

installed if a hydraulic housing is used.
Install the spray nozzle (1) into the oil supply line hole.
Tighten the spray nozzle.
Install the diamond seal (2) on the REPTO flywheel
housing cover access hole.
Apply a small amount of RTV on the two ends (3) where
the diamond seal comes together and a small amount of
clean 15W-40 oil on the diamond seal.
Apply clean 15W-40 oil on the gear teeth and bearings.

Install the hydraulic housing over the dowel pins. The gear
inside the hydraulic housing is free to rotate and will locate
the position of the idler gear as the hydraulic housing is
being installed over the dowel pins.
Install the 10 capscrews and tighten in the sequence

shown.
Verify that backlash exists between the Hydrive housing

gear and idler gear by inserting a tool into the spline to
help rotate the gear.
A small amount of backlash must be present, although
obtaining a measurement is not required.
If no backlash is present, disassemble the Hydrive
housing from the flywheel housing, and assemble the
Hydrive housing to the opposite flywheel housing
mounting pad and check for backlash.
If no backlash is present when assembled on either
flywheel housing mounting pad, the Hydrive housing
must be replaced.
If backlash is present on only one side, the flywheel
housing must be replaced.
Install the threaded plug (1) in the bottom hole of the

hydraulic housing. Tighten the threaded plug.
Install the oil line hose on the straight connectors. Tighten
the hose and check for leaks.
Measure
Bore Alignment
Attach a dial indicator to the crankshaft. Use mounting
tool, Part Number ST-1325, and indicator Part Number
3376050.
The dial indicator can be mounted by any method that
holds the extension bar of the indicator rigid so it does
not sag. If the bar sags or the indicator slips, the readings
obtained will not be accurate.
Position the indicator in the 6:00 o'clock position and the
gauge at zero.
Slowly rotate the crankshaft. Record the readings

obtained at the 9:00 o'clock, 12:00 o'clock, and 3:00
o'clock positions as (a), (b), and (c) in the concentricity
work sheet. Recheck zero at the 6:00 o'clock position.
The values for (a), (b), and (c) can be positive or negative.
Refer to the accompanying figure to determine the correct
sign when recording these values.
CAUTION
Do not force the crankshaft beyond the point where
the bearing clearance has been removed. Do not pry
against the flywheel housing. These actions can
cause false bearing clearance reading.
Rotate the crankshaft until the dial indicator is at the 12-
o'clock position and zero the gauge.
Use a pry bar to raise the rear of the crankshaft to its upper
limit. Record the value as (d) in the concentricity work
sheet. This is the vertical bearing clearance adjustment
and will always be positive.
Use the concentricity work sheet (see the accompanying

illustration) to determine the total vertical and horizontal
values.
The total horizontal is equal to the 9:00 o'clock reading (1)
minus the 3 :00 o'clock reading (c).
The total vertical is equal to the 12:00 o'clock reading (b)
plus the bearing clearance (d).
Example:
6:00 o'clock = reference = 0
9:00 o'clock = [a ] = 0.004
12:00 o'clock = [b ] = 0.003
3:00 o'clock =[c] = -0.002.
Use the work sheet and the numbers from the example.
The total horizontal value equals 0.006, and the total
vertical value equals 0.005.
Mark the total horizontal value on the horizontal side of the

chart and the total vertical on the vertical side of the chart.
Use a straightedge to find the intersection point of the total
horizontal and total vertical values. The intersection point
must fall within the shaded area for the flywheel housing
concentricity to be within specification.
Using the total horizontal and total vertical values from the
previous example, the intersection point falls within the
shaded area. Therefore, the flywheel housing
concentricity is within specification.
Use the accompanying chart for SAE 1, 2, and 3 flywheel
housings.
Use the accompanying chart for SAE 0 and flywheel

housings.
Use the accompanying chart for SAE 00 flywheel

housings.
If the intersection point falls outside the shaded area, the

ring dowels must be removed and the housing
repositioned.
The ring dowels are not required to maintain concentricity
of the housing; the clamping force of the capscrews holds
the housing in place.
After the ring dowels are discarded, install the flywheel
housing on the engine.
To position the housing, tighten the capscrews enough to
hold the flywheel housing in place, but loose enough to
enable small movement when struck lightly with a mallet.
Recheck the concentricity. When concentricity is within
specification, tighten the capscrews to the specified value.
Face Alignment
CAUTION
The dial indicator tip must not enter the capscrew
holes, or the gauge will be damaged.
Install a dial indicator as illustrated.
The extension bar for the indicator must be rigid for an
accurate reading. It must not sag. Position the indicator
at the 12:00 o'clock position. Adjust the dial until the
needle points to zero.
Slowly rotate the crankshaft. Record the readings at the

3:00 o'clock, 6:00 o'clock, and 9:00 o'clock positions.
The crankshaft must be pushed toward the front of the
engine to remove the crankshaft end clearance each time
a position is measured.
Continue to rotate the crankshaft until the indicator is at

the 12:00 o'clock position. Check the indicator to make
sure that the needle points to zero. If it does not, the
readings will be incorrect.
Determine the total indicator runout.

Total Indicator Runout (Example)
Position Runout
12:00 o'clock 0.00 mm [0.000 in]
3:00 o'clock +0.08 mm [+0.003 in]
6:00 o'clock -0.05 mm [-0.002 in]
9:00 o'clock +0.08 mm [+0.003 in]
Total Indicator Runout = 0.13 mm [0.005 in]
The maximum allowable total indicator reading is

determined by the diameter of the housing bore. If out of
specifications, replace the housing.
SAE Bore Diameter Total Indicator
Number Runout Maximum
00 787.40 to 787.65 mm 0.30 mm [0.012 in]
[30.88 to 31.00 in]
0 647.70 to 647.95 mm 0.25 mm [0.010 in]
[25.50 to 25.51 in]
584.2 to 584.4 mm 0.25 mm [0.010 in]
[23.000 to 23.008 in]
1 511.18 to 511.30 mm 0.20 mm [0.008 in]
[20.125 to 20.130 in]
2 447.68 to 447.80 mm 0.20 mm [0.008 in]
[17.652 to 17.630 in]
3 409.58 to 409.70 mm 0.20 mm [0.008 in]
[16.125 to 16.130 in]
Install the remaining capscrews. Tighten all capscrews in

two steps using the sequence shown.
Step2 197 Nm [ 145 ft-lb ]

Install
The rear crankshaft seal must be oriented with the engine
as shown in the illustration.
CAUTION
Never use a hammer or mallet to install the seal.
Damage to the seal can occur.
Do not use lubricants to install the seal. Apply a 10-
percent soap solution to the outer-ribbed surface of the
seal.
Guide the rear crankshaft seal (1), spacer (2), and replacer
plate (3) over the crankshaft.
NOTE: Spacer, Part Number 4918688, is used to make
sure of the correct installation depth of the crankshaft seal.
The flat side of the spacer should contact the crankshaft
seal during installation.
Flywheel Signature, ISX, and QSX15 Eng [...]
CAUTION
the bore. Misalignment of the seal can cause damage.
Install three flywheel mounting capscrews or replacer
screws and hex nuts, through the replacer plate and into
the end of the crankshaft.
Finger-tighten the three installation capscrews against the
replacer plate.
Tighten the screws not more than of a turn at a time,
in a clockwise pattern, until the installation tool seats
against the flywheel housing.
Tighten the screws.
Remove the replacer plate.
Measure
the seal.
0.5 mm [0.02 in].
installed.
Flywheel (016-005)
Install
Install the pilot bearing spacer into the rear of the
crankshaft with the spacer lip oriented outward.
NOTE: A small amount of clean Lubriplate 105 multi-
purpose lubricant, or its equivalent, can be used to help
keep the pilot bearing spacer in position until the flywheel
is assembled.
Signature, ISX, and QSX15 Eng [...] Flywheel
CAUTION
The flywheel mounting capscrews must be a minimum
of SAE Grade 8 with rolled threads. Use identical
replacements to avoid possible flywheel failure
resulting in personal injury or property damage.
Lubricate the threads and underneath the heads of the
capscrews with clean 15W-40 oil. Allow the excess oil to
drip off the parts. Do not lubricate the threads of the
crankshaft.
WARNING
avoid personal injury, use a hoist or get assistance to
lift the component.
Use two M6 x 1.5 guide studs during assembly.
Install the flywheel. The flywheel must be firmly against
the crankshaft.
Install the ten capscrews.

Remove the t-handles and the guide studs.
Install the remaining two capscrews into the holes from
which the guide studs were removed.
Tighten the capscrews in two steps, use the sequence
shown.
Step2 250 Nm [ 184 ft-lb ]
Use a mandrel and hammer to install the pilot bearing.

The pilot bearing must be installed even with the pilot bore
surface.
Piston Rings Signature, ISX, and QSX15 Eng [...]

Install
Articulated Piston
CAUTION
Use a copper or aluminum vise protector when
installing the connecting rod in a vise to protect the
connecting rod from damage.
The ring gap of each ring must not be aligned with the
piston pin or with any other ring. If the ring gaps are not
aligned correctly, the rings will not seal properly.
Place the connecting rod in a vise to hold the assembly in
a horizontal position while installing the rings.
A cross-sectioned view of an oil control ring is shown.

The two-piece oil control ring must be installed with the
expander ring gap 180 degrees from the gap of the oil ring.
Do not overlap the ends of the expander ring.
Install the piston rings with TOP toward the top of the
piston.
The rings have the top marked for correct installation.
The oil control ring is symmetrical and can be installed in
either orientation.
The piston must be held in a horizontal position to install

the rings in order to keep the rings in the groove while
installing the ring compressor.
For articulated pistons, the top piston ring (1) is a keystone
ring with no twist or cutback notch.
The intermediate ring (2) is a positive twist design with a
cutback notch (3) on the topside and a two-degree taper
face.
The oil control ring (4) is the bottom piston ring.
Rotate the rings to position the ring gaps as shown.

piston pin, or with any other ring gap. If the ring gaps are
not aligned correctly, the rings will not seal properly.
Single-Piece Piston
CAUTION
Install the connecting rod in a vise to hold the assembly in

piston.
either orientation.
For single-piece pistons, use a universal piston ring
expander to install the second ring into the piston.
The single-piece ring set is similar to the articulated ring

set, with the exception of the second ring. The second ring
has a rectangular cross-section (2) with an angled cut (3)
on the upper side of the inner diameter to induce a positive
twist. This design improves the slobber-resistance of the
ring pack.

If failure resulted in coolant, oil, excessive fuel or

excessive black smoke entering the exhaust system, the
aftertreatment system must be inspected. Refer to
Procedure 014-013.

Install
CAUTION
Connecting rod bearings must match the connecting
rod design. Drilled rods must use drilled rod bearings.
Non-drilled rods must use non-drilled bearings.
Mismatches will cause engine damage.
Connecting rod design must be matched with the proper
connecting rod bearing.
Drilled connecting rods must be fitted with drilled
connecting rod bearings.
Non-drilled connecting rods must be fitted with non-drilled
Signature, ISX, and QSX15 Eng [...] Bearings, Connecting Rod
Drilled and non-drilled connecting rods can be mixed in

the same engine as long as the two piece piston is used.
Engines using single piece pistons can not use non-drilled
connecting rods.
CAUTION
The connecting rod and bearing shell mating surfaces
equivalent to lubricate the crankshaft journal mating
surface of the upper bearing shell.
Install the upper bearing shell into the connecting rod with
the tang of the bearing in the slot of the rod.
Install the bearing shell into the connecting rod cap with
the tang (2) of the bearing in the slot (1) of the cap.
equivalent to lubricate the bearing shell to crankshaft
journal mating surface and the connecting rod capscrews.
CAUTION
The rod cap alpha characters must match the alpha
characters on the connecting rod and must be
installed with the characters aligned to prevent
damage to the connecting rods and crankshaft. The
locking tang of the connecting rod cap must face
toward the intake side of the cylinder block. Rod and
cap mating surfaces must be clean or engine damage
can occur.
Install the cap onto the connecting rod.
Lubricate the threads of the capscrews with clean engine

oil.
Thread the capscrews into the connecting rod and hand
tighten.
The procedure for tightening used capscrews is different
than the procedure for tightening new capscrews.
For used connecting rod capscrews:
Torque Value:
Tighten Step1 70 6 Nm[ 52 4 ft-
Capscrews in lb ]
Numerical
Sequence
Step2 Rotate capscrews in
numerical sequence 60
5 degrees
For new connecting rod capscrews:
Torque Value:
Capscrews in lb ]
Numerical
Sequence
Step2 Loosen capscrews in
numerical sequence
Step3 70 6 Nm[ 52 4 ft-
lb ]
5 degrees
Measure the connecting rod side clearance.
Connecting Rod Side Clearance

mm in
0.10 MIN 0.004
0.33 MAX 0.013
NOTE: The connecting rod must move freely from side to

side on the crankshaft journal. If the rod does not move
freely, remove the rod cap and make sure the bearing
shells are the correct size. Check for dirt or damage on
the crankshaft and the bearing shells.
Repeat the above steps to install the remaining bearing
shells and connecting rod caps.

(001-054)
Install
Immerse the piston in a container of clean 15W-40 oil.
Remove the piston from the container. Let the excess oil
drain from the piston.
Use piston ring compressor, Part Number 3164846, to

compress the rings.
The cylinder block and all parts must be clean before
assembly.
Inspect the cylinder liners for reuse. Refer to Procedure
001-028.
Use a clean, lint-free cloth to clean the connecting rods

and bearing shells.
Do not lubricate the backside of the bearing shells. The
operating clearance of the bearing will be reduced and the
bearing can be damaged during engine operation.
If new bearings are not used, the used bearings must be

installed on the same connecting rod from which they
were removed.
Install the upper bearing shell into the connecting rod.
The tang of the bearing shell (2) must be in the slot of the
cap (1). The end of the bearing shell must be even with
the cap mounting surface.
Use Lubriplate 105, Part Number 3163086, or

equivalent, to coat the entire inside circumference of the
bearing shell.
Apply a film of clean 15W-40 oil to the cylinder liner.
Install connecting rod guide pins, Part Number 3163097.
Use the compressor drive or barring device to rotate the

crankshaft so the connecting rod journal of the connecting
rod being installed is at bottom dead center.
CAUTION
Failure to align the deep valve pocket and the piston
skirt cooling nozzle notch correctly will result in
extensive engine damage.
Align the piston crown deep valve pocket on the exhaust
side of the engine, and the piston skirt cooling nozzle
notch to the intake side of the engine.
If the deep valve pocket and the piston skirt cooling nozzle
notch are not on opposite sides, the piston and
connecting rod assembly are not assembled correctly.
Disassemble the piston and connecting rod and assemble
correctly.
Insert the connecting rod through the cylinder liner until
the ring compressor contacts the top of the liner.
Both articulated pistons and single-piece pistons have an

arrow on the top of the piston crown, which will point to
the front of the engine, when the piston is installed
properly.
CAUTION
Do not use a metal drift to push the piston into the
cylinder liner. The piston rings or cylinder liner can be
damaged.
Hold the ring compressor against the cylinder liner. Push
the piston through the ring compressor and into the
cylinder liner. Push the piston until the top ring is
completely in the cylinder liner.
If the piston does not move freely, remove the piston and
inspect for broken or damaged rings.
Use the nylon guide pins to align the connecting rod with
the crankshaft while pushing the piston and connecting
rod assembly into place.
Remove the nylon guide pins.

Install
CAUTION
Properly align the nozzles in the locator notch before
tightening the capscrews. Damage to the engine can
occur.
The crankshaft must be rotated to allow access to install
all the nozzles.
Install the nozzle, washers, and capscrews.
Lubricating Oil Pan Signature, ISX, and QSX15 Eng [...]

Install
Install the block stiffener plate and the 10 capscrews.
Lubricating Oil Suction Tube (Block-

Mounted) (007-035)
Install
Lubricate the o-ring with clean 15W-40 engine oil.
Install the new o-ring on the oil suction tube.
Install the oil suction tube into the lubricating oil pump.
Install the lubricating oil suction tube capscrews. Tighten
capscrews.
Lubricating Oil Pan (007-025)

Install
Apply a 1.97 mm [1/8 in] bead of silicon sealant, Part
Number 3164067, to each of the four T-joints where the
front gear housing and flywheel housing gaskets intersect
the oil pan gasket.
Signature, ISX, and QSX15 Eng [...] Engine Support Bracket, Front
Install a new oil pan gasket.

Install the oil pan onto the cylinder block. Install one of the
13 mm oil pan mounting capscrews, hand tight, on each
side of the oil pan, halfway between the front and the rear
of the oil pan.
Finger-tighten all or the mounting capscrews.
Tighten the thirty-two 13 mm capscrews in the sequence

shown.
At the end of the sequence, loosen and tighten capscrew
number 1again.
Install the oil drain plug.

General Information
Engine Support Bracket, Front

(016-002)
Install
Install the engine support bracket and the six mounting
capscrews.
Torque: 97 Nm + 60 deg [72 ft-lb + 60 deg]
Install the rubber engine mounts into the crossmember.
Cylinder Head Signature, ISX, and QSX15 Eng [...]
WARNING
Lower the front of the engine to the rubber engine mounts.
The capscrew holes in the support bracket must be
aligned with the capscrew holes in the engine mounts.
Install the two capscrews in the support bracket and
engine mount. Tighten to the manufacturer's
specifications.
Remove the lifting fixture or the hoist from the engine.
Cylinder Head (002-004)

Install
Two different styles of head gaskets are used on
Signature, ISX, and QSX15 engines, based on the style
of liner used in the engine. Correctly identify which style
of liner is used before installing the head gasket. Refer to
Install the cylinder head gasket.
WARNING
Use engine lifting fixture, Part Number 4919360 or
equivalent, to lift the cylinder head.
Two long cylinder head capscrews placed toward each
end of the cylinder head serve as convenient guides when
lowering the cylinder head into place.
Align the cylinder head over the dowel pins and lower into
position.
Use clean 15W-40 oil to lubricate the cylinder head

capscrews.
Allow the excess oil to drain from the threads.
Install the 26 capscrews into the cylinder head.
Signature, ISX, and QSX15 Eng [...] Overhead Camshaft, Injector
CAUTION
Make sure the four longer capscrews placed in the
correct location. Engine damage can occur if these
capscrews are not placed in the correct locations.
Tighten capscrews in sequence.
socket, Tool Number 3163059 and 3163484, to rotate the
capscrew 90 degrees.
Torque Value:
Step 1 203 Nm [ 150 ft-lb ]
Step 2 407 Nm [ 300 ft-lb ]
Step 3 Rotate 90 degrees.
Overhead Camshaft, Injector (002-025)

Install
CAUTION
Use caution when installing the camshaft to avoid
Coat the inside of the injector camshaft bearings with
Lubriplate prior to installing camshaft.
Install the injector camshaft.
Install new o-rings on the retainer plate.

Install the retainer plate and capscrews.
Install the injector camshaft cover plate with new gasket.

Install the capscrews.
Overhead Camshaft, Valve (002-024)

Install
CAUTION
Use caution when installing the camshaft to avoid
Coat the inside of the valve camshaft bushings with
Lubriplate prior to installing camshaft.
Install the valve camshaft.
Install new o-rings onto the retainer plate.

Install the retainer plate and capscrews.

Install
Timing Wedges:
The timing code is located on the engine dataplate.
First number - injector wedge
Second number - valve wedge.
Make sure the wedges with the proper angles are used
and that the wedges are properly seated in their installed
position.
Insert the correct timing wedge to lock the injector
camshaft. Lightly tap the top of the timing wedge with a
mallet to be sure it is properly seated.
WARNING
Do not drive the wedges into place. Engine damage
can occur.
position.
Insert the correct timing wedge to lock the valve camshaft.
Lightly tap the top of the timing wedge with a mallet to be
sure it is properly seated.

The lower scissor idler gear must be unloaded during
installation. To unload the gear, two of the gear screws
Apply Lubriplate to the thrust bearing, shaft, and lower
scissor idler gear.
Install the thrust bearing, shaft, and lower scissor idler
gear. The shaft must be installed with the word
TOP (stamped on the end of the shaft) toward the top of
the engine.
The lower idler scissor gear front retainer plate is larger in

diameter than the adjustable idler retainer plate. The slots
in the plate go toward the scissor gear
Install the retainer and capscrews.
Tighten all capscrews in a star pattern.
Torque Value:
Step 1 30 Nm [ 22 ft-lb ]
Step 2 Rotate each capscrew an additional 60
degrees in the same sequence as
above.
CAUTION
Make sure all the scissor gear screws are tightened to
the proper torque so that they do not back out during
engine operation. Severe engine damage can occur.
Load the lower idler scissor gear by tightening all of the
gear screws.

non-scissor idler gear.
Install the thrust bearing, shaft, and lower non-scissor idler
the engine.
The lower idler non-scissor gear front retainer plate is

larger in diameter than the adjustable idler retainer plate.
The slots in the plate go toward the scissor gear
Torque Value:
above.

The spacer plate is doweled to the block with two standard
dowels.
Install the mounting spacer plate.
Apply Lubriplate to the spacer, shaft, and adjustable idler

gear.
It is possible to install the shaft in an incorrect orientation;
however, it will not be possible to set the gear backlash
correctly.
Install the spacer, shaft and adjustable idler gear. The
shaft must be installed with the word TOP (stamped on
the front face of the shaft) oriented toward the top of the
engine.
The adjustable idler front retainer plate is smaller in

diameter than the lower idler scissor gear retainer plate.
The slots on the retainer plate go toward the gear.
The adjustable idler gear is installed loosely, because it is
moved into its final position later in the timing process.
Install the retainer and capscrews. Finger-tighten the
capscrews and then loosen by one flat, which is 60
degrees.

Install the injector camshaft rear cover plate.
CAUTION
The injector camshaft nose and injector camshaft
scissor gear must be clean and dry prior to assembly.
Wipe off the taper surface with a clean lint-free cloth
and apply a thin coat of Loctite 609, Part Number
3823718, to the inside diameter of the camshaft gear.
Use care not to contaminate the joint with oil prior to
assembly or engine damage may occur.
during installation. To unload the gear, two of the gear
screws must be backed out far enough to allow the teeth
on the scissor gear to be aligned.
Apply a thin coat of Loctite 609, Part Number 3823718,

to the inside diameter of the camshaft gear.
The injector camshaft scissor gear needs to be fully

engaged on the camshaft nose taper, yet loose enough so
it can rotate on the camshaft nose.
Install the injector camshaft scissor gear loosely on the
camshaft nose taper.
The injector camshaft scissor gear mounting washer is
larger in diameter than the valve camshaft mounting
washer.
Install the mounting washer and capscrew.
Finger-tighten the capscrew and then loosen by one flat,

which is 60 degrees.
The injector camshaft scissor gear is still loose at this
point, to allow the adjustable idler gear to be properly
positioned.
Do not seat the gear.

CAUTION
non-scissor gear must be clean and dry prior to
assembly. Wipe off the taper surface with clean a lint-
free cloth and apply a thin coat of Loctite 609, Part
Number 3823718, to the inside diameter of the
camshaft gear. Use care not to contaminate the joint
with oil prior to assembly or engine damage may
occur.

The injector camshaft non-scissor gear needs to be fully

Install the injector camshaft non-scissor gear loosely on
The injector camshaft non-scissor gear mounting washer
is larger in diameter than the valve camshaft mounting
washer.

The injector camshaft non-scissor gear is still loose at this
point to allow the adjustable idler gear to be properly
positioned.
Valve Camshaft Gear
CAUTION
The valve camshaft nose and valve camshaft gear
must be clean and dry prior to assembly. Wipe off the
taper surface with a clean lint-free cloth and apply a
thin coat of Loctite 609, Part Number 3823718, to the
inside diameter of the camshaft gear. Use care not to
contaminate the joint with oil prior to assembly or
engine damage may occur.

The valve camshaft gear needs to be fully engaged on the

camshaft nose taper, yet loose enough so it can rotate on
the camshaft nose.
Install the valve camshaft gear loosely on the camshaft
nose taper.
The valve camshaft mounting washer is smaller in
diameter than the injector camshaft scissor gear mounting
washer.

The valve camshaft gear is still loose at this point to allow
the adjustable idler gear to be properly positioned.
Adjust
Backlash (Scissor Gear Combinations)
CAUTION
Do not set backlash between the adjustable idler gear
and the lower scissor idler gear. Severe engine
damage can occur.
This backlash step works with the scissor type injector
camshaft gear and lower idler gear, and the non-scissor
injector camshaft gear with a scissor type lower idler gear.
The injector camshaft scissor gear must still be unloaded
during this step. To unload the gear, two of the gear
Insert, as shown, a narrow shim (0.25 mm [0.010 in]) into
the gear teeth mesh between the adjustable idler gear and
the wide (rear side) gear of the injector camshaft scissor
gear.
Shim Tolerance
mm in
0.225 MIN 0.009
0.275 MAX 0.011
NOTE: The gear backlash set procedure for engines that

have a non-scissor injector camshaft gear and a scissor
type lower idler gear is the same as that of engines that
utilize two scissor type gears.
Use hand pressure, only, to move the adjustable idler
gear toward the center of the engine (into mesh), so there
is no gap on either side of the shim.
Both of the camshaft gears will rotate slightly on the
camshafts during this step.
Slight drag will be felt on the shim while pulling the shim
in and out.
Backlash (Non-Scissor Gear Combinations)

Removal of the lower front cover is not required when
setting the gear backlash on engines that utilize all non-
scissor gears. An access hole is provided to insert a shim
between the lower non-scissor idler gear and the
adjustable idler gear. The access hole is sealed with a
plug. The plug can be pushed out from the rear side
without removing the gear cover.
The following procedure will be shown with the lower gear
cover removed.
Insert, as shown, a shim (0.25 mm [0.010 in]) into the gear

teeth mesh between the adjustable idler gear and the
injector camshaft gear. The shim is inserted on the load
side of the gear teeth.
teeth mesh between the adjustable idler and the lower
non-scissor idler gear. The shim is inserted on the load
gear so there is no gap between the teeth and either side
of the shims.
in and out.

While holding the adjustable idler gear in position, tighten
the adjustable idler gear mounting capscrews.
Torque Value:
above.
Remove the feeler gauge.
CAUTION
Load the injector camshaft scissor gear by tightening all
of the gear screws.
The valve camshaft gear will rotate slightly on the valve
camshaft during this step.
Tighten the injector camshaft scissor gear retaining

capscrew.
Torque Value:
Step 1 136 Nm [ 100 ft-lb ]
Step 2 Rotate an additional 90 degrees
Loosen the capscrew 360 degrees and tighten again using
the toruqe-plus-angle method.
Torque Value:
Step 1 136 Nm [ 100 ft-lb ]

Use hand pressure only to rotate the injector camshaft
gear clockwise until the gear train backlash is taken up.
Obtain tooth-to-tooth contact between the crankshaft gear
and the injector camshaft gear.
Tighten the injector camshaft non-scissor gear retaining

capscrew.
Torque Value:
Step 1 136 Nm [ 100 ft-lb ]
Torque Value:
Step 1 136 Nm [ 100 ft-lb ]
Valve Camshaft Scissor Gear

Tighten the valve camshaft scissor gear retaining
capscrew.
Valve Camshaft Non-Scissor Gear

Use hand pressure, only, to rotate the valve camshaft
gear counterclockwise until the backlash between the
injector camshaft gear is taken up. Obtain tooth-to-tooth
contact between the injector camshaft gear and the valve
camshaft gear.
Tighten the valve camshaft non-scissor gear retaining

capscrew.
Coat the entire gear train with clean 15W-40 oil.
Use the access hole in the lower gear cover to lubricate

the lower idler gear and crankshaft.
Signature, ISX, and QSX15 Eng [...] Air Compressor
Air Compressor (012-014)

Install
Pin the engine crankshaft. Refer to Procedure 001-088 in
Section 1.
Rotate the gear on the air compressor until the mark on
the gear is in line with the V-notch on the air compressor
housing, located at the three o'clock position as viewed
from the front.
Loctite, Part Number 3824040 or equivalent, must be
used on the capscrews that mount the air compressor to
the gear housing. This seals the threads in the housing.
To evenly distribute the sealant as the capscrew is
torqued, a line of sealant should be placed along the
length of the capscrew.
Install the air compressor and the four capscrews onto the
front gear housing.

Tighten the capscrews again.
Install the air compressor mounting brace and four

capscrews on the block beneath the air compressor. Start
threading all four capscrews.
Air Compressor Coolant Lines Signature, ISX, and QSX15 Eng [...]
Tighten the capscrews on the cylinder block and air

compressor.
Install the air discharge line.

Install the air inlet line.
Tighten the hose clamp.
Install the air governor (if removed). Connect the air
governor pressure signal line. Refer to the OEM service
manual.
Air Compressor Coolant Lines

(012-004)
Install
Use two elbows and run the locking nuts all the way up
prior to installation.
Start threading the elbows into the cylinder head.
Use a 24 mm open-end wrench to position the elbows.
Push the tube nut away from the bell flare on the U-shaped
coolant supply line.
Position the sealing grommet behind the bell flare.
Signature, ISX, and QSX15 Eng [...] Air Compressor Coolant Lines
Install the U-shaped coolant supply line into the coolant

supply elbow.
Verify the bell flare and grommet seat correctly in the
elbow.
Start threading the compression nut onto the elbow.
Install the other end of the coolant supply line into the
grommet in the cylinder block.
Push the tube nut away from the bell flare on the coolant
return line.
Position the sealing grommet behind the bell flare.
Install the coolant return line into the coolant return elbow.
Verify the bell flare and grommet seat correctly in the
elbow.
Start threading the compression nut onto the elbow.
Gear Cover, Lower Signature, ISX, and QSX15 Eng [...]
Install the other end of the coolant return tube into the
grommet in the cylinder block.
Install the capscrews in the two locations designated by

the arrows.
Tighten the capscrews
Tighten the compression nuts and elbow locking nuts.

Install
Install a new strip seal.
Orient the overlap joint to the upper left of the gear
housing as shown.
Use a small amount of RTV at the overlap joint of strip
seal.
NOTE: Do not tighten the capscrews until the new

crankshaft seal is installed. The crankshaft seal must be
installed first to locate the gear cover properly.
Position the lower gear cover with the 15 capscrews.
Hand-tighten the capscrews.
Install a new crankshaft seal. Refer to Procedure 001-023

(Crankshaft Seal, Front) in Section 1.
Tighten the 15 capscrews in the sequence shown.


Install
The position of the front crankshaft seal on the crankshaft
is determined by the position of the lower gear cover.
The lower gear cover is mounted to the gear cover housing
using clearance holes. This allows for slight movement of
the cover when the mounting capscrews are loose.
The unitized crankshaft seal must be centered on the
crankshaft for correct operation.
The seal attaches to the lower gear cover, and must be
installed with the lower gear cover capscrews loose and
the cover free to move.
In order for the seal to be properly centered on the

crankshaft during assembly and maintain its location
during operation, the following installation instructions
must be followed.
The crankshaft seal removal and installation tool correctly
centers the seal and correctly positions the dust seal
portion of the seal on the crankshaft.
Crankshaft Seal, Front Signature, ISX, and QSX15 Eng [...]
CAUTION
Failure to loosen and remove the mounting capscrews
from the gear cover can cause the front crankshaft
seal to be misaligned and cause premature seal wear.
The front gear cover must be aligned as follows:
Removing the gear cover mounting capscrews around the
crankshaft seal allows the replacer plate to set against the
gear cover during seal installation.
Remove the gear cover mounting capscrews around the
crankshaft seal.
Loosen the remaining mounting capscrews on the gear
cover so the cover can move freely.
CAUTION
Failure to follow the installation and tightening
sequence can lead to the crankshaft seal being off
center and installed at the wrong depth causing
premature seal wear.
CAUTION
Never use a hammer or mallet to install the seal. Use
of a hammer can damage the crankshaft seal and/or
crankshaft.
The seal removal and installation tool has provisions for
any seal nut orientation, although one seal nut must
always be located at the 11 o'clock position.
Do not use lubricants on the crankshaft seal.
Position the crankshaft seal (1) onto the crankshaft until
the gear cover studs are protruding through the seal
carrier mounting holes.
Place the replacer plate (1) against the crankshaft seal.

Make sure the welded nuts on the front crankshaft seal
are seated in their respective slots on the replacer plate
(1).
The large notch between the teeth must bridge the raised
gear cover surface.
Install three washers (4) and capscrews (5) through the

three slots in the replacer plate (1) and into the crankshaft
end.
The capscrews in the replacer plate must be equally
spaced. This allows the crankshaft seal to be installed
correctly.
Tighten the capscrews hand-tight.
CAUTION
The crankshaft seal must be pressed evenly. If the
crankshaft seal is not pressed in evenly the seal can
be damaged.
Inspect the crankshaft seal during installation to make
certain it is being pressed evenly.
Tighten the capscrew(s) no more than of a revolution at
a time, alternating in a clockwise pattern until the replacer
plate (1) bottoms out against the face of the lower gear
cover.
To maintain the cover position while the replacer plate is

removed, tighten the two gear cover mounting capscrews,
as indicated by the arrows in the graphic.
Install the crankshaft seal mounting nuts (1) through the
holes provided in the replacer plate.
Tighten the mounting nuts in the sequence shown.
Install all the gear cover mounting capscrews.

The torque sequence must be followed to prevent the
gear cover strip seal from squeezing out of the groove.

Install
Install a new strip seal. Orient the overlap at the top and
center of the gear housing.
Use a small amount of RTV at the overlap joint of the strip
seal.
WARNING
Install the cover with 16 capscrews.


seal.
WARNING
Install two guide pins in the gear housing.
Install the front gear cover over the guide pins.
Install the clamping plate, if used.
Install 14 capscrews.
Remove the two guide pins and install the last two
capscrews.

Install
Make sure the mounting surfaces of the crankshaft nose,
vibration damper, and the pulley are clean, dry, and free
from burrs.
Install two guide studs into the crankshaft nose.
Align the dowel pin in the crankshaft wit the dowel hole in
the vibration damper.
Install the vibration damper, pulley, and clamping plate
onto the guide plate.
Use clean 15W-40 oil to lubricate the capscrew threads.

Remove the two guide studs and install the remaining
capscrews.
Tighten the capscrews in a star pattern.

Fan or PTO
vibration dampers, mounting spacer, and pulley are clean,
dry, and free from burrs.
Install one of the vibration dampers (1), mounting spacer

(2), second vibration damper (3), and the pulley (4) onto
the guide studs.
Lubricate the capscrew threads with clean 15W-40 oil.

Install four capscrews.
Remove the two guide studs and install the remaining two
capscrews.
Tighten the six capscrews in a star pattern.
Install the crankshaft adapter (1).

Make sure the crank shaft adapter sets flush against the
pulley (2).
Install the six capscrews and tighten in a star pattern.

Fan or PTO

the guide studs.

Remove the two guide studs and install the two remaining
capscrews.
Tighten the 12 capscrews in a star pattern.
Injector Signature, ISX, and QSX15 Eng [...]
Eccentricity Check
All Applications
Clean the outside surface of the vibration damper.
To measure the vibration damper eccentricity (out of
round), install a dial indicator onto the gear cover as
indicated.
Rotate the crankshaft with the accessory driveshaft one
complete revolution (360 degrees), and record the total
indicator movement.
Vibration Damper Eccentricity

mm in
0.28 MAX 0.011
If the vibration damper is not within specifications, it
must be replaced.
Wobble Check
All Applications
To measure wobble (face alignment), install a dial
indicator as shown.
Push the crankshaft to the front or rear of the engine and
set the indicator to 0 (zero).
Rotate the crankshaft one complete revolution (360
degrees) while maintaining the position of the crankshaft,
either toward the front or rear of the engine.
Record the total indicator movement.
Vibration Damper Wobble Measurement

mm in
0.28 MAX 0.011
must be replaced.
Injector (006-026)
Install
Use clean 15W-40 lubricating oil to lubricate the o-rings.
Signature, ISX, and QSX15 Eng [...] Rocker Lever Assembly
CAUTION
Make sure the injector hold down clamp is properly
aligned before tightening the capscrew. It is possible
for the clamp to contact a nearby ledge, and result in
low clamp load.
Install the injector into the cylinder head.
Install the injector clamp and the capscrew with washer.
Tighten the capscrew.
Install the crossheads.
Rocker Lever Assembly (003-009)

Install
Install the adjusting screw and locknut into each rocker
lever. Do not tighten the locknuts.
Install the injector rocker levers on the shaft.

Install the exhaust (1), intake (2), and engine brake (3)
rocker levers onto the shaft.
WARNING
Clear the rocker lever assembly mounting capscrew
holes of oil and debris. Extensive engine damage can
result if this warning instruction is not followed.
Install the valve crossheads.
Position the valve/brake rocker lever assemblies onto the
cylinder head.
CAUTION
To reduce the possibility of valve rocker shaft damage
due to inadequate brake rocker lever running
clearance, follow the specified procedure to seat the
valve rocker shafts on the cylinder head pedestals (1).
Each valve rocker shaft must be seated in the cylinder
head pedestals prior to tightening the rocker shaft
capscrews.
The front and rear rocker lever shaft assemblies will seat
separately as the engine is rotated in the clockwise
direction.
Use the compressor drive or barring device to bar the

engine over in the direction of rotation, clockwise as
viewed from the front of the engine.
Align the A mark on the vibration damper with the timing
mark on the gear cover.
Either the front or the rear rocker shaft assembly will be

fully seated on the cylinder head pedestals at this point.
Check the position of the front and rear valve rocker shaft
assemblies to determine which one is fully seated.
Lubricate the capscrews of the fully seated rocker shaft
with clean 15W-40 oil.
Signature, ISX, and QSX15 Eng [...] Rocker Lever Assembly
CAUTION
because of inadequate brake rocker lever running
clearance, follow the specified capscrew torque
procedure. The valve rocker lever shaft has a
machined flat on the front of the shaft to provide
proper brake rocker lever position. Therefore, the
front rocker shaft capscrew (1) must be tightened first
to control brake rocker lever position. Brake lever
running clearance must always be checked after valve
rocker lever shaft installation.
Check the brake running clearance. Refer to Procedure
003-004.
Tighten the front mounting capscrew for the fully seated
valve rocker lever shaft to the initial torque value to locate
the shaft.
Tighten all the capscrews to the final torque value using
the torque plus angle method. Tighten the capscrews from
the center out.
Step2 Rotate 60 degrees

viewed from the front of the engine.
Align the B mark on the vibration damper with the timing
mark on the gear cover.
The remaining rocker shaft will be fully seated at this point.
Lubricate the capscrews of the fully seated rocker shaft
with clean 15W-40 oil.
CAUTION
because of inadequate brake rocker lever running
clearance, follow the specified capscrew torque
procedure. The valve rocker lever shaft has a
machined flat on the front of the shaft to provide
proper brake rocker lever position. Therefore, the
front rocker shaft capscrew must be tightened first to
control brake rocker lever position. Brake lever
running clearance must always be checked after valve
rocker lever shaft installation.
Check the brake running clearance. Refer to Procedure
003-004.
Tighten the front mounting capscrew for the remaining
valve rocker lever shaft to the initial torque value to locate
the shaft.
Tighten all the capscrews to the final torque value using
the torque plus angle method. Tighten the capscrews from
the center out.
Position the injector rocker lever assemblies onto the

cylinder head.
Lubricate the injector rocker lever shaft capscrews with
clean 15W-40 oil. Install the capscrews and washers.
Tighten all the mounting capscrews.
Loosen capscrews one at a time 360 and tighten again,

using the torque-plus-angle method. Tighten capscrews
from center out.
Adjust the valve, injectors, and brake.
Refer to Procedure .
Signature, ISX, and QSX15 Eng [...] Overhead Set
Overhead Set (003-004)

Measure
General Information
All overhead lash measurements must be made when the
engine is cold. Stabilized coolant temperature must be at
60C [140F] or below.
Remove the rocker lever cover. Refer to Procedure

003-011 (Rocker Lever Cover) in Section 3.
Make sure the engine base timing is properly set before
attempting to measure, adjust, or set the overhead. Refer
to Procedure 001-088 (Engine Base Timing) in Section 1.
Early engine vibration dampers are marked with BRAKE

SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4. The engine
brakes must be set at the appropriate mark on these
engines. Newer engine vibration dampers are marked
with only A, B, or C, and are adjusted with the valves and
injector on the same cylinder.
Locate the valve set marks on the outside of the vibration
damper.
The set marks are A, B, and C:
Set to mark A to adjust cylinder 1 or 6.
Set to mark B to adjust cylinder 2 or 5.
Set to mark C to adjust cylinder 3 or 4.
Two complete revolutions are required to set all valves,
engine brakes, and injectors.
If the engine is equipped with an air compressor:

Remove the oil fill connector from the lower gear case
cover.
Insert a 3/4-inch drive ratchet and extension into the air
compressor drive.
Rotate the air compressor drive clockwise, as viewed
from the front of the engine.
Overhead Set Signature, ISX, and QSX15 Eng [...]
WARNING
Do not pull or pry on the fan to manually rotate the
engine. To do so can damage the fan blades.
Damaged fan blades can cause premature fan failures
which can result in serious personal injury or property
damage.
The crankshaft rotation is clockwise, as viewed from the
front of the engine.
The cylinders are numbered from the front of the engine
(1-2-3-4-5-6).
The engine firing order is 1-5-3-6-2-4.
If the engine is not equipped with an air compressor:

Loosen the cover plate capscrews and rotate the cover or
remove the oil fill tube, if equipped.
Use a 1 inch socket to push the barring gear into the

gear mesh and rotate the barring adapter
counterclockwise to bar the engine.
Rock the barring device back and forth until it disengages.
Each cylinder has four rocker levers:

The exhaust valve rocker lever (1)
The injector rocker lever (2)
The intake valve rocker lever (3)
The engine brake rocker lever (4).
The intake valve rocker lever is always the long lever on
the valve rocker lever shaft.
The valves, brakes, and the injectors on the same cylinder
are adjusted at the same index mark on the vibration
damper.
Injector and Valve Adjustment Sequence

Bar Engine
Set Set Set
in Pulley
Cylinder Cylinder Cylinder
Direction Position
Injector Valve Brake
of Rotation
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Firing Order: 1-5-3-6-2-4
NOTE: For illustrative purposes, position A is shown as

the first step. It is not necessary to start with position A,
as long as the proper sequence is followed.
engine over in the direction of engine rotation,
clockwise as viewed from the front of the engine. Align
the A mark on the vibration damper with the pointer on the
gear cover.
Check the valve rocker levers on the given cylinder to see

if both intake and exhaust valves are closed.
Both sets of valves are closed when the rocker levers and
the brake lever are loose. If both sets of valves are not
closed, rotate the compressor drive gear one complete
revolution, and align the A mark on the front damper with
the pointer again.
Valve Lash
Use feeler gauges to measure the amount of clearance
(lash) between the crosshead and the rocker lever nose.
Measure and record the intake, exhaust, and brake valve
lash. If the valve lash is not within the specifications listed
below, the valve must be adjusted. See the adjust step in
this procedure.
Press the brake lever down to verify the camshaft follower
is in contact with the camshaft prior to measurement of
the brake lash.
ISX, QSX Series Valve Lash Recheck Limits

Intake 0.23 mm minimum 0.006 in
Intake 0.48 mm maximum 0.019 in
Exhaust 0.56 mm minimum 0.022 in
Exhaust 0.81 mm maximum 0.032 in
Brake 6.87 mm minimum 0.271 in
Brake 7.13 mm maximum 0.281 in
Brake Running Clearance

Rotate the brake lever to the detent (neutral) position.
Check the clearance between the engine brake actuator
piston and the cross head guide pin (1). If the brake
running clearance is not within the specifications listed
below, the running clearance must be adjusted. See the
Adjust step in this procedure.
Brake Running Clearance

mm in
0.635 MIN 0.025
2.79 MAX 0.110
Injector Lash
There is no service procedure to check the injector free
load.
Install the rocker lever cover. Refer to Procedure 003-011
(Rocker Lever Cover) in Section 3.
Adjust
Read the entire procedure for overhead adjustment before
attempting to perform this operation.
Valves, injectors, and engine brakes (if equipped) must
be correctly adjusted for the engine to operate efficiently.
Valve, injector, and engine brake adjustment must be
performed using the values listed in this section.
After an engine rebuild or any major repair where the
injector and valve setting must be disturbed, set all of the
valves, injectors, and brakes.
Valve, Brake, and Injector Adjustment Values

Injector Adjustment is 8 Nm [70 in-lb]
Intake Valve 0.35 mm [0.014 in]
Exhaust Valve 0.68 mm [0.027 in]
Engine Brake 7.00 mm [0.276 in]

Locate the valve set marks on the outside of the vibration
damper.
The set marks are A, B, and C:
Set to mark A to adjust cylinder 1 or 6.
Set to mark B to adjust cylinder 2 or 5.
Set to mark C to adjust cylinder 3 or 4.
Two complete revolutions are required to set all valves,
engine brakes, and injectors.
If the engine is equipped with an air compressor:

Remove the oil fill connector from the lower gear case
cover.
Insert a 3/4-inch drive ratchet and extension into the air
compressor drive.
Rotate the air compressor drive clockwise, as viewed
from the front of the engine.
WARNING
Do not pull or pry on the fan to manually rotate the
engine. To do so can damage the fan blades.
Damaged fan blades can cause premature fan failures
which can result in serious personal injury or property
damage.
The crankshaft rotation is clockwise as viewed from the
front of the engine.
The cylinders are numbered from the front of the engine
(1-2-3-4-5-6).
The engine firing order is 1-5-3-6-2-4.
If the engine is not equipped with an air compressor:

Loosen the capscrews and rotate the cover or remove the
oil fill tube, if equipped.
Use a 1 inch socket to push the barring gear into the

gear mesh and rotate the barring adapter
counterclockwise to bar the engine.
Rock the barring device back and forth until it disengages.
Each cylinder has four rocker levers:

The exhaust valve rocker lever (1)
The injector rocker lever (2)
The intake valve rocker lever (3)
The engine brake rocker lever (4).
The intake valve rocker lever is always the long lever on
the valve rocker lever shaft.
The valves, brakes, and injectors on the same cylinder are
adjusted at the same index mark on the vibration damper.

Bar Engine
Set Set Set
in Pulley
Direction Position
of Rotation
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
NOTE: For illustrative purposes, position A is shown as

the first step. It is not necessary to start with position A,
as long as the proper sequence is followed.
engine over in the direction of engine rotation,
clockwise as viewed from the front of the engine. Align
the A mark on the vibration damper with the pointer on the
gear cover.

the pointer again.
Loosen the injector adjusting screw locknut on the

cylinder.
Do not use a click-type torque wrench.
Use a dial-type torque wrench with a range of 0 to 150 in-
lb to tighten the injector rocker lever adjusting screw. If the
screw chatters during setting, repair the screw and lever
as required.
Back out the adjusting screw one or two turns.
Hold the torque wrench in a position that allows you to look
in a direct line at the dial. This is to make sure the dial will
be read accurately.
Make sure the parts are aligned, and squeeze the oil out
of the valve and injector train by tightening the adjusting
screw.
Use this initial adjustment to preload the valve train and
injector.
Tighten the injector lever adjusting screw.

Back the adjusting lever screw out 1 or 2 turns.
Tighten the injector lever adjusting screw.
Hold the injector lever adjusting screw and tighten the

adjusting screw locknut.
After setting the injector on a cylinder, set the valves and

engine brakes on the same cylinder.
with only A, B, or C, and are adjusted with the valve and
With the set mark aligned with the pointer on the gear
cover and both sets of valves closed on the cylinder,
loosen the locknuts on the intake and exhaust valve
adjusting screws.
Back out the adjusting screws one or two turns.
Select a feeler gauge for the correct valve lash

specification.
Valve Lash Specification

mm in
Intake 0.36 NOM 0.014
Exhaust 0.69 NOM 0.027
Insert the feeler gauge between the top of the crosshead
and the rocker lever nose pad.
Make sure the feeler gauge is completely under the
pivoting rocker lever nose pad.
Tighten the adjusting screw.

Torque Value: 0.6 Nm [ 5 in-lb ]
Use a torque wrench and crows foot adapter to tighten the

locknut.
Hold the adjusting screw in this position. The adjusting
screw must not turn when the locknut is tightened.
After tightening the locknut to the correct torque value,

remove the feeler gauge.
CAUTION
To get maximum brake operating efficiency and to
prevent engine damage, the brake adjustment
instructions must be followed.
For older engines, locate the engine brake set marks on
the outside of the vibration damper.
The set marks are BRAKE SET 1-6, and BRAKE SET 2-5,
and BRAKE SET 3-4.
BRAKE SET 1-6: Cylinder 1 or 6 adjust

viewed from the front of the engine. Align the A mark on
the vibration damper with the pointer on the gear cover.
For illustrative purposes, position A is shown as the first
step. It is not necessary to start with position A, as long
as the proper sequence is followed.

the pointer again.
Press the engine brake lever down to verify the camshaft

follower is in contact with the camshaft.
Loosen the locknut on the brake lever adjusting screw,

and back out the adjusting screw one turn.
Insert the feeler gauge, Part Number 3163530, between
the bottom of the engine brake piston and the top of the
exhaust valve pin on the exhaust valve crosshead.
Brake Lever Lash Specification

mm in
7.00 NOM 0.276
Tighten the adjusting screw until drag on the feeler gauge

is felt. Proper drag means that there is no motion of the
brake lever camshaft follower against the cam lobe.
Hold the engine brake lever adjusting screw and tighten

the locknut.
CAUTION
Engine damage can occur if the running clearance is
not within specifications.
Check the running clearance:
1. Rotate the engine brake rocker lever to the detente
(neutral) position.
2. Check the clearance (1) between the engine brake
lever actuator piston and the crosshead guide pin.
Engine Brake Rocker Lever Running Clearance

mm in
0.635 MIN 0.025
2.790 MAX 0.110
If the running clearance does not meet specification,
loosen, but do not remove the rocker shaft capscrews,
and rotate the shaft in the direction required to bring the
running clearance within the listed specification. It is
critical that this clearance be set and verified on all six
brake levers. Engine damage can result if this task is
not completed.
Check the brake running clearance.
The rocker lever shafts must be adjusted so that all three
engine brake levers fall within the given running clearance
specification.
Repeat the process to adjust all injectors, engine brakes,
and valves according to the chart shown below.

Bar Engine
Set Set Set
in Pulley
Direction Position
of Rotation
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Water Pump (008-062)

Install
CAUTION
Do not use petroleum based lubricants. Petroleum
based lubricants cause the o-ring seals to crack,
leading to a coolant leak.
Lubricate and install the new o-ring seal.
Install the two guide studs.
Install the water pump and three capscrews.

mounting capscrews.

Install a new o-ring seal in the water inlet.
CAUTION
Install a new o-ring seal in the water pump outlet groove.
Apply a thin layer of non-petroleum-based lubricant, such
as vegetable oil, to both o-ring seals.
Use clean engine oil to lubricate the threads and bottom

of the capscrew heads of all the water pump capscrews.
Install the water pump and two lower capscrews.
Tighten the capscrews to hold the pump in place.
NOTE: Some configurations do not use the middle

aluminum belt tensioner bracket shown. Refer to
Procedure for the appropriate tensioner bracket
installation.
Install the belt tensioner bracket, if equipped, and
capscrews in the location shown.
Finger tighten all capscrews.
Tighten the water pump mounting capscrews in the

sequence and values shown.
Torque Value:
Capscrews 1, 2, 58 Nm [ 43 ft-lb ]
and 3
Capscrews 4 and 72 Nm [ 53 ft-lb ]
5
All Capscrews, 72 Nm [ 53 ft-lb ]
Engines Without
Belt Tensioner
Bracket

CM570
Install a new o-ring seal in the water inlet.
CAUTION
Install a new o-ring seal in the water pump outlet groove.
Apply a thin layer of non-petroleum-based lubricant, such
as vegetable oil, to both o-ring seals.
Use clean engine oil to lubricate the threads and bottom

of the capscrew heads of all the water pump capscrews.
Position the water pump on the engine.
Install the bottom two capscrews finger tight.
NOTE: Some configurations do not use the middle

aluminum belt tensioner bracket. Refer to Procedure
008-088 for the appropriate tensioner bracket installation.
NOTE: Early engines that did not have a slotted hole on
the middle aluminum belt tensioner idler bracket required
the vibration dampers to be removed to remove and install
the water pump.
Install the belt tensioner bracket, if equipped, and the
capscrews in the locations shown.
Finger tighten all capscrews.
Tighten the water pump mounting capscrews in the

sequence and values shown.
Torque Value:
Capscrews 1, 2, 58 Nm [ 43 ft-lb ]
and 3
Capscrews 4 and 72 Nm [ 53 ft-lb ]
5
All Capscrews, 72 Nm [ 53 ft-lb ]
Engines Without
Belt Tensioner
Bracket
Align the idler pulley (1) and the shaft of the pilot adapter
(2) with the belt tensioner bracket (3) using the guide pin
on the pilot adapter (4), if equipped.
Install the belt idler pulley and shaft on the belt idler
bracket using one washer and capscrew.
Install the dust seal.
Signature, ISX, and QSX15 Eng [...] Refrigerant Compressor Mounting Bracket
CAUTION
Do not use petroleum based lubricants, petroleum
based lubricants cause the o-ring to crack or swell,
Install a new water pump inlet o-ring seal and a new EGR
tube outlet o-ring seal.
Install the five water pump housing capscrews.
Install the two bracket capscrews.
Install the EGR tube outlet capscrew.
Water Inlet Connection (008-082)

Install
Replace the o-ring and gasket.
Install the gasket, water inlet connection, and the four
capscrews.
Install the coolant hoses.
Refrigerant Compressor Mounting

Bracket (009-055)
Install
Sanden
Install the two mounting capscrews and the refrigerant
compressor mounting bracket.
Refrigerant Compressor Mounting Bracket Signature, ISX, and QSX15 Eng [...]

Install the refrigerant compressor mounting bracket to the
refrigerant compressor. The refrigerant compressor is
positioned on top of the bracket ledge.
Install the four mounting capscrews and the refrigerant
compressor bracket.

Before installation, inspect the refrigerant compressor
bracket to make sure the mounting spacers are installed
properly.
Install the refrigerant compressor bracket on the gear

housing with two long capscrews.
Position both links in the assembly with the part number

facing outward.
Insert one capscrew through the elongated hole in the
long link and attach the long link to the left side of the
refrigerant compressor bracket.
Insert one capscrew through the small hole in the short
link and attach the short link to the right side of the
refrigerant compressor bracket.
Signature, ISX, and QSX15 Eng [...] Alternator/Refrigerant Compressor Mounting Bracket
Alternator/Refrigerant Compressor
Mounting Bracket (009-056)
Install
Install the wire harness jumper to the alternator/refrigerant
compressor mounting bracket.
Tap the split washers out slightly. This will ease the
installation.
Install the alternator/refrigerant compressor mounting
bracket to the gear housing.
Install the five mounting capscrews.

Torque Value:
(1, 2 3 and 4) 36 Nm [ 27 ft-lb ]
(5) 56 Nm [ 41 ft-lb ]

The alternator/refrigerant compressor mounting bracket
mounts to the gear housing at the top and the water pump
at the bottom.
Install the bracket and six mounting capscrews.
Tighten the capscrew that threads into the gear housing.
Tighten the short capscrew (1).

Tighten the remaining capscrews (2, 3, 4, and 5).
Torque Value:
(1, 2, 3, 4, and 5) 34 Nm [ 25 ft-lb ]
Coolant Thermostat Signature, ISX, and QSX15 Eng [...]
Alternator (013-001)
Install
Driven by Cooling Fan Drive Belt
Install the alternator and the four mounting capscrews.
No alignment is required for the alternator to the alternator
bracket.

Install the alternator, capscrew, washer, and nut to the
alternator mounting bracket. Tighten the nut.
Install the adjusting link and mounting capscrews. Tighten
the capscrews.
Coolant Thermostat (008-013)

Install
Install the two thermostats into the thermostat housing
cover by pushing on the outer rims.
Install the thermostat housing cover, gasket, and four

capscrews on the cylinder head.
Tighten the capscrews to the values shown.
Torque Value:
Short Capscrews 34 Nm [ 25 ft-lb ]
Long Capscrews 56 Nm [ 41 ft-lb ]
Signature, ISX, and QSX15 Eng [...] Coolant Thermostat
Connect the vent line. Refer to the OEM instructions.

Connect the coolant sensor connector.
Industrial engines use a thermostat housing cover with

either a cover plate or a water connection.
If removed, tighten the capscrews to the following
specification.
Install the upper radiator hose. Tighten the hose clamp.

Coolant Thermostat Housing Signature, ISX, and QSX15 Eng [...]
Coolant Thermostat Housing (008-014)

Install
Single Thermostat
To reduce the possibility of a coolant leak, the 90-degree
elbow on the thermostat housing must be positioned
appropriately and tightened before the thermostat housing
is installed on the cylinder head.
Use two thermostat housing capscrews to align the
thermostat housing.
Install the thermostat housing, gasket, and three
capscrews to the cylinder block.
Tighten the three thermostat housing mounting
capscrews.
Install the thermostat into the thermostat housing cover by

pushing on the outer rim.

capscrews.
Signature, ISX, and QSX15 Eng [...] Coolant Thermostat Housing
Dual Thermostat
Use two thermostat housing cover capscrews to align the
thermostat housing.
Install the thermostat housing, gasket, and two capscrews
on the cylinder head.
Tighten the two thermostat housing capscrews.
Remove the two thermostat housing cover capscrews
used as guides.
Install the two thermostats into the thermostat housing

cover by pushing on the outer rims.

capscrews on the cylinder head.
Torque Value:
Short capscrews 34 Nm [ 25 ft-lb ]
Long capscrews 56 Nm [ 41 ft-lb ]
Connect the vent line. Refer to the OEM instructions.

Connect the coolant sensor connector.
Engine Lifting Brackets Signature, ISX, and QSX15 Eng [...]
Install the upper radiator hose.

Industrial engines use a thermostat housing cover with

either a cover plate or a water connection.
Install the thermostat cover if removed.
Automotive has a similar design with connector for
transmission cooler.
Engine Lifting Brackets (016-001)

Install
Install the front bracket and four capscrews.
Install the rear bracket and four capscrews.
Lubricating Oil Cooler (007-003)

Install
All Applications
WARNING
When installing a new two-element oil cooler on an older
engine, be sure the cooler element mounting capscrews
do not interfere with the cylinder block.
Install the guide pins.
Remove the protective plugs from the oil passages. Make
sure no debris enters the lubrication system. Using a clean
shop towel, carefully wipe out the oil passages and inspect
to make sure no debris is left in these passages.
Install a new mounting gasket and the oil cooler housing
assembly.
Remove the guide pins and install the two capscrews.

Tighten the capscrews in a circular motion from the center
out.
EGR Cooler (011-019)

Install
Install a new hose onto the rear EGR connection tube and
install the hose clamps.
Install new o-rings on the coolant supply and vent tubes

on the EGR cooler and the jumper tubes.
Use clean engine coolant, soapy water, or vegetable oil to
lubricate the o-rings for easier installation.
Install the coolant supply and the vent jumper tubes onto
the EGR cooler.
Align the coolant supply and vent tubes to the
corresponding openings on the block.
Install the EGR cooler on the studs in the lubricating oil
cooler assembly.
Install a new gasket on the pilot end of the EGR cooler

where it connects to the EGR cooler connection.
Apply a film of high-temperature anti-seize compound to
the inside of the v-band clamp, to make sure of proper
loading on the clamp.
Install a v-band clamp.
Install and hand tighten the four mounting nuts and

capscrews. Tighten the capscrews and nuts in the
sequence shown.
Torque Value:
Capscrews 47 Nm [ 35 ft-lb ]
Torque Value:
Nuts 23 Nm [ 204 in-lb ]
Connect the EGR cooler to the new hose on the rear EGR
connection tube.
Tighten the hose clamps.

Torque Value:
Breeze Clamp (1) 7 Nm [ 62 in-lb ]
Torque Value:
Normal Clamp (2) 5 Nm [ 44 in-lb ]
Tighten the v-band clamp between the EGR cooler

connection and the EGR cooler.
CAUTION
Keep all protective caps on the EGR cooler in place
while grinding clearance in the upper mounting
bracket. Failure to do so could cause progressive
damage to the engine once the EGR cooler is
installed. It's important to prevent any debris from
entering the cooler.
Inspect for an interference fit between the upper EGR
cooler mounting bracket and the lower portion of the
exhaust manifold flange. If this interference is present,
grind a clearance on the upper EGR cooler mounting
bracket in the area shown in the illustration.

the inside of the v-band clamp, to make sure of proper
loading on the clamp.
Install a v-band clamp onto the exhaust manifold front
section.
Install a new gasket on the pilot end of the EGR cooler
where it connects to the exhaust manifold front section.
Install the EGR cooler on the studs in the lubricating oil
cooler assembly.
Install the EGR cooler bracket clamping plates.
Install the four EGR cooler mounting capscrews at the top

of the EGR cooler mounting bracket.
Install and hand tighten the four mounting nuts. Tighten
the capscrews and nuts in the sequence shown.
Torque Value:
Capscrews 47 Nm [ 35 ft-lb ]
Torque Value:
Nuts 23 Nm [ 204 in-lb ]
CAUTION
Do not use air tools to remove or install the nut on the
v-band clamp. Use of these tools can seriously
damage the threads or the bolt and cause the clamp
to not be able to be reused.
Position the v-band clamp onto the EGR cooler inlet
connection.
Tighten the two retaining capscrews on the rear EGR

connection tube.
Signature, ISX, and QSX15 Eng [...] EGR Connection Tubes
EGR Connection Tubes (011-025)

Install
Part Number 4919403 and Part Number 4919425, at the
end of the rear EGR connection tube that interfaces with
the EGR cooler before working the tube into position, to
reduce the possibility of introducing dirt or debris.
Install the p-clips onto the rear EGR connection tube.
Make sure the tube insulation is properly and fully located
under the p-clips and that the p-clip rubber sleeve does
not block the mounting hole.
Install the rear EGR connection tube and the p-clip
mounting capscrew and nuts.
Hand-tighten the capscrew and nuts.
Remove the protective caps from the component.

Install a new hose with the hose clamps loosely attached
between the rear EGR connection tube and the EGR
cooler.
Tighten the p-clip mounting capscrews, nuts, and hose
clamps.
Torque Value:
M10 P-clip nut 46 Nm [ 34 ft-lb ]
Torque Value:
M8 P-clip nut 23 Nm [ 204 in-lb ]
Torque Value:
P-clip capscrew and nut 45 Nm [ 33 ft-lb ]
Torque Value:
Breeze Clamp (1) 7 Nm [ 62 in-lb ]
Torque Value:
Norma Clamp (2) 5 Nm [ 44 in-lb ]
EGR Connection Tubes Signature, ISX, and QSX15 Eng [...]

on the rear EGR connection tube where it interfaces with
the front EGR connection tube.
Install the p-clips onto the front EGR connection tube.
Install the front EGR connection tube and the p-clip
mounting capscrews or nuts. Finger tighten the
capscrews or nuts.
Tighten the p-clip mounting capscrews or nuts and the
hose clamps.
Torque Value:
M10 p-clip nut 46 Nm [ 34 ft-lb ]
Torque Value:
Hose clamps 5 Nm [ 44 in-lb ]
Torque Value:
P-clip capscrew and nut 45 Nm [ 33 ft-lb ]
between the front EGR connection tube and the EGR
mixer.
Tighten the p-clip mounting capscrews, nuts, and clamps.
Torque Value:
P-clip capscrews and nut 45 Nm [ 33 ft-lb ]
Torque Value:
Hose clamps 5 Nm [ 44 in-lb ]

Remove the protective caps from the component.
Apply lubricant to the hose end of the rear EGR
connection tube.
Loosely install the hose clamp and install the rear EGR
connection tube and gasket onto the EGR cooler and EGR
valve mounting bracket.
Tighten the two capscrews.
Make sure the indentation near the end of the hose slides
past the hose bead on the EGR valve mounting bracket.
Position the hose clamp on this indentation groove.
NOTE: Install the protective sleeve onto the exposed
threads of a T-bolt style clamp.
NOTE: Two different types of hose clamps can be used in
this location. The torque value for each clamp is the same,
regardless of which clamp is used.
Signature, ISX, and QSX15 Eng [...] Exhaust Manifold, Dry
Loosen the two rear tail support mounting capscrews.

Install a new press-in place seal on the EGR venturi.
Install the EGR venturi on the air intake connection by
loosely installing all three capscrews. Hand-tighten all five
capscrews.
In order to reduce assembly stress, tighten the capscrews
in the following sequence:
Tighten the two front EGR venturi mounting capscrews.
Tighten the rear EGR venturi mounting capscrews.
Tighten the two rear tail support mounting capscrews.
Apply lubricant to the hose end of the front EGR

connection tube and the EGR venturi inlet.
Slide the new EGR connection hose on the EGR venturi
inlet and loosely install both retaining clamps.
Attach a new EGR gasket to the front EGR connection
tube flange, holding it in place with the two retaining
capscrews.
Insert the hose end of the EGR connection tube into the
EGR connection hose, and align the mounting flange with
the EGR valve outlet.
Install the two retaining capscrews into the EGR valve.
Tighten the capscrews in the following sequence:
Capscrew 1, Capscrew2, Capscrew 1.
Make sure to tighten Capscrew 1 twice.
Center the EGR connection hose evenly between the tube
and the EGR venturi and tighten both retaining clamps.
NOTE: Two different types of hose clamps can be used in
this location. The torque value for each clamp is the same,
regardless of which clamp is used.
Exhaust Manifold, Dry (011-007)

Install
Remove the tape from the open exhaust ports and cylinder
head.
Install two guide studs into the center section mounting
location.
Do not use adhesive, grease, or heavy grease to hold the
gaskets in place on the cylinder head.
Install a new center section gasket.
Exhaust Manifold, Dry Signature, ISX, and QSX15 Eng [...]
Special capscrews with spacers are required for this

particular manifold.
Do not use short capscrews.
WARNING
Install the exhaust manifold over the guide studs.
the capscrew threads to make sure of proper loading on
capscrews.
Slide each manifold gasket between the exhaust manifold
and the cylinder head.
Install the capscrews and spacers through the exhaust
manifold and gasket into the cylinder head.
capscrews.


Install two guide studs into center section mounting
location.
Signature, ISX, and QSX15 Eng [...] Exhaust Manifold, Dry
Install the center mounting gasket over the guide studs.
WARNING
Install the exhaust manifold assembly on the guide pins.
Special capscrews with spacers are required for this

particular manifold.
Do not use short capscrews.
Slide each exhaust manifold gasket between the manifold

and cylinder head.
Insert the exhaust manifold mounting capscrews and
spacer through the manifold and gasket and start
capscrews into the cylinder head.
EGR Valve Mounting Bracket Signature, ISX, and QSX15 Eng [...]
To aid in future capscrew removal, apply a film of high-

temperature anti-seize compound to the capscrew
threads.
Remove the guide studs and install the remaining two
capscrews.

Torque values given have been established using anti-
seize compound as a lubricant.
Exhaust Gas Pressure Sensor Adapter

(011-033)
Install
All Applications
Install the sensor adapter and the p-clamp mounting
capscrew.
EGR Valve Mounting Bracket (011-044)

Install
Install the EGR valve mounting bracket onto the engine
block and the EGR valve mounting bracket rear support.
Install three capscrews into the engine block and the rear
support.
Tighten the two EGR valve mounting bracket capscrews
first (1).
Tighten the rear support bracket capscrew into the back
of the engine block (2).
Signature, ISX, and QSX15 Eng [...] EGR Valve
Exhaust Gas Pressure Sensor Tube

(011-027)
Install
Apply a film of high temperature anti-seize compound to
the threads of the tube nuts.
Install the tube.
Connect and tighten the tube nuts.
EGR Valve (011-022)

Install
Before installing the v-band clamp, coat the clamping
surface with high temperature anti-seize compound.
Install the smaller v-band clamp on the EGR cooler

connection. Do not tighten.
Install the larger v-band clamp on the end of the EGR valve
that connects with the exhaust manifold. Do not tighten.
Install a new gasket on the piloted end of the EGR cooler
connection.
Install a new gasket on the piloted end of the EGR valve
where it connects to the exhaust manifold.
Install the EGR valve. Position the EGR connection v-band
clamp, as shown, and tighten.

Lubricate the EGR valve seal with clean engine oil.
Install the EGR valve onto the EGR valve mounting
bracket.
EGR Valve Coolant Lines Signature, ISX, and QSX15 Eng [...]
Install the four mounting capscrews into the EGR valve

mounting bracket.
NOTE: The longest capscrew passes through the EGR
valve and EGR valve mounting bracket and threads into
the engine block.
Connect the EGR valve connector.
EGR Valve Coolant Lines (011-030)

Install
Connect the EGR valve coolant lines making sure the
sealing washers are in place on the banjo connector.
Tighten the EGR valve coolant line nut and capscrew.
Signature, ISX, and QSX15 Eng [...] EGR Cooler Coolant Lines
EGR Cooler Coolant Lines (011-031)

Install
CAUTION
Do not use petroleum products on the EGR cooler
coolant line o-rings. The o-rings will swell and cause
the connection to leak.
Install new the o-rings on the EGR cooler coolant return
line.
Lubricate the o-rings with clean engine coolant, soapy
water, or vegetable oil for easier installation.
Install the EGR cooler coolant return line from the EGR
cooler to the thermostat housing.
Tighten the mounting capscrews.
Install the EGR cooler coolant vent line. Attach the rigid
section of the vent line to the EGR cooler and the flexible
section to the EGR cooler coolant return line.
CAUTION
Do not use petroleum products on the EGR cooler
Install the new o-rings on the EGR cooler coolant supply
tubes and jumper connection.
water, or vegetable oil to aid in installation.
EGR Cooler Coolant Lines Signature, ISX, and QSX15 Eng [...]
Install the EGR cooler coolant supply tube mounting

bracket and nuts.
Tighten the nuts.
Insert the EGR cooler coolant supply jumper tube into the
EGR cooler coolant supply tube.
Slide the EGR cooler coolant supply jumper tube into the
EGR cooler inlet.
Install the retaining clamp and capscrew to the EGR
cooler.
NOTE: Do not tighten at this time.
Insert the EGR cooler coolant supply tube into the water
pump outlet.
Install the EGR cooler coolant supply tube retaining clamp
and capscrew.
NOTE: Do not tighten at this time.
Tighten in the following sequence.

Install the EGR cooler coolant supply tube mounting
capscrew and tighten.
Tighten the EGR cooler coolant supply jumper tube
retaining clamp capscrew.
Tighten the EGR cooler coolant supply tube retaining
clamp capscrew.
Signature, ISX, and QSX15 Eng [...] Heat Shield
Install the EGR cooler coolant vent line to the thermostat

housing and the EGR cooler.
Install the o-rings on the coolant return tube jumper tube.

water, or vegetable oil, for easier installation.
Install the jumper tube into the EGR cooler.
Install the press in place seal and the coolant return tube.
Install and tighten the capscrews.
Heat Shield (011-032)

Install
Apply high temperature anti-seize compound onto the
mounting capscrews.
Install the three mounting capscrews and the heat shield.

Apply high temperature anti-seize compound onto the
mounting capscrews.
Install the four capscrews and the heat shield.
Turbocharger (010-033)
Assemble
ISX Automotive with CM570, QSX15 with CM570 and
To install the turbine housing, position the V-band
clamp over the bearing housing and align the ink
marks applied during the disassembly process.
Apply anti-seize compound to the bearing housing
locating bore of the turbine housing.
Carefully slide the bearing and compressor housing
assembly into the turbine housing. Use the ink
alignment mark to locate the turbine housing assembly
in the correct orientation with the turbine housing.
Place the new V-band clamp in the correct orientation and

torque the locknut.
Torque value for Cummins-branded turbochargers.
Torque value for Holset-branded turbochargers.
Loosen the locknut 180 degrees, and torque the locknut.
Torque value for Cummins-branded turbochargers.
Torque value for Holset-branded turbochargers.
Make certain the rotor assembly rotates freely and neither
compressor wheel or turbine wheel is rubbing against the
housing.
Install
ISX Automotive with CM570, QSX15 with CM570, and
Apply a film of high-temperature anti-seize compound,
Part Number 3823097, or equivalent, to the
turbocharger mounting studs.
WARNING
NOTE: If the exhaust manifold and turbocharger were
removed together in order for the turbocharger to clear the
lubricating oil cooler assembly, see the following
procedure for installation of the exhaust manifold. Refer
Install a new mounting gasket, the turbocharger, and the
four mounting nuts.
Tighten the mounting nuts.
Torque value for the standard nut:
Torque value for the Spiralock nut (identified by "SPL"
on the nut flange):
Install the discharge elbow and clamp onto the charge-air

cooler pipe connection.
Do not tighten the clamp until the elbow is installed on the
turbocharger.
If a new turbocharger is being installed, the variable

geometry turbocharger actuator from the original
turbocharger must be reused.
Install a new o-ring, the clamp, and the discharge elbow
to the turbocharger.
Tighten the clamp.
Install a new gasket, oil drain tube, and capscrews.

Install the turbocharger anti-rotation brace (if equipped) .

The end rests on the oil cooler housing.
This brace requires longer, 1.25 mm [0.049 in],
capscrews.
Pour approximately 50 to 60 cc [1.7 to 2 oz] of clean

engine oil into the turbocharger oil supply opening.
CAUTION
Proper routing of the turbocharger oil supply tube is
critical to prevent failure. Avoid any tube-to-metal
contact. (The inlet supply fitting must be oriented
slightly off vertical to allow proper alignment.)
If installing a new turbocharger, make sure the
turbocharger is aligned, loosen the compressor and
turbine v-bands, and adjust as needed. Tighten the v-
bands.
If installing a new turbocharger, install the male union
elbow.
Install the turbocharger oil supply tube on the elbow.
Install the intake and exhaust pipes to the turbocharger.

Tighten the clamp.

Variable Geometry
Part Number 3823097, to the turbocharger mounting
studs.
WARNING
CAUTION
When installing lifting eye, be sure the shoulder of the
lifting eye is bottomed against bearing housing.
Failure to do so can result in failure of lifting eye and
personal injury.
CAUTION
If a lifting eye is installed in turbocharger bearing
housing, it is to be used exclusively for turbocharger
removal and installation. It is not to be used in
removal of the exhaust manifold, or engine. Doing so
will cause damage to the turbocharger.
CAUTION
Do not rotate the turbocharger turbine housing.
Loosening turbine v-band and rotating the turbine
housing can cause damage to internal variable
geometry mechanism.
The capscrew in the top of the turbocharger bearing
housing can be removed and replaced with a lifting eye to
aid in the installation of the turbocharger.
Install a new gasket, the turbocharger, and the four
mounting nuts. Tighten the mounting nuts.
Install the discharge elbow and clamp onto the charge-air

cooler pipe connection.
Do not tighten the clamp until the elbow is installed on the
turbocharger.
Install a new o-ring, the clamp, and the discharge elbow

to the turbocharger.
Tighten the clamp.

Install the intake and exhaust pipes to the turbocharger,

and tighten the clamps.

Part Number 3823097, or equivalent, to the turbocharger
mounting studs and to the flange area on the retaining
nuts. Properly applying anti-seize compound will reduce
the possibility of the nuts loosening over time.
If installing a new turbocharger, install the coolant and oil

fittings into the bearing housing.
NOTE: Use a ratchet and deepwell socket to install these
fittings.
CAUTION
Proper routing of the turbocharger oil supply tube is
critical to prevent failure. Avoid any tube-to-metal
contact.
Install the turbocharger oil supply hose onto the oil supply
fitting. The oil supply hose must point directly downward
in order for it to properly connect to the oil supply fitting
on the lubricating oil filter head.
Install the turbocharger actuator coolant supply and return
fittings into the electronic actuator. Refer to Procedure
WARNING
avoid personal injury, use a hoist or get assistance to
lift this component.
CAUTION
Do not rotate the turbocharger turbine housing.
Loosening turbine v-band and rotating the turbine
housing can cause damage to internal variable
geometry mechanism.
NOTE: Thread a lifting strap around the turbocharger
bearing housing. Take care not to bend the coolant lines
when lifting the turbocharger.
Care must be taken not to damage the turbocharger
compressor inlet air temperature sensor, the turbocharger
speed sensor, and the turbocharger actuator coolant lines
when installing the turbocharger.
Install a new gasket, the turbocharger, and the four
mounting nuts. Tighten the mounting nuts.
Install a new o-ring seal, the clamp, and the discharge

elbow to the turbocharger.
Tighten the clamps.
Signature, ISX, and QSX15 Eng [...] Turbocharger Coolant Hoses

Connect the oil supply hose to the oil supply fitting located
on the lubricating oil filter head.
Tighten the oil supply hose.
Turbocharger Coolant Hoses (010-041)

Install
CAUTION
Do not bend or kink hoses while tightening. Doing so
can damage the hoses.
Install the turbocharger coolant supply hose to the bottom
of the turbocharger and the lubricating oil filter head.
Tighten the fittings.
while tightening the line.
CAUTION
can damage the lines.
Check the face of the coolant fittings on the engine and
on the turbocharger to be sure the o-ring is in place and
is not damaged.
A damaged or missing o-ring will result in a coolant leak.
Install the turbocharger coolant return hose to the top of
the turbocharger and the thermostat housing. Tighten the
fittings.
while tightening the line.
Turbocharger Coolant Hoses Signature, ISX, and QSX15 Eng [...]
Install the tube brace onto the turbocharger coolant return

hose and the air tube.
CAUTION
can damage the hoses.
CAUTION
Do not use petroleum products on the turbocharger
coolant hose o-rings. The o-rings will swell and cause
Install the four new banjo sealing washers on the
turbocharger coolant supply hose.
Lubricate the sealing washers with clean engine coolant,
soapy water, or vegetable oil.
Install the turbocharger coolant supply hose to the
turbocharger bearing housing (3).
turbocharger actuator (2).
lubricating oil filter head (1).
NOTE: Use a second wrench to hold the coolant hose
coupling while tightening the hose.
Tighten the fittings.
Signature, ISX, and QSX15 Eng [...] Turbocharger, Variable Geometry Actuator
CAUTION
can damage the lines.
CAUTION
Do not use petroleum products on the turbocharger
Install four new banjo sealing washers on the turbocharger
bearing housing coolant return hose and turbocharger
actuator coolant return tube.
Install the turbocharger coolant return hose to the
turbocharger. Tighten the fitting.
Install the turbocharger coolant return hose in the
thermostat housing. Tighten the banjo fitting.
Install the turbocharger actuator coolant hose to the
thermostat housing. Tighten the fitting.
It is possible for the turbocharger actuator coolant return
hose to contact the turbocharger coolant return hose
when the fittings are torqued. Be sure to space the hoses
apart while the fittings are torqued. If the hoses are not
spaced apart, hose failure can result.
NOTE: Use a second wrench to hold the coolant line
coupling while tightening the line.
Install the turbocharger actuator coolant hose to the
turbocharger actuator. Tighten the banjo fitting.

Actuator (010-113)
Install
Variable Geometry
WARNING
Keep fingers and hands away from the actuator link to
reduce the possibility of personal injury as a result of
sudden movement when air is supplied.
Use coupling, Part Number 3824843, to apply 414 kPa [60
psi] regulated air pressure to the actuator.
Install the actuator on the turbocharger bearing housing.
Install and tighten the two capscrews.
Aftertreatment Adapter Pipe Signature, ISX, and QSX15 Eng [...]
Install the actuator rod to the turbocharger cross-shaft.

Install the snap ring.
Install and tighten the capscrew.
Aftertreatment Fuel Injector (011-042)

Install
Attach the heat shield to the injector.
Install a new high temperature EZ tie to hold the injector
harness to the heat shield.
Install a new fibrous insulator.
Install a new metal gasket.
NOTE: The fibrous insulator will be against the injector.
Install the aftertreatment injector onto the adapter pipe.
Apply a coat of high temperature anti-seize compound to
the capscrews.
Install the capscrews and spacers.
Aftertreatment Adapter Pipe (011-043)

Install
Install the aftertreatment injector assembly onto the
adapter pipe. Refer to Procedure 011-042 in Section 11.
Install new gaskets on each end of the adapter pipe.
Place the exhaust adapter pipe in position with the pin in
the correct location in the turbocharger.
Tighten the v-band clamps on each end.
Signature, ISX, and QSX15 Eng [...] Turbocharger Control Shutoff Valve Filter Head

Actuator Air Supply Line (010-120)
Install
CAUTION
CAUTION
Do not use thread sealant. The use of thread sealant
will cause damage to the turbocharger control valve.
Mask both ends of the turbocharger actuator supply line
before installing.
Install the turbocharger actuator air supply line.
Connect the air supply line to the turbocharger air control

valve.
Connect the p-clip to the thermostat housings.
Connect the air supply line to the turbocharger actuator.
Start and run the engine.
Verify proper operation.
Check for air leaks.
Turbocharger Control Shutoff Valve

Filter Head (010-115)
Install
Variable Geometry
Install the two mounting capscrews and the turbocharger
control shutoff valve filter head.
Turbocharger Air Shutoff Valve Filter Signature, ISX, and QSX15 Eng [...]

Control Valve Air Supply Line
(010-121)
Install
CAUTION
CAUTION
Do not use thread sealant. The use of thread sealant
will cause damage to the turbocharger control valve.
Mask both ends of the turbocharger control valve air
supply line before installing.
Install the turbocharger control valve air supply line.
Connect the air supply line to the turbocharger control

valve.
Connect the p-clips holding air line to engine.
Connect the air supply line to the turbocharger control
shutoff valve.
Start and run the engine.
Verify proper operation.
Check for air leaks.
Turbocharger Air Shutoff Valve Filter

(010-114)
Install
Variable Geometry
Apply a thin coat of lubricant on the filter gasket.
Install and hand tighten a new turbocharger control shutoff
valve filter on the turbocharger control shutoff valve body.
Use a filter wrench to tighten the filter full turn after gasket
contact.
Signature, ISX, and QSX15 Eng [...] Integrated Fuel System Module (IFSM)
Integrated Fuel System Module (IFSM)

(005-073)
Install
Install two guide pins into the mounting holes on the
cylinder head.
Install a new gasket onto the guide pins.
WARNING
Install the IFSM on the guide pins.
Install and tighten the capscrews.
Remove the guide pins.
Install and tighten the remaining capscrews.
Aftertreatment Fuel Shutoff Manifold Signature, ISX, and QSX15 Eng [...]
Aftertreatment Fuel Shutoff Manifold

(011-052)
Install
NOTE: The pressure sensor and shutoff valve are located
on the same side of the shutoff manifold.
NOTE: The pressure sensor is mounted above the shutoff
valve.
Install the pressure sensor, the fuel shutoff valve, and the
fuel drain valve.
Torque Value:
Pressure Sensor 14 Nm [ 124 in-lb ]
Torque Value:
Fuel Shutoff Valve 14 Nm [ 124 in-lb ]
Torque Value:
Fuel Drain Valve 14 Nm [ 124 in-lb ]
Install the two capscrews to attach the aftertreatment fuel

shutoff manifold to the bracket on the engine.

NOTE: The pressure sensor and shutoff valve are located
on the same side of the shutoff manifold.
NOTE: The pressure sensor is mounted above the shutoff
valve.
Install the pressure sensor, the fuel shutoff valve, and the
fuel drain valve.
Torque Value:
Pressure Sensor 14 Nm [ 124 in-lb ]
Torque Value:
Fuel Shutoff Valve 14 Nm [ 124 in-lb ]
Torque Value:
Fuel Drain Valve 14 Nm [ 124 in-lb ]

Aftertreatment Injector Lines

(011-051)
Install
Connect the aftertreatment injector coolant supply line to
the aftertreatment injector and the EGR cooler.
Connect the aftertreatment injector coolant return line to

the oil cooler.
the aftertreatment injector.
Connect the aftertreatment injector fuel supply line to the

aftertreatment injector.
outlet of the union fitting, located just above the EGR
valve.
Install the P-clips.

inlet of the union fitting, located just above the EGR valve.
outlet of the fuel shutoff manifold.
Connect the fuel return line to the fuel shutoff valve

manifold and the fuel control module.
Torque Value:
O-ring joint 24 Nm [ 212 in-lb ]
Torque Value:
Banjo joint 15 Nm [ 133 in-lb ]


inlet of the shutoff manifold.
Torque Value:
Banjo joint 34 Nm [ 25 ft-lb ]
fuel rifle.
Torque Value:
O-ring joint 24 Nm [ 212 in-lb ]

Connect the aftertreatment injector coolant supply line to
the aftertreatment injector and the coolant heater housing.

the coolant return line to the coolant return manifold.
the aftertreatment injector.

aftertreatment injector.
outlet of the fuel shutoff manifold.
Connect the fuel return line to the fuel shutoff valve

manifold and the fuel return tee fitting, located in front of
the engine control module.
Install the P-clips
Torque Value:
O-ring fitting 24 Nm [ 212 in-lb ]
Torque Value:
Banjo fitting 15 Nm [ 133 in-lb ]
ECM Cooling Plate, Fuel Cooled Signature, ISX, and QSX15 Eng [...]

inlet of the shutoff valve manifold.
fuel rifle.
ECM Cooling Plate, Fuel Cooled

(006-006)
Install
Install five insulating washers. The one ground washer
must be installed in the upper left cooling plate mounting
capscrew hole.
CAUTION
Make sure that the insulating washers and the ground
washer are installed properly on the cooling plate or
malfunction of the ECM can occur.
Install the cooling plate gasket.
Install the six cooling plate mounting capscrews and
washers.
Install the ECM.
Install and tighten the five ECM mounting capscrews.
Install the ECM cooling plate fuel supply line (bottom) to

the integrated fuel system module and the ECM cooling
plate.
Install the ECM cooling plate fuel return line (top) to the
fuel pump and the ECM cooling plate.
Signature, ISX, and QSX15 Eng [...] Air Intake Connection
Air Intake Connection (010-080)

Install
Install the four mounting capscrews, air inlet connection,
and new gasket.
Install the four-step wastegate controller, mounting

capscrews, hose, and controller wires.
Connect the boost sensor wire.
Connect the air pipe from the charge air cooler to the air
inlet connection.

Install a new gasket between the cylinder head and the air
intake connection.
Install and tighten the four capscrews.

Install a new gasket between the cylinder head and the air
intake connection.
Install and tighten the four capscrews.
EGR Mixer (011-021)

Install
Install a new hose at the EGR mixer inlet.
Install a new o-ring between the EGR mixer and the air
intake connection. Install and tighten capscrews.
Lubricating Oil Dipstick Tube

(007-011)
Install
Install the dipstick tube and tighten the nut finger-tight.
Install the dipstick tube clamp, capscrew, and nut.
Tighten the dipstick tube nut.
Tighten the clamp.

Install the dipstick tube and tighten the nut finger-tight.
Install the dipstick tube clamp, capscrew, and nut.
Tighten the dipstick tube nut.
Tighten the clamp.
Lubricating Oil Fill Tube (007-065)

Install
Install a new oil fill connection ring seal.
Use clean engine oil to lubricate the oil fill connection ring
seal.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Fill Tube
Install the oil fill connection to the lower gear cover.
Install the new ring seals on the bottom of the oil fill tube
(1) and on the oil fill tube cap (2).
Install the oil fill tube cap and the oil fill tube.
Install and tighten the tube brace gear cover capscrew (2).
Tighten the tube brace capscrew (1).

Install a new oil fill connection ring seal.
Use clean engine oil to lubricate the oil fill connection ring
seal.
Install the oil fill connection to the lower gear cover.
Install the new o-rings on the bottom of the oil fill tube and
a new ring seal on the oil fill tube cap.
Install the oil fill tube cap and the oil fill tube.
Signature, ISX, and QSX15 Eng [...] Crankcase Breather (External)
Install and tighten the tube brace gear cover capscrews.

Crankcase Breather (External)

(003-001)
Install
Assemble the breather tube as shown.
Two p-clips attach the vent hose to the gear housing and
two p-clips attach the vent hose to the side of the block.
With the breather hose installed on the new cover, the
hose (3) must extend lower than the flywheel housing.
Install the crankcase vent hose (1). Use the four p-clips
(2), to secure the crankcase vent hose to the engine.
Refrigerant Compressor Signature, ISX, and QSX15 Eng [...]

Connect the inlet and outlet rubber hoses, oil drain line,
and install the three hose clamps to the housing. Be sure
to push the hose on until it stops on the housing
connector. Verify that the hose clears the fan blade.
Connect the breather sensor wiring connector to the
breather sensor.
Install and tighten the four mounting capscrews.
Torque Value:
M10 47 Nm [ 35 ft-lb ]
M8 20 Nm [ 15 ft-lb ]
Remove and install the crankcase pressure sensor. Refer
to Procedure 019-445 in the Troubleshooting and Repair
CM871 and CM876 Electronic Control System, ISX and
ISM Engines, Bulletin 4021560.
Refrigerant Compressor (009-051)

Install
Sanden
Install the four mounting capscrews through the
refrigerant compressor and refrigerant compressor
bracket.

Install the four mounting capscrews through the
refrigerant compressor to the alternator/refrigerant
compressor mounting bracket. Make sure the roll pins
align properly.
Signature, ISX, and QSX15 Eng [...] Fan Support
Belt Tensioner, Refrigerant

Compressor, Automatic (009-053)
Install
Routing
Install the refrigerant compressor belt tensioner.
Install and tighten capscrew.
Idler Pulley, Refrigerant Compressor

(009-054)
Install
Routing
Install the refrigerant compressor idler pulley and the
mounting capscrew.
NOTE: A special alignment procedure is not required for
the refrigerant compressor idler pulley to the alternator/
Drive Belt, Refrigerant Compressor

(009-052)
Install
Routing
CAUTION
Pivot counterclockwise and hold the belt tensioner.
Install the drive belt and relieve the tensioner.
Fan Support (008-088)

Install
Install two guide studs into the upper gear cover.
Fan Support Signature, ISX, and QSX15 Eng [...]
Use clean 15W40 oil to lubricate the capscrew threads.

Install six capscrews.
capscrews.
Tighten the eight capscrews in the sequence shown.
Install the belt tensioner support bracket to the engine and

fan support.
Tighten all eight capscrews finger tight.
Tighten capscrew numbers 1 and 2 finger tight to mate the

surfaces of the belt tensioner support bracket to the fan
support.
Tighten capscrew numbers 3, 4, 5, and 6.

Signature, ISX, and QSX15 Eng [...] Fan Hub, Belt Driven
Tighten capscrew numbers 1, 2, 7, and 8.

Fan Hub, Belt Driven (008-036)

Install
WARNING
Install the fan hub assembly and the capscrews.
WARNING
This assembly weighs 23 kg [50 lb] or more. To avoid
personal injury, use a hoist or get assistance to lift
this assembly.
Install the fan hub and the capscrews.
Install the belt tensioner bracket.

CM570
The fan hub must be installed in the correct location on
the fan support to allow proper clearance between the fan
and fan shroud. Refer to the OEM service manual.
Belt Tensioner, Automatic (Water Pump) Signature, ISX, and QSX15 Eng [...]
Make certain the correct fan center is used for the

application.
Install the fan hub on the fan support using four capscrews
and washers.
Belt Tensioner, Automatic (Water

Pump) (008-080)
Install
Drives Alternator
Install the belt tensioner and mounting capscrew.
For the low-mount belt tensioner:
Install the belt tensioner bracket to the water pump.
Tighten capscrew.
Install the belt tensioner and capscrew.
For the mid-mount belt tensioner:

Install the belt tensioner mounting capscrew and the belt
The mid-mount aluminum belt tensioner/idler bracket is
part of the water pump removal and installation due to
common capscrew usage. Refer to Procedure 008-062.
Signature, ISX, and QSX15 Eng [...] Belt Tensioner, Automatic (Water Pump)

For the low-mount (small tensioner):
Install the belt tensioner bracket to the front engine
support with three mounting capscrews.
Install the belt tensioner.

For the low-mount (large tensioner):

Install the belt tensioner bracket to the front engine
support with three mounting capscrews.
Install the belt tensioner.

Starting Motor Signature, ISX, and QSX15 Eng [...]
Drive Belt, Cooling Fan (008-002)

Install
Drives Alternator
CAUTION
Pivot and hold the belt tensioner.
Install the drive belt and release the tensioner.
Starting Motor (013-020)

Install
All Except 50MT With Aluminum Flywheel Housing
CAUTION
Make sure to use the same thickness of starting motor
spacer (if used) as the one removed to install the
starting motor to reduce the possibility of engine or
starting motor damage.
Install the starting motor, spacer (if applicable) and the
three mounting capscrews.
Torque Value:
5/8-11 x 1.75 in 140 Nm [ 103 ft-lb ]
capscrew
5/8-11 x 2.00 in 201 Nm [ 148 ft-lb ]
capscrew
39 MT Starters 129 Nm [ 95 ft-lb ]
(Aluminum
Flywheel
Housing)
39 MT Starters 163 Nm [ 120 ft-lb ]
(Cast Iron
Flywheel
Housing)
50MT With Aluminum Flywheel Housing
CAUTION
Make sure to use the same thickness of starting motor
spacer (if used) as the one removed to install the
starting motor to reduce the possibility of engine or
starting motor damage.
Install the starting motor, spacer (if applicable), and the
three mounting capscrews.
Torque Value:
5/8-11 x 1.75 in 140 Nm [ 103 ft-lb ]
capscrew
5/8-11 x 2.00 in 201 Nm [ 148 ft-lb ]
capscrew
Signature, ISX, and QSX15 Eng [...] Rocker Lever Cover
Assemble the upper bracket (1) to the block mounting stud

and to the starter motor end bracket. Tighten capscrews
and nuts finger tight.
Assemble the lower bracket (2) to the oil pan rail mounting
stud and to the starter motor end bracket.
Tighten the capscrews and nuts finger tight.
Tighten all capscrews and nuts.
Tighten all capscrews and nuts in the following sequence:

Torque Value:
(1) 45 Nm [ 33 ft-lb ]
(2) and (3) 23 Nm [ 17 ft-lb ]
(4) and (5) 41 Nm [ 30 ft-lb ]
Rocker Lever Cover (003-011)

Install
NOTE: Engines built after September 7, 2006, or engines
that have the cover gasket embedded in the rocker lever
cover.
If the cover gasket was removed, install the cover
gasket as soon as possible to avoid swelling of the
cover gasket as the cover gasket swells due to its
prior exposure to lubricating oil.
If a new cover gasket is required, use P80
lubriplate, Part Number 3163086, or soapy water to
lubricate the cover gasket.
If the cover gasket was removed or requires replacement,
start the installation of the cover gasket at each bolt hole
and press the cover gasket into the groove in the rocker
level cover around each bolt hole.
After the cover gasket is in place around all bolt holes,
press the cover gasket into the grove of the rocker level
cover starting from the bolt holes moving to the center of
each span.
Inspect and make certain that there are no kinks, twists or
other damage.
Fuel Filter (Spin-On Type) Signature, ISX, and QSX15 Eng [...]
Align the capscrew holes in the cylinder head to the cover

gasket, and rocker lever cover prior to installing the
capscrews and isolator assemblies.
Install the eight capscrews and isolator assemblies.
NOTE: Engines built before September 7, 2006, have the
separate cover and a separate gasket, install the eight
capscrews and isolator assemblies.
Tighten capscrews in sequence shown.
Fuel Filter (Spin-On Type) (006-015)

Install
With Pressurized Fuel Filtering
Use the correct filter(s) for your engine. It must remove a
minimum of 95 percent of free and emulsified water. It
must also have a minimum of 98.7 percent 15-micron
particle-removal efficiency.
Apply a thin coating of clean engine oil to the filter gasket
surface.
CAUTION
Mechanical overtightening of the filter can distort the
threads or damage the filter element seal.
NOTE: Engines equipped with priming pumps do not
require the fuel filter to be filled prior to installation, if the
following filling procedure is followed:
Install the filter onto the filter head. Turn the filter until the
gasket contacts the filter head surface.
Tighten the filter an additional of a turn after the gasket
contacts the filter head surface, or as specified by the filter
manufacturer.
To perform the priming procedure, use the following

ittems to fabricate a fuel bypass hose:
2- Quick-disconnect fittings, Part Number 3376859
Clear tubing (capable of 2758 kPa [400 psi])
Install the fuel bypass hose fabricated above between the
suction-side Compuchek fitting at the top of the IFSM
and the fuel pump Compucheck fitting located on the head
of the fuel pump.
Connect the clear hose and the shutoff valve normally
used to check for air in fuel to the rail Compuchek fitting.
Refer to Procedure 006-003 in Section 6. Place the open
end of the tube in a suitable container and fully open the
shutoff valve in the hose.
Signature, ISX, and QSX15 Eng [...] Fuel Filter (Spin-On Type)
Fill the fuel filter by turning the ignition switch to the ON

position, but do not start the engine. The fuel lift pump
should begin to operate. Monitor the open end of the bleed
line from the rail Compuchek. When fuel is seen coming
out of this line, turn the ignition OFF. Remove the bleed
line and the air in fuel test line.
With Vacuum Fuel Filtering and Priming Pump

must also have a minimum of 98.7 percent at 25-micron
surface and the center seal.
CAUTION
Tighten the filter an additional 3/4 of a turn after the gasket
manufacturer.
If the filter is equipped with a water-in-fuel sensor, rotate
the sensor to the desired location and connect the wiring
harness.
NOTE: The engine will, perhaps, run rough for several

minutes until the air is out of the system.
Fill the fuel filter by turning the ignition keyswitch to the
ON position. The priming pump will operate for 2 minutes,
which will adequately fill the fuel filter. The engine can
then be started.
Some engines utilize a manual, remote mount priming
pump. Flip the priming pump mounted toggle switch to the
ON position. Operate the pump for 2 minutes and shut it
off. The engine can then be started.
Fuel Filter (Spin-On Type) Signature, ISX, and QSX15 Eng [...]
With Vacuum Fuel Filtering and Without Priming

Pump
must also have a minimum of 98.7 percent at 25-micron
surface and the center seal.
CAUTION
Tighten the filter an additional 3/4 of a turn after the gasket
manufacturer.
If the filter is equipped with a water-in-fuel sensor, rotate
the sensor to the desired location and connect the wiring
harness.
NOTE: The engine will, perhaps, run rough for several

minutes until the air is out of the system.
Fill the fuel filter by turning the ignition switch to the ON
position. The priming pump will operate for 2 minutes,
which will adequately fill the fuel filter. The engine can
then be started.
Signature, ISX, and QSX15 Eng [...] Lubricating Oil Filter (Spin-On)
Coolant Filter (008-006)

Install
CAUTION
Mechanical overtightening can distort the threads or
damage the filter head.
Apply a thin film of clean engine oil, or its equivalent, to
the coolant filter gasket sealing surface before installing
the coolant filter.
Tighten the coolant filter to of a turn after initial
gasket contact, or as specified by the manufacturer.
Turn the coolant on/off valve to the ON position.
Install the radiator pressure cap.
WARNING
Operate the engine until the coolant temperature is above
82C [180F], and check for coolant leaks.
After the air has been purged from the system, check the
coolant level again.
Lubricating Oil Filter (Spin-On)

(007-013)
Install
NOTE: The o-ring can stick onto the filter head. Make sure
it is removed before installing a new filter.
Clean the oil filter head surface.
Use clean engine oil to lubricate the gasket surface of the
filter.
CAUTION
Mechanical overtightening can distort the threads or
damage the filter element seal.
Fill the oil filter with clean 15W-40 oil.
Install the oil filter onto the oil filter head. Tighten the filter
until the gasket contacts the filter head surface.
Use oil filter wrench, Part Number 3375049, 3397929, or
3400157 to tighten the filter an additional 3/4 to 1 turn, or
follow the instructions supplied with the filter.
Confirm that the oil level in the pan is to the full mark.
82C [180F].
Check the oil pressure and for leaks.
Engine Installation (000-002)

Install

WARNING
WARNING
CAUTION
were removed.
Connect the OEM wiring harness to the ECM. Refer to

Manual CM870 Electronic Control Systems Signature and
ISX Engines, Bulletin 4021334.
Power Generation

WARNING
WARNING
CAUTION
were removed.
Connect the OEM wiring harness to the ECM. Refer

Manual Electronic Control System Signature, ISX and
Signature, ISX, and QSX15 Eng [...] Lubricating Oil System
Lubricating Oil System (007-037)

Prime
CAUTION
The lubricating oil system must be primed before
operating the engine after any internal engine repairs
or extended engine storage (beyond 6 months) to
avoid internal component damage.
Bar the engine during oil priming.
Remove the oil plug from the lubricating oil cooler housing
and install fitting and hose.
Use the coupler, Part Number 3376859, to connect the
priming pump to the coupling.
Connect the priming pump oil supply hose to the

lubricating oil pump coupling. Use clean 15W-40
lubricating oil from a drum or a container to supply oil to
the lubricating oil pump and engine.
Turn the priming pump on.
Allow the oil to flow until the oil pressure gauge indicates
a maximum pressure of 69 to 138 kPa [10 to 20 psi] at the
main oil rifle.
Turn the priming pump off.
Remove the priming pump oil supply hose and fitting.

Install the oil cooler housing plug.
Lubricating Oil System Signature, ISX, and QSX15 Eng [...]
Check the oil level on the dipstick before adding additional

oil.
If necessary, fill the engine with lubricating oil.
Fill
Fill and install the lubricating oil filter before putting oil into
the engine. Refer to Procedure 007-013.
Add the specified amount of clean 15W-40 oil to fill the oil
pan.
Oil Pan Capacity
Automotive and Industrial Power Generation
41.6 liters [11 gal] 83.3 liters [22 gal]
Check the oil level on the dipstick. It must be filled to the

H (high) mark.
Refer to Procedure 007-009 for dipstick calibration.
82C [180F], and check for leaks.
Shut off the engine. Wait 15 minutes for the oil to drain
back to the oil pan.
Check the oil level. Add oil as necessary to bring the level
up to the H (high) mark on the dipstick.
Cooling System (008-018)

Fill
CM570
Close the radiator draincocks.
Install the lower radiator hose(s).
Cummins Inc. recommends the use of either a 50/50

mixture of good-quality water and fully-formulated
antifreeze, or fully-formulated coolant when filling the
cooling system. The fully-formulated antifreeze or coolant
must meet TMC RP329 or TMC RP330 specifications.
Good-quality water is important for cooling system
performance. Excessive levels of calcium and magnesium
contribute to scaling problems, and excessive levels of
chlorides and sulfates cause cooling system corrosion.
Water Quality
Calcium Magnesium Maximum 170 ppm as (CaCO3 +
(Hardness) MgCO3)
Chloride 40 ppm as (CI)
Sulfate 100 ppm as (SO4)
Cummins Inc. recommends the use of Fleetguard ES

COMPLEAT. It is available in glycol forms (ethylene and
propylene) and complies with TMC RP329 and RP330
standards.
Fill the cooling system with heavy-duty coolant and install

the correct service filter.
Identify the correct filter. For automotive applications, use
the Signature and ISX Operation and Maintenance
Manual, Bulletin 3666251.Refer to Procedure 018-004 in
Section V.
Section V.
Cooling System Signature, ISX, and QSX15 Eng [...]
CAUTION
Opening the manual bleed valve or removing the pipe
plug on applicable installations is critical. Failure to
do so can result in engine damage.
NOTE: Some applications can have a manual bleed valve
or pipe plug that is required to be opened to properly fill
the system. The upper radiator pipe is a common location.
NOTE: Some applications can have a pipe plug installed
in place of the manual bleed valve.
If applicable, open the manual bleed valve or remove the
pipe plug before filling the cooling system.
Once filled, close the manual bleed valve or install the pipe
plug. For the torque specification, refer to the OEM service
manual.
NOTE: Some radiators have two fill locations, both of

which must be filled when the cooling system has been
drained.
Fill the cooling system with coolant to the bottom of the fill
neck in the radiator fill (or expansion) tank.
Install the radiator or expansion tank fill cap.

Operate the engine until it reaches a temperature of 82
C [180F], and check for leaks.
Shut off the engine and allow it to cool.

WARNING
CAUTION
Do not add cold coolant to a hot engine. This can
cause engine casting damage. Allow the engine to
cool to below 50C [120F] before adding coolant.
Remove the radiator or fill cap and check the coolant level
according to the operator equipment manual
recommendations. Add coolant if necessary. Do not
overfill.

Close the radiator draincocks.
Install the lower radiator hose(s).
Cummins Inc. recommends the use of either a 50/50

mixture of good-quality water and fully-formulated
antifreeze, or fully-formulated coolant when filling the
cooling system. The fully-formulated antifreeze or coolant
must meet TMC RP329 or TMC RP330 specifications.
Good-quality water is important for cooling system
performance. Excessive levels of calcium and magnesium
contribute to scaling problems, and excessive levels of
chlorides and sulfates cause cooling system corrosion.
Water Quality
Calcium Magnesium Maximum 170 ppm as (CaCO3 +
(Hardness) MgCO3)
Chloride 40 ppm as (CI)
Sulfate 100 ppm as (SO4)
Cummins Inc. recommends the use of Fleetguard ES

COMPLEAT. It is available in glycol forms (ethylene and
propylene) and complies with TMC RP329 and RP330
standards.
Fill the cooling system with heavy-duty coolant and install

the correct service filter.
Identify the correct filter. For automotive applications, use
the Signature and ISX Operation and Maintenance
Manual, Bulletin 3666251.Refer to Procedure 018-004 in
Section V.
Section V.
CAUTION
Opening the manual bleed valve or removing the pipe
plug on applicable installations is critical. Failure to
do so can result in engine damage.
NOTE: Some applications can have a manual bleed valve
or pipe plug that is required to be opened to properly fill
the system. The upper radiator pipe is a common location.
NOTE: Some applications can have a pipe plug installed
in place of the manual bleed valve.
If applicable, open the manual bleed valve or remove the
pipe plug before filling the cooling system.
Once filled, close the manual bleed valve or install the pipe
plug. For the torque specification, refer to the OEM service
manual.
NOTE: Some radiators have two fill locations, both of

which must be filled when the cooling system has been
drained.
Fill the cooling system with coolant to the bottom of the fill
neck in the radiator fill (or expansion) tank.
Without installing the coolant pressure cap, operate the

engine until the thermostat opens.
Shut off the engine.
CAUTION
Do not add cold coolant to a hot engine. This can
cause engine casting damage. Allow the engine to
cool to below 50C [120F] before adding coolant.
Check the coolant level according to the operator
equipment manual recommendations. Add coolant, if
necessary. Do not overfill.
Notes
Section 1 - Cylinder Block - Group 01 Page 1-a
Section 1 - Cylinder Block - Group 01

Section Contents
Page
Bearings, Connecting Rod ................................................................................................................................1-5
Clean and Inspect for Reuse.............................................................................................................................1-6
Finishing Steps...............................................................................................................................................1-11
Install................................................................................................................................................................1-8
Preparatory Steps.............................................................................................................................................1-5
Remove............................................................................................................................................................1-5
Bearings, Main .................................................................................................................................................1-11
Clean and Inspect for Reuse...........................................................................................................................1-12
Finishing Steps...............................................................................................................................................1-19
Install..............................................................................................................................................................1-14
Preparatory Steps...........................................................................................................................................1-11
Remove.......................................................................................................................................................... 1-12
Bearings, Thrust ..............................................................................................................................................1-19
Finishing Steps...............................................................................................................................................1-22
Inspect for Reuse............................................................................................................................................1-21
Install..............................................................................................................................................................1-21
Remove.......................................................................................................................................................... 1-20
Block Stiffener Plate .....................................................................................................................................1-178
Finishing Steps.............................................................................................................................................1-179
Install............................................................................................................................................................1-179
Preparatory Steps.........................................................................................................................................1-178
Remove.........................................................................................................................................................1-178
Bracket, Accessory .......................................................................................................................................1-152
Inspect for Reuse..........................................................................................................................................1-154
Install............................................................................................................................................................1-154
Automotive Applications.............................................................................................................................1-154
Industrial and Power Generation.................................................................................................................1-156
Remove.........................................................................................................................................................1-152
Bracket, Retaining Brace ..............................................................................................................................1-148
Install............................................................................................................................................................1-150
Remove.........................................................................................................................................................1-148
Connecting Rod ...............................................................................................................................................1-23
Bend and Twist Inspect...................................................................................................................................1-27
Calibration Procedure...................................................................................................................................1-27
Test..............................................................................................................................................................1-29
Finishing Steps...............................................................................................................................................1-33
Magnetic Crack Inspect...................................................................................................................................1-30
Crankshaft .......................................................................................................................................................1-34
Bend and Twist Inspect...................................................................................................................................1-40
Finishing Steps...............................................................................................................................................1-51
Install..............................................................................................................................................................1-50
Magnetic Crack Inspect...................................................................................................................................1-46
Remove.......................................................................................................................................................... 1-36
Rotation Check............................................................................................................................................... 1-34
Crankshaft Adapter .........................................................................................................................................1-51
Page 1-b Section 1 - Cylinder Block - Group 01

Finishing Steps...............................................................................................................................................1-58
Install..............................................................................................................................................................1-56
Remove.......................................................................................................................................................... 1-52
Crankshaft Gear, Front (Crankshaft Installed) ................................................................................................1-58
Finishing Steps...............................................................................................................................................1-63
Install..............................................................................................................................................................1-62
On-Engine Repair.........................................................................................................................................1-58
Remove.......................................................................................................................................................... 1-59
Crankshaft Pulley ............................................................................................................................................1-64
Install..............................................................................................................................................................1-66
Automotive Applications...............................................................................................................................1-66
Industrial and Power Generation...................................................................................................................1-66
Remove.......................................................................................................................................................... 1-64
Automotive Applications...............................................................................................................................1-64
Industrial and Power Generation...................................................................................................................1-64
Crankshaft Seal, Front ....................................................................................................................................1-68
Finishing Steps...............................................................................................................................................1-73
Install..............................................................................................................................................................1-70
Remove.......................................................................................................................................................... 1-69
Crankshaft Seal, Rear ..................................................................................................................................... 1-73
Finishing Steps...............................................................................................................................................1-77
Install..............................................................................................................................................................1-75
Measure..........................................................................................................................................................1-76
Remove.......................................................................................................................................................... 1-74
Crankshaft Tone Wheel .................................................................................................................................1-138
Finishing Steps.............................................................................................................................................1-139
Inspect..........................................................................................................................................................1-138
Install............................................................................................................................................................1-139
Remove.........................................................................................................................................................1-138
Cylinder Block .................................................................................................................................................1-77
Repair.............................................................................................................................................................1-78
Cylinder Block and Liner Seats ...................................................................................................................... 1-87
Leak Test........................................................................................................................................................1-87
Cylinder Liner ..................................................................................................................................................1-91
Finishing Steps...............................................................................................................................................1-99
Install..............................................................................................................................................................1-96
Measure..........................................................................................................................................................1-97
Remove.......................................................................................................................................................... 1-92
Engine Base Timing ......................................................................................................................................1-157
Adjust............................................................................................................................................................1-172
Finishing Steps.............................................................................................................................................1-176
General Information.......................................................................................................................................1-157
Install............................................................................................................................................................1-166
Remove.........................................................................................................................................................1-161
Gear Cover, Lower ........................................................................................................................................1-145
Clean and Inspect for Reuse.........................................................................................................................1-145
Finishing Steps.............................................................................................................................................1-148
Install............................................................................................................................................................1-147
Section 1 - Cylinder Block - Group 01 Page 1-c
Remove.........................................................................................................................................................1-145
Gear Cover, Upper .........................................................................................................................................1-140
All Applications...........................................................................................................................................1-141
Finishing Steps.............................................................................................................................................1-144
Install............................................................................................................................................................1-143
Remove.........................................................................................................................................................1-140
Gear Housing, Front ......................................................................................................................................1-100
Finishing Steps.............................................................................................................................................1-104
Install............................................................................................................................................................1-102
Remove.........................................................................................................................................................1-100
Idler Gear, Adjustable ...................................................................................................................................1-140
Idler Gear, Lower Scissor .............................................................................................................................1-140
Piston .............................................................................................................................................................1-104
Articulated Piston.......................................................................................................................................1-106
Single-Piece Piston.....................................................................................................................................1-107
Finishing Steps.............................................................................................................................................1-110
Piston and Connecting Rod Assembly .........................................................................................................1-127
Assemble......................................................................................................................................................1-131
Disassemble..................................................................................................................................................1-130
Finishing Steps.............................................................................................................................................1-137
Install............................................................................................................................................................1-134
Remove.........................................................................................................................................................1-128
Piston Cooling Nozzle ...................................................................................................................................1-111
Finishing Steps.............................................................................................................................................1-112
Install............................................................................................................................................................1-112
Remove.........................................................................................................................................................1-112
Piston Rings ..................................................................................................................................................1-114
Install............................................................................................................................................................1-116
Measure........................................................................................................................................................1-115
Remove.........................................................................................................................................................1-114
Service Tools ....................................................................................................................................................1-1
.........................................................................................................................................................................1-1
Vibration Damper, Viscous ...........................................................................................................................1-118
Page 1-d Section 1 - Cylinder Block - Group 01

Eccentricity Check.........................................................................................................................................1-125
Finishing Steps.............................................................................................................................................1-126
Industrial and Power Generation with Crank-Driven Fan or PTO.................................................................1-126
Industrial and Power Generation without Crank-Driven Fan or PTO.............................................................1-126
Install............................................................................................................................................................1-123
Remove.........................................................................................................................................................1-119
Wobble Check...............................................................................................................................................1-125
Section 1 - Cylinder Block - Group 01 Page 1-1
Service Tools
Cylinder Block
The following special tools are recommended to perform procedures in this section. The use of these tools
is shown in the appropriate procedure. These tools can be purchased from a local Cummins Authorized
Repair Location.

Protective Plug Kit
Used to plug oil passages and drillings during a repair process.
4918319
Main Bearing Cap Puller

Used to remove the main bearing caps from the cylinder block.
ST 1178
Connecting Rod Checking Fixture

Used with Guide Kit, Part Number 4918339, to inspect the connecting
ST 561 rods for bend, twist, and length.
Oil Seal Puller/Installer

Used to pull or install the rear crankshaft seal on both the REPTO
3164780 and Non REPTO applications. The previous kits 3162994 and
3164153 can be updated to work on REPTO applications by adding
the replacer plate, Part Number 3164763.
Oil Seal Puller/Installer

Used to pull or install the front crankshaft seal.
3162992
Connecting Rod Guide Pins (Two)

Used to protect the crankshaft journal by guiding the connecting rod
3163097 during installation or removal.
Service Tools Signature, ISX, and QSX15 Eng [...]
Page 1-2 Section 1 - Cylinder Block - Group 01

Universal Cylinder Liner Puller
Used to remove the cylinder liners from all present engine series.
3163745 Used with cylinder liner puller plate, Part Number 3162462, on
Signature engines. Cylinder liner remover, Part Number 3162873,
can also be used for this application.
Cylinder Liner Puller Plate

Used with the universal cylinder liner puller, Part Number 3162873,
3162462 to remove the cylinder liners.
Cylinder Liner Installation Tool

Used to install cylinder liners and clamp for protrusion readings into
3164606 the cylinder block. Cylinder liner installation tool, Part Number
3162461 can be also used for this application, if updated with the
cylinder liner installation plate, Part Number 3164606.
Safety Solvent
Used to clean machine surfaces prior to the installation of thread
3824510 repair inserts, coolant passage surfaces, and upper deck repair
sleeves.
Marked Socket
Used to tighten the rod capscrews and cylinder head bolts. Part
3165161 Number 3163059 is a 3/4 inch impact wrench with ample range to
tighten bolts.
Piston Ring Compressor

Used to install piston into cylinder block. The piston ring compressor,
3164846 Part Number 3163158, can also be used, if machined to work with
flat top cylinder liners.
Timing Pin and Wedges Kit

Kit contains a pin and three wedges. Used to set engine base timing.
3163021
Injector Cam and Valve Gear Puller

Used to pull the cam gear. The puller will only work on camshaft
3163069 gears with puller holes.

Mounting Plate
Used with either Part Number 3375193 or Part Number 3375194
3162464 engine stand.
Injector Installation and Removal Tool

Used to remove and install injectors.
3163483
Thick Wear Sleeve/Wet Flywheel Housing Oil Seal Installation

and Removal Tool
3163826 Used to remove and install the wear sleeve and wet flywheel housing
oil seal on QSX15 engines.
Crankshaft Adapter and Gear Removal Kit

Used to remove and install the crankshaft adapter and crankshaft
4918530 gear.
Loctite 518 Flexible Anerobic Gasket Sealant (Color Red)

Used to seal the main bearing cap to the mating surface of the
4918675 cylinder block.
Protective Plug
Used to plug the front oil passage of the cylinder block during a repair
4918874 process. For use on engines built after August 2006.
Protective Plug
Used to plug the rear oil passage of the cylinder block during a repair
4918875 process. For use on engines built after August 2006.
Thread Salvage Kit

Used to salvage/repair damaged cylinder head capscrew threads in
3164021 the cylinder block.
Service Tools Signature, ISX, and QSX15 Eng [...]

Regular Hexagon Jam Nut
3163842 the cylinder block. Used with Part Number 3164021 Thread Salvage
Kit.
Threaded Insert [50mm]

Kit.
Threaded Insert [76mm]

Kit.
Reamer
Kit.
Tap
Kit.
Drill
Kit.
Connecting Rod Checking Guide

Use with ST 561 Connecting Rod Checking Fixture to measure
4918339 stretch and twist in the connecting rod.

Preparatory Steps
WARNING
WARNING
Remove the lubricating oil pan. Refer to Procedure
007-025.
Remove the lubricating oil suction tube. Refer to
Procedure 007-035.
Remove the lubricating oil pump. Refer to Procedure
007-031.
Remove the block stiffener plate. Refer to Procedure
001-089.
Remove the piston cooling nozzles. Refer to
Procedure 001-046.
Remove
Rotate the crankshaft so that two of the connecting rods
are at bottom dead center.
Do not remove the capscrews at this time.

Loosen the connecting rod capscrews.
Hit the connecting rod capscrews with a rubber hammer
to loosen the rod caps from the dowels.
Remove the capscrews and the rod cap.

Remove the bearing shell from the rod cap and mark the
cylinder number and the letter "L on the flat surface of
the bearing tangs.
Install two guide pins, Part Number 3163097, in the

connecting rod.
Push the rod up far enough to allow the upper bearing
shell to be removed. Use a T-handle piston pusher.
Remove the bearing shell and mark the cylinder number
and the letter "U" on the flat surface of the bearing tangs.
Clean and Inspect for Reuse
WARNING
personal injury.
WARNING
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
Steam-clean the parts and dry with compressed air.
Inspect the rod caps, connecting rod bearing saddles, and

capscrews for nicks, cracks, burrs, scratches, or fretting.
Inspect the connecting rod journal of the crankshaft for

scratches or nicks.
Use crocus cloth to remove the nicks and scratches.
Inspect the bearings for damage.

Replace any bearings with the following damage:
Pitting
Flaking
Corrosion
Lock tang damage
Scratches (deep enough to be felt with a fingernail).
Normal bearing wear produces a smooth finish that will

wear into the lining. Refer to the Parts Reuse Guidelines,
Bulletin 3810303.
For more detailed information of bearing damage, refer to

Analysis and Prevention of Bearing Failures, Bulletin
3810387.
Inspect the bearing seating surface for nicks or burrs.
If nicks or burrs can not be removed with a fine crocus
cloth, the bearings must be replaced.
Measure the rod bearing shell thickness with an outside

micrometer that has a ball tip.
Discard a bearing shell if its thickness is below the
minimum specification.
Standard Connecting Rod Bearing Thickness

mm in
2.366 MIN 0.093
2.378 MAX 0.094
Crankshafts that are ground undersize in the connecting

rod or the main bearing journals are marked on the front
counterweight. If the crankshaft is marked, check the
bearing shell part number to make sure the correct
bearing size is used.
Install
CAUTION
Connecting rod bearings must match the connecting
rod design. Drilled rods must use drilled rod bearings.
Non-drilled rods must use non-drilled bearings.
Mismatches will cause engine damage.
Connecting rod design must be matched with the proper
connecting rod bearing.
Drilled connecting rods must be fitted with drilled
Non-drilled connecting rods must be fitted with non-drilled
Drilled and non-drilled connecting rods can be mixed in

the same engine as long as the two piece piston is used.
Engines using single piece pistons can not use non-drilled
connecting rods.
CAUTION
The connecting rod and bearing shell mating surfaces
equivalent to lubricate the crankshaft journal mating
surface of the upper bearing shell.
Install the upper bearing shell into the connecting rod with
the tang of the bearing in the slot of the rod.
Install the bearing shell into the connecting rod cap with
the tang (2) of the bearing in the slot (1) of the cap.
equivalent to lubricate the bearing shell to crankshaft
journal mating surface and the connecting rod capscrews.
CAUTION
The rod cap alpha characters must match the alpha
characters on the connecting rod and must be
installed with the characters aligned to prevent
damage to the connecting rods and crankshaft. The
locking tang of the connecting rod cap must face
toward the intake side of the cylinder block. Rod and
cap mating surfaces must be clean or engine damage
can occur.
Install the cap onto the connecting rod.

oil.
tighten.
Torque Value:
Capscrews in lb ]
Numerical
Sequence
5 degrees
Torque Value:
Capscrews in lb ]
Numerical
Sequence
numerical sequence
Step3 70 6 Nm[ 52 4 ft-
lb ]
5 degrees
Measure the connecting rod side clearance.
Connecting Rod Side Clearance

mm in
0.10 MIN 0.004
0.33 MAX 0.013
NOTE: The connecting rod must move freely from side to

side on the crankshaft journal. If the rod does not move
freely, remove the rod cap and make sure the bearing
shells are the correct size. Check for dirt or damage on
the crankshaft and the bearing shells.
Repeat the above steps to install the remaining bearing
shells and connecting rod caps.
Finishing Steps
CAUTION
to avoid internal component damage.
Install the piston cooling nozzles. Refer to Procedure
001-046.
Install the oil pump. Refer to Procedure 007-031.
Install the block stiffener plate. Refer to Procedure
001-089.
Install the lubricating oil suction tube. Refer to
Procedure 007-035.
Install the lubricating oil pan. Refer to Procedure
007-025.
Prime the lubricating oil system. Refer to Procedure
007-037.
Operate the engine until it reaches a temperature of
82C [180F], and check for lubricating oil leaks.

Preparatory Steps
WARNING
WARNING
Drain the lubricating oil. Refer to Procedure 007-037
(Lubricating Oil System) in Section 7.
007-025 (Lubricating Oil Pan) in Section 7.
Procedure 007-035 (Lubricating Oil Suction Tube
(Block Mounted)) in Section 7.
007-031 (Lubricating Oil Pump) in Section 7.
001-089 (Block Stiffener Plate) in Section 1.
Remove
CAUTION
Mark any unmarked bearing caps before removing
them from the cylinder block. Do not remove main
bearing capscrews until the main bearing cap is
pulled, or the cap could fall out, causing personal
injury and parts damage.
If the crankshaft is not going to be removed, replace the
main bearings one at a time.
Loosen the main bearing cap capscrews.
Use the main bearing cap puller, Part Number ST-1178,
to remove the cap. The tool must be centered on the cap.
Remove the main bearing capscrews and cap.
Mark the bearing shells with the journal number from

which they were removed.
Remove the lower main bearing shell from the cap.
Rotate the crankshaft with the air compressor drive or a

barring device to remove the main bearing shell.
Mark each main bearing for location if they are to be
installed again in the engine.
WARNING
bodily injury.
Use a soft bristle brush to clean the parts.
Dry the parts with compressed air.
Inspect the main bearing cap and capscrews for damage.

Inspect the bearing shells and thrust bearings for nicks,
scratches, or other damage.
If the main bearings are damaged, inspect the crankshaft
main bearing journals. If the crankshaft is damaged, the
engine must be removed for repair. Refer to Procedure
000-001 (Engine Removal) in Section 0.
Cummins Inc. recommends replacing the thrust bearings
when the main bearings are replaced. Refer to Procedure
001-007 (Bearings, Thrust) in Section 1 for thrust bearing
replacement.
Use an outside diameter ball-tipped micrometer to

measure the main bearing shell thickness.
Standard Main Bearing Shell Thickness

mm in
3.196 MIN 0.126
3.214 MAX 0.127
If the bearing shell is not within specifications, it must be
replaced.
For more detailed information on bearing damage, refer
to Analysis and Prevention of Bearing Failures, Bulletin
3810387.
Crankshafts that are ground undersize in the connecting

rod and main bearing journals are marked on the front
counterweight. If the crankshaft is marked, check the
bearing shell part number to make sure the correct
bearing size is used.
Install
CAUTION
The cylinder block saddle and the cap mating surfaces
CAUTION
The bearing tang must fit into the slot in the bearing
saddle or engine damage can occur.
CAUTION
Do not use a capscrew or any hard metal object to
install bearings, as this can damage the crankshaft
and cause an engine failure.
equivalent, to lubricate the upper main bearing shell to
crankshaft journal mating surface.
Start the bearing into the upper saddle by hand. Slide the
bearing into position. Take care to not damage the
crankshaft journal while installing the bearing.

equivalent, to lubricate the inside diameter of the bearing
shells and the liner side of the upper thrust bearings.
Align the lower main bearing shell and push it into place.
CAUTION
in engine damage.
equivalent, to lubricate the liner side of the lower thrust
bearings.
CAUTION
in engine damage.
bearing saddle.
the front thrust bearing and toward the front of the engine
to install the rear thrust bearing.
CAUTION
Only use Loctite 518 thread sealant on the main cap
joint mating surface. Other sealants can become hard,
brittle, and allow oil and debris into the main bearing/
block joint, causing engine damage.
CAUTION
The bead must be 3 to 5 mm [0.12 to 0.20 in] wide and
must not enter the main bearing shell inside the main
bearing shell inside diameter. Sealant in the main
bearing can cause engine damage.
Apply a bead of Loctite 518 thread sealant to the two
main bearing cap surfaces on each main bearing cap as
shown.
Use clean 15W-40 engine oil to lubricate the capscrew

threads and flat washers (or the underside of the capscrew
heads if washers are not used).
Drain the excess oil from the capscrews before installing
them.
CAUTION
The main bearing caps are marked with a `V.' Position
the `V' mark so that it points to the front of the engine.
Incorrect positioning will result in severe engine
damage.
Align the capscrew holes in the cap with the holes in the
cylinder block. Make sure the lower bearing shell is in
position.
Install the capscrews through the cap and into the cylinder
block.
To reduce the possibility of bore size issues, clearance

issues, or both, the main bearing capscrews must be
tightened within 15 minutes of the Loctite 518 thread
sealant application.
Make sure the bearing shell does not move.

Tighten the capscrews in far enough to use a heel bar to
pry the caps into place.
Tighten both of the capscrews on a main bearing cap to

203 Nm [150 ft-lb].
Loosen both capscrews completely.
The remaining main bearings do not have thrust bearings.


socket, Tool Numbers 3163059 and 3163060, to rotate the
capscrews an additional 180 degrees.
Use the torque plus angle method to tighten the main
bearing capscrews in the sequence shown.
To measure the end clearance of the crankshaft, install a

dial indicator onto the oil pan flange.
Place the tip of the gauge against the crankshaft
counterweight.
Push the crankshaft toward the rear of the cylinder block.
Set the dial indicator at "0" (zero).

Push the crankshaft toward the front of the cylinder block.
If the end clearance is less than 0.10 mm [0.004 in], loosen

all main bearing capscrews one turn.
Push the crankshaft toward the front and then toward the
rear of the cylinder block.
Tighten the main bearing capscrews in sequence.

Torque Value:
Block Main Step1 149 Nm [ 110 ft-lb ]
Bearing
Capscrews
Measure the crankshaft end clearance.
Crankshaft End Clearance - New or Reground

mm in
0.10 MIN 0.004
0.50 MAX 0.020
Crankshafts that have been reground on the thrust

bearing surfaces are marked for oversize thrust bearings
on the rear crankshaft counterweight. If the crankshaft
counterweight is marked, check the thrust ring part
number to make sure the correct thrust ring size is used.
Example: F0.010 = front 0.25 mm [0.010 in]
Example: R0.020 = rear 0.51 mm [0.020 in]
If the crankshaft end play is more than 0.50 mm [0.020 in],

the engine must be removed to allow for replacement of
the crankshaft. Refer to Procedure 000-001 (Engine
Removal) in Section 0.
Finishing Steps
CAUTION
to avoid internal component damage.
001-089 (Block Stiffener Plate) in Section 1.
Install the lubricating oil pump. Refer to Procedure
007-031 (Lubricating Oil Pump) in Section 7.
Procedure 007-035 (Lubricating Oil Suction Tube
(Block Mounted)) in Section 7.
007-025 (Lubricating Oil Pan) in Section 7.
Prime the lubricating system. Refer to Procedure
007-037 (Lubricating Oil System) in Section 7.
Fill the engine with lubricating oil. Refer to Procedure
007-037 (Lubricating Oil System) in Section 7.
Operate the engine until it reaches a temperature of
82C [180F], and check for lubricating oil leaks.

Preparatory Steps
WARNING
WARNING
Cummins Inc. recommends replacing the thrust bearings
when the main bearings are replaced.

007-025.
Remove the oil suction tube. Refer to Procedure 007-035.

001-089.
Remove the number four main bearing cap. Refer to
Procedure 001-006.
Remove
Remove the thrust bearings from the number four main
bearing cap.
Mark the thrust bearings as being lower, and front or rear
bearings.
CAUTION
To reduce the possibility of damage to the crankshaft,
use care when removing the upper thrust bearings.
Use a blunt tool to remove the upper thrust bearings.
Mark these bearings as being upper, and front or rear
bearings.
Inspect for Reuse

Inspect the thrust bearings for scratches, galling, uneven
wear, or other damage.
Replace the thrust bearings if damage is found.
If damage is found on any of the thrust bearings, be sure
to inspect the crankshaft, block, and main bearing cap for
damage as well.
Install
Use Lubriplate 105, or equivalent, to coat the upper
thrust bearings.

the rear thrust bearing, and to the front of the engine to
install the front thrust bearing.
bearing saddle.
The bevel must be toward the crankshaft.
Use Lubriplate 105, or equivalent, to coat the lower thrust

bearings.
The bevel of the thrust bearing must be toward the
crankshaft.
Finishing Steps
Install the main bearing cap. Refer to Procedure 001-006.
001-089.
Install the lubricating oil suction tube. Refer to Procedure

007-035.
Install the lubricating oil pan. Refer to Procedure 007-025.
Fill the engine with clean lubricating oil. Refer to

Procedure 007-037.
Signature, ISX, and QSX15 Eng [...] Connecting Rod
The engine must have adequate oil pressure within 15

seconds after starting. If the warning light indicating low
oil pressure has not gone out or there is no oil pressure
indicated on a gauge within 15 seconds, shut off the
engine immediately to avoid engine damage. Confirm that
the correct oil level is in the oil pan.
Operate the engine to normal operating temperature and
check for leaks.
Connecting Rod (001-014)

Preparatory Steps
NOTE: The piston and connecting rod must be removed
as an assembly on Signature, ISX, and QSX15 engines.
Remove the piston and connecting rod assembly.
Refer to Procedure 001-054 (Piston and Connecting
Rod Assembly) in Section 1.
Disassemble the piston and connecting rod. Refer to
Procedure 001-054 (Piston and Connecting Rod
Assembly) in Section 1.

CAUTION
Prevent damage to the capscrews. Nicks in the body
of the capscrew can cause an area of stress that can
fail during engine operation. Damage to the threads
will cause torque values to be incorrect and will
damage the mating parts.
Connecting Rod Signature, ISX, and QSX15 Eng [...]
WARNING
can cause serious injury.
WARNING
cleaning, follow manufacturer's recommendations for
use. Wear goggles and protective clothing to reduce
the possibility of personal injury.
WARNING
personal injury.
Use solvent or steam to clean the capscrews, connecting
rod, and connecting rod cap.
Dry with compressed air.
Use a soft bristle brush to clean the oil drilling.
CAUTION
Repair of rolled threads by use of a thread die is not
recommended. The die can create a sharp corner on
the minor diameter (root) of the threads. This sharp
corner can cause an area of increased stress.
Inspect the capscrews for the following:
Damaged threads
Rust or corrosion-caused pitting
Nicks, bent, stretched, or galled.
The capscrew must be replaced if it has any of the listed
damages.
Inspect the connecting rod and connecting rod cap for

damage.
Replace the connecting rod if the I-beam or connecting
rod cap is damaged.
Inspect the connecting rod and connecting rod cap for

fretting damage on the mating surfaces.
The connecting rod and connecting rod cap must be
replaced as an assembly if fretting damage is visible on
either piece.
Check the bearing surface for nicks or burrs.

If it is not possible to remove any nicks or burrs with a fine
emery cloth, the connecting rod must be replaced.
Inspect the rod pin bushing for damage.

Replace any piston pin bushing that has evidence of
scoring, galling, or scuffing.
Replace any bushing that has turned in the bore.
Special tools and precision machining are required to
replace bushings. If Cummins approved tools and
procedures are not available, the connecting rod must be
replaced.
CAUTION
The connecting rod cap alpha characters must match
the alpha characters on the connecting rod and must
be installed with the characters aligned to prevent
damage to the connecting rods and crankshaft.
CAUTION
Use a vise with brass jaws to hold the connecting rod.
Notches, scratches, or dents in the I-beam area can
cause engine failure.
Place the connecting rod into a vise with brass jaws.
Support the connecting rod at the large bearing end to
avoid I-beam damage.
Install the connecting rod cap onto the connecting rod.
oil.
tighten.
Torque Value:
Capscrews in lb ]
Numerical
Sequence
5 degrees
Torque Value:
Capscrews in lb ]
Numerical
Sequence
numerical sequence
Step3 70 6 Nm[ 52 4 ft-
lb ]
5 degrees
Measure the connecting rod crankshaft bore inside

diameter with a bore dial indicator.
Connecting Rod Crankshaft Bore Inside Diameter

mm in
98.801 MIN 3.890
98.839 MAX 3.891
If the connecting rod crankshaft bore inside diameter is
not within specifications, the connecting rod must be
replaced.
Measure the connecting rod piston pin bushing inside

diameter.
Connecting Rod Piston Pin Bushing Inside Diameter

mm in
63.55 MIN 2.502
63.57 MAX 2.503
If the connecting rod piston pin bushing inside diameter is
not within specifications, the connecting rod must be
replaced.
Bend and Twist Inspect

Calibration Procedure
A connecting rod of known length, bend, and twist is called
the reference connecting rod, and is required to calibrate
the fixture.
A new connecting rod, for which the distance from the
center of the crankshaft bore to the center of the piston
pin bore (rod length) is known, can also be used.
The connecting rod cap must be installed and tightened

to the correct specifications or the calibration will be
incorrect.
Install the appropriate connecting rod checking guide into
the reference connecting rod piston pin bore and center
the guide.
Install the appropriate connecting rod checking guide into
the reference connecting rod crankshaft bore.
Make sure the pin on the guide is down and centered in
the connecting rod.
Lock the guide in position by rotating the end of the guide.
Install the reference connecting rod into the connecting

rod checking fixture.
Loosen the knob and move the indicator bracket until both
indicators touch the top of the piston pin guide.
Move the bracket toward the guide until the indicator
needles have moved approximately 0.25 mm [0.010 in].
Turn the knob to tighten the bracket.
Adjust the indicator needles to zero. Move the connecting
rod in and out to confirm the zero setting.
Remove the reference connecting rod from the fixture.

Rotate the connecting rod 180 degrees horizontally and
install it into the fixture.
Be sure the indicators are at the zero setting.

If the indicator needles do not return to zero, adjust the
indicator so the zero moves of the indicated difference
from the needle to the zero established during the
previous step.
If the needle is more than 0.10 mm [0.004 in] from the zero
established during the previous step, check for dirt or
burrs on the connecting rod checking guides and fixture.
If the zero is still not within the specification, check to
make sure the reference connecting rod is not damaged.
Do not adjust the indicators after this step of the
procedure or the measurements will be incorrect.
After completing the calibration of the fixture, remove the
reference connecting rod.
Test
CAUTION
To reduce the possibility of engine damage, the
connecting rod testing fixture must be calibrated prior
to testing the connecting rod.
Install the appropriate mandrel in the piston pin end of the
connecting rod.
Make sure the locating pin in the mandrel for the crank pin
end is touching the connecting rod cap, directly opposite
the beam of the connecting rod.
Install the mandrel in the crank pin bore of the master
connecting rod.
Tighten the mandrel so it is centered in the bore correctly.
Install the master connecting rod in the testing fixture.
Loosen the knob and move the indicator bracket until both
indicators touch the top of the piston pin end mandrel.
Move the bracket toward the mandrel until the indicator
needles have moved approximately 0.25 mm [0.010 in].
Turn the knob to tighten the bracket.
Adjust the indicator needles to zero. Move the master
connecting rod in and out to confirm the zero setting.
Remove the master connecting rod from the fixture.
Rotate the connecting rod 180 degrees horizontally and
install it in the checking fixture.
Record the indicator reading. The difference calibrated
0 of the indicator must be added or subtracted from the
known length of the master connecting rod to determine
the length of the connecting rod being measured.
Connecting Rod Length

mm in
261.45 MIN 10.293
261.55 MAX 10.297
If the connecting rod length is not within specifications,
the connecting rod must be replaced.
CAUTION
Never attempt to straighten a connecting rod with the
use of heat or force. The connecting rod can
eventually break and cause extensive engine damage.
Record indicator readings.
Remove the connecting rod from the fixture.
Turn the connecting rod 180 degrees horizontally and
install it into the checking fixture.
Compare the indicator readings with those noted in the
previous step. The difference between the indicator
readings is the amount of bend in the connecting rod.
Maximum Connecting Rod Bend (Bushing Installed)

mm in
0.021 MAX 0.0008
If the connecting rod bend is not within specification, the
connecting rod must be replaced.
CAUTION
Never attempt to straighten a connecting rod with the
use of heat or force. The connecting rod can
eventually break and cause extensive engine damage.
Check the fixture and mandrel in the piston pin end for a
gap between the two. If there is any twist in the connecting
rod, the mandrel will touch only one side of the fixture.
Hold the end of the mandrel that is touching the fixture
firmly against the fixture.
Use a feeler gauge to measure the gap between the
mandrel and the fixture. The amount of gap between the
mandrel and the fixture is the amount of connecting rod
twist.
Maximum Connecting Rod Twist (Bushing Installed)

mm in
0.05 MAX 0.002
If the connecting rod twist is not within specification, the
connecting rod must be replaced.
Magnetic Crack Inspect

This procedure describes the magnetic particle inspection
for the connecting rod and connecting rod cap.
Use a magnetic particle testing machine.
The connecting rod and connecting rod cap must be
assembled during this process.
Use the residual method. Apply head shot amperage.
Adjust the amperage to 1500 ampere direct current or
rectified alternating current.
Check for cracks.
The connecting rod must be replaced if any cracks are
visible.
Use the residual method. Apply coil shot amperage.
Amperage (Ampere Turns)

Minimum Maximum
2600 amps direct current 2800 amps direct current
Ampere turn is an electrical current of one ampere flowing

through the coil, multiplied by the number of turns in the
coil.
Check for cracks.

The connecting rod must be replaced if any indications
are visible in the critical (shaded) areas.
WARNING
can cause serious injury.
WARNING
cleaning, follow manufacturer's recommendations for
use. Wear goggles and protective clothing to reduce
the possibility of personal injury.
CAUTION
The connecting rod must be demagnetized
completely and cleaned thoroughly. Any small metal
particles will cause engine damage.
Demagnetize the connecting rod.
Use solvent or steam to clean the connecting rod.
This procedure describes the magnetic particle inspection

for the connecting rod capscrew.
Use a Magnaflux or similar magnetic particle testing

machine.
Use the continuous method. Apply a head shot of 300 to
400 amperes direct current or rectified alternating current.
Use an ultraviolet light. Check for indications of cracks.

The magnetic particles tend to form on sharp corners and
edges. Do not mistake these for cracks.
Any indications of cracks are not acceptable.
Prepare the machine for a coil shot.

Make sure the capscrew is near one side of the coil and
not in the center.
Apply 1000 to 1350 ampere-turns.
Use an ultraviolet light. Check for indications of cracks.

Any indications of cracks are not acceptable.
WARNING
When using solvents, acids or alkaline materials for
WARNING
Wear eye and face protection when using compressed
air. Flying debris and dirt can cause personal injury.
CAUTION
The connecting rod must be demagnetized
completely and cleaned thoroughly. Any small metal
particles will cause engine damage.
Demagnetize the capscrew thoroughly.
Use solvent to clean the capscrew and dry with
compressed air.
Finishing Steps
NOTE: The piston and connecting rod must be installed
as an assembly on Signature, ISX, and QSX15 engines.
Assemble the piston and connecting rod. Refer to
Install the piston and connecting rod assembly.
Refer to Procedure 001-054 (Piston and Connecting
Rod Assembly) in Section 1.
Crankshaft Signature, ISX, and QSX15 Eng [...]
Rotation Check
Use only the compressor drive or barring device to rotate
the crankshaft.
Rotate the crankshaft clockwise through two complete
revolutions.
If the engine does not turn freely, the equipment can have
a malfunction or was assembled incorrectly. Refer to the
OEM service manual.
Signature, ISX, and QSX15 Eng [...] Crankshaft
Preparatory Steps
WARNING
WARNING
Coolant is toxic. Keep away from children or pets. If
WARNING
WARNING
Drain the cooling system. Refer to Procedure 008-018
in Section 8.
Drain the lubricating oil. Refer to Procedure 007-037 in
Section 7.
Remove the engine. Refer to Procedure 000-001 in
Section 0.
Remove the cylinder heads. Refer to Procedure
Remove the flywheel. Refer to Procedure 016-005 in
Section 16.
Remove the flywheel housing. Refer to Procedure
Remove the front gear housing. Refer to Procedure
Remove the piston and connecting rod assemblies.
Remove the main bearing caps. Refer to Procedure
Remove
WARNING
Use a hoist and a sling that to remove the crankshaft.

Use crocus cloth or a Scotch-Brite pad to remove
discoloration or light scratches from the machined
surfaces of the crankshaft.
WARNING
Use a bristle brush and solvent to clean all of the
crankshaft oil drillings.
WARNING
can cause personal injury.
WARNING
personal injury.
Steam clean the crankshaft and dry with compressed air.
WARNING
WARNING
personal injury.
CAUTION
Do not use a thread chaser to clean the capscrew
threads in the crankshaft, severe engine damage can
result.
ISX applications use rolled capscrew threads in the
capscrew holes of the crankshaft.
To clean the rolled threads, flush with solvent, and dry with
compressed air.
If additional cleaning is required, brush with a nylon bristle
brush.
Place tape over the threaded capscrew holes.
Inspect the machined surfaces for scratches or nicks.

Use a crocus cloth to remove any nicks and scratches.
If scratches or nicks can be felt with a fingernail after the
crankshaft has been polished with crocus cloth, the
crankshaft must be replaced.
Inspect the crankshaft for dynamic balancing marks. One

or more of the crankshaft counterweights will contain a
drilled hole or drilled start point indicating that the
crankshaft has been balanced.
NOTE: This applies to engines built March 2009 or later
only.
Inspect the threaded capscrew holes for damage.
If the threaded capscrew holes are damaged, the
Inspect the crankshaft gear and tone wheel for excessive
wear or damage.
If any teeth on the crankshaft gear are missing, chipped,
or pitted, the crankshaft gear must be replaced.
If any teeth on the tone wheel are missing, the tone wheel
must be replaced.
Measure the crankshaft connecting rod journal outside

diameter.
Crankshaft Connecting Rod Journal Outside Diameter

mm in
93.98 MIN 3.700
94.02 MAX 3.702
If the crankshaft connecting rod journal outside diameter
is not within specifications, the crankshaft must be
replaced.
Measure the crankshaft main bearing journal outside

diameter.
Crankshaft Main Bearing Journal Outside Diameter

mm in
126.98 MIN 4.999
127.02 MAX 5.001
If the crankshaft main bearing journal outside diameter is
not within specifications, the crankshaft must be
replaced.
Measure the crankshaft thrust face width.
Crankshaft Thrust Face Width

mm in
54.95 MIN 2.163
55.05 MAX 2.167
If the crankshaft thrust face width is not within
specifications, the crankshaft must be replaced.
Measure the crankshaft rear oil seal flange outside

diameter.
Crankshaft Rear Oil Seal Flange Outside Diameter

mm in
Flange Diameter 164.964 MIN 6.495
Location (1)
165.035 MAX 6.497
Location (2)
165.525 MAX 6.517
If the crankshaft rear oil seal flange outside diameter is
replaced.
Check the crankshaft rear oil seal flange for nicks, burrs,
and grooves.
If a fingernail catches in a nick, burr, or groove, the
crankshaft must be replaced. Damage to the sealing
surface can result in a seal leak.
Measure the crankshaft front oil seal flange outside

diameter.
Crankshaft Front Oil Seal Flange Outside

mm in
Location (1)
139.63 MAX 5.497
Location (2)
140.04 MAX 5.513
If the crankshaft front oil seal flange outside diameter is
replaced.
Check the crankshaft front oil seal flange for nicks, burrs,
and grooves.
crankshaft must be replaced. Damage to the sealing
surface can result in a seal leak.
Measure the crankshaft damper pilot outside diameter.
Crankshaft Pilot Outside Diameter

mm in
49.985 MIN 1.968
50.015 MAX 1.969
If the crankshaft pilot outside diameter is not within
Lubricate the entire crankshaft with clean 15W-40 oil to

prevent rust.
Bend and Twist Inspect

The crankshaft alignment limits are based on total
indicator runout. The runout is measured as the
crankshaft is turned one revolution while recording the
total movement of the dial indicator.
When measuring the crankshaft alignment, four

measurements must be taken:
Full length alignment
Bearing to bearing runout
Rear oil seal flange diameter runout
Front oil seal crankshaft adapter diameter runout.
WARNING
CAUTION
Measuring from the top of the main bearing journal
will cause inaccurate alignment measurements
because of crankshaft sag.
To check the crankshaft full length alignment, support the
crankshaft on the number one and number seven main
bearing journals.
The dial indicator must be set up so the indicator is

located on the side of the number four main bearing
journal.
Set up the dial indicator.
Rotate the crankshaft one complete revolution and record

the total indicator runout.
Total Indicator Runout

mm in
0.200 MAX 0.008
If the crankshaft total indicator runout is not within
Bearing to bearing runout is defined as the relationship of

the total indicator runout of a main bearing journal as it is
rotated on a common axis to the total indicator runout of
an adjacent journal.
Bearing to bearing runout is often referred to as step
runout, adjacent runout or journal to journal runout.
The clock position is defined as the location of the journal

at the highest total indicator runout point. Compare its
angular relationship with the number one crankshaft pin,
as viewed from the front of the crankshaft.
In the illustration, the crankshaft pin is at the 8 o'clock
position. This is the clock position of the journal being
measured.
WARNING
CAUTION
Measuring from the top of the main bearing journal
will cause inaccurate alignment measurements
because of crankshaft sag.
To check the crankshaft full length alignment, support the
crankshaft on the number one and number seven main
bearing journals.
Set the dial indicator up on the side of the main bearing

journal.
Rotate the crankshaft and measure the total indicator

runout at each bearing journal.
Record the value and clock position for each location.
For each journal, plot the total indicator runout value at its
clock position on a polar chart.
The end journals, supported by vee blocks, must be
plotted at the center of the chart.
The illustration illustrates the plot points.
Journal Total Indicator Runout Clock Position
(1) 0 0
(2) 0.002 12
(3) 0.003 12
(4) 0.004 1
Draw a straight line between the plotted points. From
journal number one, to journal number two, to journal
number three, until all journals are plotted on the chart.
To determine the adjacent journal runout, measure the
length of the line from each journal to its corresponding
journal point.
In the above table journal number three and number four
are 51 mm [2 in]. This represents a runout of 0.051 mm
[0.002 in].
Record the adjacent runout for each main bearing journal.
Adjacent Journal Runout

mm in
0.075 MAX 0.003
If the alignment between adjacent journals is not within specifications, it can not be repaired by grinding. The
crankshaft must be replaced. ISX crankshafts are fully fillet hardened and can not be straightened.
Rear oil seal flange diameter runout measurement:

With the crankshaft supported on the number one and
number seven main bearing journals, position a dial
indicator 25.4 mm [1.0 in] from the flywheel mounting face
of the crankshaft.

Rear Oil Seal Flange Total Indicator Runout

mm in
0.03 MAX 0.0012
If the rear oil seal flange total indicator runout is not within
Front oil seal crankshaft adapter diameter runout

measurement:
With the crankshaft supported on the number one and
number seven main bearing journals, position a dial
indicator 25.4 mm [1.0 in] from the balancer mounting face
of the crankshaft.

Front Oil Seal Crankshaft Adapter Diameter Runout

mm in
0.05 MAX 0.002
If the front oil seal crankshaft adapter diameter runout is
replaced.
Magnetic Crack Inspect

The crankshaft must be tested by the continuous
method. The entire surface must be wetted with the
magnetic bath solution before and during the flow of
magnetic current through the crankshaft.
For the head shot (longitudinal magnetization) method,
apply the magnetic bath solution to the crankshaft and use
3800 amperes with VDC or rectified VAC to magnetize the
crankshaft.
A minimum of three successive head shots are required

for each section of the crankshaft.
Flow the magnetic solution over the first 1/3-length of the
crankshaft and apply two head shots of magnetizing
current.
To prevent washing the metal particles off the crankshaft,
turn the magnetic solution flow off.
Apply a third head shot of magnetizing current.
Inspect the crankshaft for open indications.
Flow the magnetic solution over the second 1/3-length of

the crankshaft and apply two head shots of magnetizing
current.
Apply a third head shot of magnetizing current.
Flow the magnetic solution over the last 1/3-length of the

crankshaft and apply two head shots of magnetizing
current.
Apply a third shot of magnetizing current.
For the coil shot (circumferential magnetization) method,

apply the magnetic solution and magnetize the crankshaft
in a 51.35 mm [20.249 in] inside coil or equivalent. Use
3,600 to 4,000 ampere-turns with VDC or rectified VAC.
Amepere-turn is the amperage flowing through the coil
multiplied by the number of turns in the coil.
A minimum of three coil shots are required for each 457

mm [18 in] length to correctly magnetize the crankshaft.
Flow the magnetic solution over the crankshaft in 1/3
sections.
Apply two coil shots, after wetting with the magnetic
solution, with the coil placed at -length points along the
crankshaft.
Apply the third coil shot with the coil placed at -length
points along the crankshaft.
Inspect each 457 mm [18 in] section after the third coil shot
is completed.
An open indication is a crack open to the surface that can

be observed without using optical enhancement.
An open indication can sometimes be felt with a fingernail.
Do not mistake forging trim lines for crack indications.
If open indications are observed in the hardened fillet area
or the critical areas shown (A), the crankshaft must be
replaced.
Open indications longer than 6 mm [0.25 in] are not

acceptable.
Open indications in any fillets or the critical areas are

not acceptable.
Open indications on the crankpin or main bearing journal

surfaces that extend closer than 3 mm [0.12 in] to the fillet
but do not enter the fillet are acceptable.
Open indications in the longitudinal direction up to 12.5

mm [0.5 in] in length, but not closer than 3 mm [0.12 in]
to the oil hole chamfer are acceptable.
Open indications that enter the oil hole chamfer or
intersect the oil hole at 45 degrees 10 degrees are
not acceptable.
Any open indication in the crankpin bearing hole entrance

chamfer is not acceptable.
Open indications in the counterweights inside the critical
area are not acceptable.
Open indications that extend over the face of the

crankshaft or extend into the damper mounting capscrew
holes are not acceptable.
Subsurface indications can not be seen with the eye after

magnetic particles have been removed. These are
indications of open areas or foreign objects below the
surface.
Inspect for subsurface indications.
CAUTION
All magnetism must be removed from the crankshaft
completely and the crankshaft cleaned thoroughly.
Small metal particles will cause engine damage.
Demagnetize the crankshaft.
The maximum residual magnetic field on any pin or main
bearing journal is 8 gauss.
It will possibly be necessary to use reverse D.C.-30 point
step down equipment, or equivalent, to remove the
magnetism.
WARNING
can cause personal injury.
WARNING
personal injury.
Steam clean the crankshaft.
Dry the crankshaft with compressed air.
Use a light preservative oil to lubricate the crankshaft to

prevent rust.
If the crankshaft is not going to be used immediately,
protect it with a plastic cover to prevent dirt sticking to the
oil.
Install
WARNING
CAUTION
Do not drop the crankshaft on the bearings.
Install the main bearings. Refer to Procedure 001-006 in
Section 1.
The end of the crankshaft with the smallest diameter
must point toward the front of the cylinder block.
Install the crankshaft.
Signature, ISX, and QSX15 Eng [...] Crankshaft Adapter
Finishing Steps
Install the main bearing caps. Refer to Procedure
Install the piston and connecting rod assemblies. Refer
Install the lubricating oil pump. Refer to Procedure
Install the front gear housing. Refer to Procedure
Install the flywheel housing. Refer to Procedure
Install the flywheel. Refer to Procedure 016-005 in
Section 16.
Install the cylinder heads. Refer to Procedure 002-004
in Section 2.
Install the engine. Refer to Procedure 000-002 in
Section 0.
Fill the cooling system. Refer to Procedure 008-018 in
Section 8.
Crankshaft Adapter (001-017)

Preparatory Steps
On-Engine Repair
CAUTION
To reduce the possibility of engine damage, the
removal of the lubrication oil pan is required to
prevent debris collection in the oil pan.
Remove the radiator, charge air cooler, and the hood
if applicable. Refer to the OEM service manual.
Remove the crankshaft pulley and vibration damper.
Remove the lubrication oil pan. Refer to Procedure
Crankshaft Adapter Signature, ISX, and QSX15 Eng [...]
Remove
NOTE: If the threaded hole adjacent to the dowel pin is
selected, the dowel pin must be removed prior to drilling.
In most instances, this procedure is easiest to perform
when staring with a threaded hole near the 12 o'clock
position.
Use a 12.7-mm [1/2-in] drill bit, Part Number 4918535 or
equivalent, to ream out the threaded hole so the 6.35-mm
[1/4-in] bushing, Part Number 4918538 or equivalent, will
insert easily.
Install the stop collar, Part Number 4918541 or equivalent,

onto a 6.35-mm [1/4-in] drill bit, Part Number 4918533 or
equivalent, at a depth of 60.3 mm [2.375 in].
WARNING
personal injury.
CAUTION
Do not drill holes completely through the crankshaft
adapter or gear. Damage to the engine, crankshaft,
and or tools can occur.
The use of a generous amount of cutting fluid will increase
tool life and ease the drilling operation.
A maximum drill speed of 850 rpm is recommended.
Insert a 6.35-mm [1/4-in] drill bushing, Part Number
4918538 or equivalent, into the reamed hole.
Drill a 6.35-mm [1/4-in] hole to the preset depth.
Clean out the debris using low pressure air and a shop
towel to cover the hole as necessary.
Install the stop collar, Part Number 4918542 or equivalent

onto a 12.7-mm [1/2-in] drill bit, Part Number 4918535 or
equivalent, at a depth of 54 mm [2.125 in].
WARNING
personal injury.
CAUTION
Remove the 6.35-mm [1/4-in] drill bushing, Part Number
4918538 or equivalent. Using the previously drilled 6.35-
mm [1/4-in] hole as a pilot, drill a 12.7-mm [1/2-in] hole to
the preset depth.
Install the drill guide adapter, Part Number 4918276, onto

the crankshaft nose so the drill guide bushing labeled "A"
is aligned with the previously drilled 21.7-mm [1/2-in] hole.
Install and tighten 2 existing damper capscrews through
the drill guide adapter.
WARNING
personal injury.
CAUTION
Install the 19.05-mm [3/4-in] drill bushing, Part Number
4918540 or equivalent, into the drill guide bushing "A".
Drill a 19.05-mm [3/4-in] hole using drill bit, Part Number
4918536 or equivalent, to a depth of the previous 21.7-mm
[1/2-in] hole.
Remove the 19.05-mm [3/4-in] drill bit.
Clean out the debris. Use low pressure air and a shop
WARNING
personal injury.
CAUTION
A right angle, clutched, 1/2-inch drive drill at a maximum
drill speed of 300 rpm is recommended.
Drill a 25.4-mm [1-in] hole using drill bit, Part Number
4918537 or equivalent, to a depth of the previous 19.05-
mm [3/4-in] hole.
Remove the 25.4-mm [1-in] drill bit.
Remove the drill guide adapter from the crankshaft and

rotate the drill guide adapter 180 degrees so the drill guide
bushing labeled "B" is aligned with the previously drilled
hole.
Install and tighten 2 existing damper capscrews through
the drill guide adapter.

onto a 19.05-mm [3/4-in] end mill, Part Number 4918532,
at a depth of 111 mm [4.375-in].
WARNING
personal injury.
CAUTION
A right angle, clutched, 1/2-inch drive drill at a maximum
drill speed of 300 rpm is recommended.
Bore a 19.05-mm [3/4-in] hole to the preset depth.
Remove the 19.05-mm [3/4-in] end mill, the 2 damper
capscrews, and the drill guide adapter.
Remove the front crankshaft seal. Refer to Procedure

Remove the lower gear cover. Refer to Procedure 001-080
in Section 1.
Insert the wedge, Part Number 4918546, into the 19.05-

mm [3/4-in] drilled hole.
Strike the wedge firmly with a hammer until the crankshaft
adapter splits.
The crankshaft adapter will be easily removable by hand
after splitting, however, a suitable puller can be used to
facilitate the removal.

Inspect the crankshaft, tone wheel, and crankshaft gear
for damage.
Inspect the machined surface for scratches or nicks.
Use a crocus cloth to remove the scratches or nicks. If
scratches or nicks can be felt with a fingernail after the
crankshaft has been polished with the crocus cloth, the
Inspect the crankshaft gear and tone wheel for excessive

wear or damage.
If any teeth on the tone wheel are missing, the tone wheel
must be replaced.
Install
WARNING
To reduce the possibility of personal injury, wear
protective gloves when handling parts that have been
heated.
NOTE: During the installation of the crankshaft adapter,
the pin located on the backside of the crankshaft adapter
must align with the slot on the front surface of the tone
wheel.
Do not lubricate the crankshaft prior to installing the
crankshaft adapter.
Heat the crankshaft adapter for 6 hours at 260C [500F]

before attempting the installation.
NOTE: The crankshaft adapter must be installed within

15 seconds after being removed from the oven.
Install the crankshaft adapter. Use a twisting motion until
the pin is aligned in the slot on the tone wheel.
Hold the crankshaft adapter against the tone wheel for
approximately 30 seconds.
To check the installation, attempt to insert a 0.25-mm

[0.010-in] feeler gauge between the crankshaft gear and
the tone wheel at 4 locations approximately 90 degrees
apart.
If the feeler gauge can be inserted, the tone wheel must
be removed and replaced.
Crankshaft Gear, Front (Crankshaft Installed) Signature, ISX, and QSX15 Eng [...]
Finishing Steps
Install the lubrication oil pan. Refer to Procedure
Install the lower gear cover. Refer to Procedure
Statically time the engine. Refer to Procedure 001-088
in Section 1.
NOTE: If the timing pin, Part Number 3163020, can not
be inserted when the damper marking "Insert Pin" is
aligned with the marking on the lower gear, the tone wheel
or crankshaft adapter is not properly aligned with the
crankshaft.
NOTE: It will be necessary to remove the lower gear cover,
crankshaft seal, and vibration damper and check for
missing dowel pins and or misalignment in the crankshaft
adapter or tone wheel.
Install the radiator, charge air cooler, and the hood, if
applicable. Refer to the OEM service manual.
Crankshaft Gear, Front (Crankshaft

Installed) (001-018)
Preparatory Steps
On-Engine Repair
WARNING
cable last.
Disconnect the battery. Refer to Procedure 013-009
in Section 13.
Remove the lower gear cover. Refer to Procedure
Remove the crankshaft adapter. Refer to Procedure
Remove the tone wheel. Refer to Procedure 001-069
in Section 1.
Remove the alignment dowel pin.
Remove the lubrication oil pan. Refer to Procedure
Remove the lubrication oil pump. Refer to Procedure
Remove the rocker lever cover and gasket. Refer to
Disconnect and remove the engine brake wiring
harness. Refer to Procedure 020-015 in Section 20.
Remove the rocker lever shaft. Refer to Procedure
Remove the upper gear cover. Refer to Procedure
Remove the valve camshaft gear, injector camshaft
gear, adjustable idler gear, and the lower idler gear.
Signature, ISX, and QSX15 Eng [...] Crankshaft Gear, Front (Crankshaft Installed)
Remove
WARNING
personal injury.
CAUTION
Protect the engine internals from debris generated
during the drilling operation. Mask the engine
internals using tape, plugs, and or shields to prevent
debris from entering the engine internals. Failure to
do this will result in significant engine damage.
Install the plastic drill guide, Part Number 4918547, with
the "FRONT" facing the operator. Align the slot with the
crankshaft gear tooth root.

onto a 6.35-mm [0.250-in] drill bit at a depth of 111 mm
[4.375 in].
Tool life will be extended if the drill bit does not break
through the back of the crankshaft gear.
Drill a 6.35-mm [0.250-in] pilot hole to the preset depth.
Install the large drill guide adapter, Part Number 4918276,

onto the crankshaft nose with the hole labeled "C" aligned
with the pilot hole.
Use the alignment pin, Part Number 4918577, to align the

guide with the hole.
Tighten the 7.94-mm [5/16-in] set screw to hold the guide
to the crankshaft.
Install the countersink cutter, Part Number 4918578 or

equivalent, into a 102-mm [4-in] extension, Part Number
4918544 or equivalent.
Slide the 11.5-mm [29/64-in] drill bushing, Part Number
4918534 or equivalent, onto the shaft.
Install the assembly and lock the 11.5-mm [29/64-in] drill
bushing into the hole labeled "C".
Countersink the pilot hole until the outside diameter of the

countersink is approximately 1.6 to 3.2 mm [1/16 to 1/8 in]
deep.
Remove the countersink and the drill bushing.
Insert the drill bushing, Part Number 4918539, or

equivalent, into the hole labeled "C" and lock the 12.7-mm
[1/2-in] drill bushing into the drill guide.

Drill a 12.7-mm [1/2-in] hole to depth of the previously
6.35-mm [1/4-in] drilled hole.
Remove the tone wheel alignment dowel from the
crankshaft.
Install the locating gauge, Part Number 4918314, or other

suitable spacer, onto the crankshaft gear.
A spacer must be installed or the crankshaft will be
damaged during the crankshaft gear removal.
Insert the small splitting wedge, Part Number 4918545,

with the flatted area facing toward the crankshaft and into
the drilled hole.
Strike the small splitting wedge with a suitable hammer

until the crankshaft gear splits.
Remove the crankshaft gear by hand or use a suitable
puller if necessary.
WARNING
When using solvents, acids or alkaline materials for
WARNING
personal injury.
NOTE: If scratches or nicks can be felt with a fingernail
after the crankshaft has been polished with a crocus cloth,
the crankshaft must be replaced.
Inspect the crankshaft for damage.
Inspect the machined surface for scratches or nicks.
Install
Install the locating gauge, Part Number 4918314, onto the
side of crankshaft gear.
Heat the crankshaft gear for 3 hours at 177C [350F]
before attempting the installation.
WARNING
heated.
NOTE: The crankshaft gear must be installed within 15
seconds after being removed from the oven.
Install the crankshaft gear until the locating gauges make
contact with the front crankshaft journal.
Hold the crankshaft gear in position for approximately 60
seconds to allow the shrink fit to properly hold the
components.
Remove the locating gauge from the crankshaft gear.
Use a brass hammer, tap the alignment dowel pin in the

crankshaft hole until the alignment dowel pin bottoms out.
Check the gap between the crankshaft gear and the
crankshaft first journal by inserting the locating gauge,
Part Number 4918314.
If the locating gauge is loose or can not be inserted,
replace the crankshaft gear.
Finishing Steps
WARNING
cable last.
Install the valve camshaft gear, injector camshaft
gear, adjustable idler gear, and the lower idler gear.
Install the upper gear cover. Refer to Procedure
Install the rocker lever shaft. Refer to Procedure
Connect the engine brake wiring harness. Refer to
Install the rocker lever cover and gasket. Refer to
Install the lubrication oil pump. Refer to Procedure
Install the lubrication oil pan. Refer to Procedure
Install the tone wheel. Refer to Procedure 001-069 in
Section 1.
Install the crankshaft adapter. Refer to Procedure
Install the lower gear cover. Refer to Procedure
Connect the battery. Refer to Procedure 013-009 in
Section 13.
Crankshaft Pulley Signature, ISX, and QSX15 Eng [...]
Crankshaft Pulley (001-022)

Remove
Remove the fan and water pump drive belt. Refer to
Procedure 008-003.
Remove the alternator drive belt. Refer to Procedure
013-005.
Remove the fan and water pump drive belt tensioner.
CAUTION
damper. These tools can damage the damper.
Remove two of the vibration damper and crankshaft pulley
retaining capscrews.
Remove the remaining 10 capscrews. Remove the pulley
and damper.

Remove the fan. Refer to the OEM service manual.
If equipped with a crank-driven fan, remove the crankshaft

adapter (1) from the pulley (2).
Signature, ISX, and QSX15 Eng [...] Crankshaft Pulley

CAUTION
damper. These tools can damage the damper.
Remove the remaining 10 capscrews. Remove the pulley
(4), damper (3), mounting spacer (2), and second damper
(1).
Inspect for Reuse

Inspect the pulley for cracks, excessive wear in the belt
grooves, or other damage.
Crankshaft Pulley Signature, ISX, and QSX15 Eng [...]
Install
the vibration damper, and the pulley are clean, dry, and
free of burrs.
NOTE: Align dowel pin in crankshaft with dowel hole in
damper.
Install the vibration damper(s) and pulley on the guide
studs.

capscrews.
Install the fan and water pump belt tensioner. Refer to

Procedure 008-080.
NOTE: Align dowel of tensioner to bracket.
Install the fan and water pump drive belt. Refer to
Procedure 008-003.
Install alternator drive belt. Refer to Procedure 013-005.

the dampers, mounting spacer, and pulley are clean, dry,
and free of burrs.
Signature, ISX, and QSX15 Eng [...] Crankshaft Pulley
Install one of the dampers (1), mounting spacer (2), the

second damper (3), and the pulley (4) onto the guide studs.

Install ten capscrews.
capscrews.
Tighten the twelve capscrews in a star pattern.
If equipped with a crank-driven fan, install the crankshaft

adapter (1), making sure it seats flush against the pulley
(2).
Use clean 15W40 oil to lubricate the capscrew threads.
Install the fan and water pump belt tensioner. Refer to

Procedure 008-080.
NOTE: Align dowel of tensioner to bracket.
Install the alternator drive belt. Refer to Procedure

013-005.

Procedure 008-003.
Install the fan. Refer to the OEM service manual.

Preparatory Steps
WARNING
Procedure 008-003 (Drive Belt, Water Pump) in
Section 8.
Remove the fan and water pump belt tensioner.
Refer to Procedure 008-080 (Belt Tensioner,
Automatic (Water Pump) in Section 8.
Remove the crankshaft pulley and vibration damper
(s). Refer to Procedure 001-052 (Vibration Damper,
Viscous) in Section 1.
Remove
Remove the eight mounting nuts from the gear cover
studs.
Position the replacer plate (1) over the crankshaft end and
against the crankshaft seal. The large notch between the
teeth needs to bridge the raised gear cover surface.
Make certain that the alignment of the three welded nuts
on the crankshaft seal are positioned into the counterbore
slots of the replacer plate (1).
Install a capscrew (4) with a flat washer (5) in the upper
slot of the replacer plate to hold it in position
CAUTION
Tighten the capscrews by hand until a slight
resistance is felt. Do not overtighten the capscrews or
the seal nuts can break off causing damage to the seal
and leading to front cover damage.
Use a small allen wrench to thread the removal tool
capscrews (2) through the replacer plate and into the seal
nuts.
Tighten the socket head capscrews (2) clockwise into the
three seal removal nuts that are welded on the crankshaft
seal until a slight resistance is felt.
Remove the capscrew in the upper slot of the replacer
plate (1).
Install the replacer screw (3) into the replacer plate (1).
Turn the screw (3) clockwise until the crankshaft seal is
removed from the crankshaft.

NOTE: All lower gear covers have either a beveled half
groove, or a full o-ring groove under the crankshaft seal
flange.
Full o-ring groove covers contain an o-ring in the lower
gear cover groove and were only used prior to June 5,
1999. The lower gear cover must be replaced if installing
a new seal. Refer to Procedure 001-080 (Gear Cover,
Lower).
Beveled half groove covers do not contain an o-ring and
only require replacement if damaged. Refer to Procedure
001-080 (Gear Cover, Lower).
Use a small magnet to remove any metal shavings.
Use a crocus cloth to remove any deposits from the
crankshaft and seal bore area.
Inspect the crankshaft for nicks, burrs, and grooves.

Damage to the sealing surface can result in seal leakage.
Install
The position of the front crankshaft seal on the crankshaft
is determined by the position of the lower gear cover.
The lower gear cover is mounted to the gear cover housing
using clearance holes. This allows for slight movement of
the cover when the mounting capscrews are loose.
The unitized crankshaft seal must be centered on the
crankshaft for correct operation.
The seal attaches to the lower gear cover, and must be
installed with the lower gear cover capscrews loose and
the cover free to move.
In order for the seal to be properly centered on the

crankshaft during assembly and maintain its location
during operation, the following installation instructions
must be followed.
The crankshaft seal removal and installation tool correctly
centers the seal and correctly positions the dust seal
portion of the seal on the crankshaft.
CAUTION
Failure to loosen and remove the mounting capscrews
from the gear cover can cause the front crankshaft
seal to be misaligned and cause premature seal wear.
The front gear cover must be aligned as follows:
Removing the gear cover mounting capscrews around the
crankshaft seal allows the replacer plate to set against the
gear cover during seal installation.
Remove the gear cover mounting capscrews around the
crankshaft seal.
Loosen the remaining mounting capscrews on the gear
cover so the cover can move freely.
CAUTION
Failure to follow the installation and tightening
sequence can lead to the crankshaft seal being off
center and installed at the wrong depth causing
premature seal wear.
CAUTION
Never use a hammer or mallet to install the seal. Use
of a hammer can damage the crankshaft seal and/or
crankshaft.
The seal removal and installation tool has provisions for
any seal nut orientation, although one seal nut must
always be located at the 11 o'clock position.
Do not use lubricants on the crankshaft seal.
Position the crankshaft seal (1) onto the crankshaft until
the gear cover studs are protruding through the seal
carrier mounting holes.
Place the replacer plate (1) against the crankshaft seal.

Make sure the welded nuts on the front crankshaft seal
are seated in their respective slots on the replacer plate
(1).
The large notch between the teeth must bridge the raised
gear cover surface.
Install three washers (4) and capscrews (5) through the

three slots in the replacer plate (1) and into the crankshaft
end.
The capscrews in the replacer plate must be equally
spaced. This allows the crankshaft seal to be installed
correctly.
Tighten the capscrews hand-tight.
CAUTION
The crankshaft seal must be pressed evenly. If the
crankshaft seal is not pressed in evenly the seal can
be damaged.
Inspect the crankshaft seal during installation to make
certain it is being pressed evenly.
Tighten the capscrew(s) no more than of a revolution at
a time, alternating in a clockwise pattern until the replacer
plate (1) bottoms out against the face of the lower gear
cover.
To maintain the cover position while the replacer plate is

removed, tighten the two gear cover mounting capscrews,
as indicated by the arrows in the graphic.
Install the crankshaft seal mounting nuts (1) through the
holes provided in the replacer plate.
Tighten the mounting nuts in the sequence shown.
Install all the gear cover mounting capscrews.

The torque sequence must be followed to prevent the
gear cover strip seal from squeezing out of the groove.
Finishing Steps
WARNING
Install the crankshaft pulley and vibration damper(s).
Refer to Procedure 001-052 (Vibration Damper,
Viscous) in Section 1.
Install the fan and water pump belt tensioner. Refer
to Procedure 008-080 (Belt Tensioner, Automatic
(Water Pump) in Section 8.
Section 8.

Preparatory Steps
WARNING
Disconnect the driveline. Remove the transmission
and clutch. Refer to the manufacturer's instructions.
Remove the flywheel. Refer to Procedure 016-005 in
Section 16.
Remove
The rear crankshaft seal requires the rear crankshaft seal
replacer kit, Part Number 3164780, for the seal removal
and installation.
1 Replacer plate
2 Pilot drill
3 Replacer screw
4 Self-tapping screw x 10
5 Stud x 3
6 Hex nut x 3.
Use three flywheel mounting capscrews to secure the

replacer plate (1) to the crankshaft.
Install a pilot drill (2) into one of the holes in the rear
crankshaft seal tool and drill a hole through the seal
casing.
Remove the pilot drill (2) and repeat the procedure for at
least two more evenly spaced holes of the rear crankshaft
seal tool. As many as six holes may be drilled to assist in
removing the rear crankshaft seal.
NOTE: Three stud screws (3) and three hex nuts (4) are
required for some engines with flywheel mounting
capscrews that are too short to mount the replacer plate
(1) to the crankshaft.
Install at least three self-tapping screws (1) into the

replacer plate (2).
Remove the flywheel capscrews from the rear crankshaft
seal tool.
Install the replacer screw (3) into the center hole of the
replacer plate and turn clockwise to remove the seal.
WARNING
for use. Wear goggles and protective clothing to avoid
personal injury.
WARNING
Clean the seal bore surface of the flywheel housing.
Use an emery cloth to remove any rust or other deposits

from the crankshaft flange.
Use a clean, lint-free cloth to clean the crankshaft flange
and to remove all traces of oil film.
Visible scratches can result in seal leakage.
Install
The rear crankshaft seal must be oriented with the engine
as shown in the illustration.
CAUTION
Never use a hammer or mallet to install the seal.
Damage to the seal can occur.
Do not use lubricants to install the seal. Apply a 10-
percent soap solution to the outer-ribbed surface of the
seal.
Guide the rear crankshaft seal (1), spacer (2), and replacer
plate (3) over the crankshaft.
NOTE: Spacer, Part Number 4918688, is used to make
sure of the correct installation depth of the crankshaft seal.
The flat side of the spacer should contact the crankshaft
seal during installation.
CAUTION
the bore. Misalignment of the seal can cause damage.
Install three flywheel mounting capscrews or replacer
screws and hex nuts, through the replacer plate and into
the end of the crankshaft.
Finger-tighten the three installation capscrews against the
replacer plate.
Tighten the screws not more than of a turn at a time,
in a clockwise pattern, until the installation tool seats
against the flywheel housing.
Tighten the screws.
Measure
the seal.
0.5 mm [0.02 in].
installed.
Signature, ISX, and QSX15 Eng [...] Cylinder Block
Finishing Steps
WARNING
Install the flywheel. Refer to Procedure 016-005 in
Section 16.
Install the clutch transmission and driveline. Refer to
the manufacturer's instructions.
Operate the engine until it reaches normal operating
temperature and check for leaks.
Cylinder Block (001-026)

Inspect for Reuse
Inspect the cylinder block for cracks. If any cracks are
found, the cylinder block must be replaced.
If upper bore erosion is discovered during block

inspection, it must be disregarded. It is not a failure mode
and the use of new o-rings on the cylinder liner provides
an adequate seal.
If liner ledge pitting is discovered during block inspection,

the block can be reused, if no leak is evident in the liner-
to-liner ledge (block) interface.
Cylinder Block Signature, ISX, and QSX15 Eng [...]
The main bearing bore diameter must be measured with

the main bearings removed and the main bearing caps
assembled and torqued to the correct specification.
Main Bearing Bore Diameter
mm in
133.49 MIN 5.2555
133.52 MAX 5.2565
Repair
Follow this procedure to salvage capscrew holes that are
missing a portion of threads or that have cracks extending
into the threaded sidewall from the upper counterbore.
Cracks that extend into the capscrew bosses or the

coolant cavity below the upper counterbore can not be
salvaged using this procedure.
Remove any burrs from the top deck surface of the

cylinder block. A 12 inch flat surface mill file is effective
for this step. Burr removal is necessary to obtain an
accurate fixture location.
NOTE: The thread salvage kit is designed to be used with

the cylinder liner removed. If the cylinder liner remains in
the block, shims must be installed to both sides of the
base, equally, to bridge the liner.
NOTE: On some engines, it will be necessary to use the
spacer, Part Number 3376206, between the mounting
base and the drilling fixture.
Select two capscrew holes so the failed capscrew hole is
positioned approximately in the middle. Install the
mounting plate assembly onto the capscrew holes using
the appropriate spacers, four plain washers, and the
existing cylinder head capscrews.
Use a heavy washer and the 5/8-18 x 3 inch hex head
capscrew to attach the drilling fixture to the mounting plate
assembly.
For main bearing capscrew thread repair, mounting plate,

Part Number 3164014, will not accommodate all engines.
In those cases, the repair must be performed by a
qualified machine shop.
Slide the locating pin through the appropriate drilling

fixture bushing hole until it rests in the failed capscrew
hole of the cylinder block.
Center the drilling fixture guide bar and bushing over the
failed capscrew hole.
Tighten the three capscrews to secure the fixture
assembly.
Remove the locating pin.
Setting the stop collar is required only for repairs using

drills.
Drills are used in some kits to allow for quick removal of
waste material; however, care must be taken to make
certain the depth of the repaired capscrew hole is not
increased beyond specification.
The following steps will result in the drill stopping short of
the original hole depth. The remaining material is then
removed with the reamer.
Place a 0.76 mm [0.030 in] feeler gauge over the hole to
be repaired.
Insert the drill through the drill bushing until its tip rests
against the feeler gauge.
Place the thread insert to be installed between the drill
bushing and the stop collar.
Move the stop collar down until is rests against the insert
and tighten the stop collar.
Place the drill through the drill fixture bushing and let it
rest over the top of the failed capscrew hole.
Use a drill motor with a clutch and a maximum operating
speed of 300 rpm. Use a suitable cutting fluid. Operate the
drill motor until the stop collar contacts the drill bushing.
WARNING
personal injury.
Remove the chips with a chip vacuum.
Place the reamer through the drill fixture bushing and let
it rest over the top of the failed capscrew hole.
While reaming the hole, it will be necessary to stop
frequently to clean the hole with the chip vacuum.
speed of 300 rpm, a suitable cutting fluid and operate the
drill motor until the reamer reaches the bottom of the
original capscrew hole.
The reamer will stop cutting when it reaches the bottom of
the hole.
WARNING
personal injury.
Stop the tapping operation frequently to clean the bore

with a chip vacuum.
Install a inch square drive socket on the end of the
appropriate tap.
When tapping, keep the tap well lubricated.
Install the tap (4), and use a suitable tapping fluid. Hand-
tap to the bottom of the failed capscrew hole.
Remove the tap.
WARNING
personal injury.
Remove the mounting capscrews, spacers, four plain

washers, and mounting plate assembly.
Thread the tap in and out of the newly-cut threads several

times to verify the thread condition and clean debris from
the threads.
WARNING
WARNING
Check the capscrew hole for evidence of porosity and
cracks.
Clean the threads and flush any debris from the tapped
hole using a solvent-degreasing agent.
WARNING
personal injury.
Remove the solvent-degreasing agent from the hole with
a chip vacuum.
Place the appropriate jam nut (1) on an appropriate

capscrew.
Install the appropriate thread insert (2) onto the cylinder
head mounting capscrew until it nears the bottom of the
insert.
Rotate the jam nut (1) until it contacts the thread insert (2)
to lock the insert and jam nut together.
WARNING
WARNING
Remove the preservative coating from the circumference
of the thread insert. Use a solvent-degreasing agent.
Install the thread insert, jam nut, and capscrew into the
newly-tapped hole. Make certain the thread insert threads
freely into the hole.
NOTE: For applications with a counterbore, measure the

protrusion depth starting at the counterbore face, which is
recessed into the hole.
Check for protrusion. Make certain the thread insert
protrusion is 0 to 1.0 mm [0 to 0.040 in] above the cylinder
block surface.
It is important to make certain the minimum required
thread depth is maintained after thread repair.
If the insert protrusion exceeds 1 mm [0.040 in], the
cylinder head capscrew can bottom out when tightened.
Record the amount the insert protrudes.
It is necessary to increase the depth of the original
capscrew hole.
If the insert protrusion is correct, install the insert.
If the protrusion is not correct, record the measurement
and adjust the bore depth.
Prior to increasing the capscrew hole depth, check the

following:
1 Make certain the correct thread insert is being used.
Two inserts are available, two inserts are identical
except for their length.
2 Make certain the insert used is the correct length.
3 Make certain the capscrew hole is threaded all the way
to the bottom.
4 Make certain there are no burrs or other damage that
would prevent the insert from threading to the bottom
of the capscrew hole.
After checking the above listed items, if the thread insert
protrusion still exceeds 1.0 mm [0.040 in], the depth of the
original capscrew hole must be increased.
NOTE: The thread salvage kit is designed to be used with

the cylinder liner removed. If the cylinder liner remains in
the block, shims must be installed to both sides of the
base, equally, to bridge the liner.
NOTE: On some engines, it will be necessary to use the
spacer, Part Number 3376206, between the mounting
base and drilling fixture.
Install the mounting plate assembly.
Do not tighten the fasteners.
Slide the drill through the drill bushing and into the
threaded hole until it rests at the bottom of the hole.
Tighten all fasteners.
The drill must slide freely in the bushing and threaded
hole, indicating that it is centered in the hole.
Do not increase the depth of the original capscrew hole

more than 3.0 mm [0.120 in].
Slide the stop collar over the drill bit.
Subtract 0.50 mm [0.020 in] from the insert protrusion.
Select a feeler gauge equivalent to this value.
With the drill resting at the bottom of the hole, insert the
feeler gauge between the stop collar and drill bushing.
Tighten the stop collar.
speed of 300 rpm, a suitable cutting fluid and operate the
drill motor until the stop collar contacts the drill bushing.
WARNING
personal injury.
It is not necessary to ream the hole prior to the second

tapping.
Install a inch square drive socket on the end of the
appropriate tap.
When tapping, keep the tap well lubricated.
Install the tap (4), and use a suitable tapping fluid. Hand-
tap to the bottom of the failed capscrew hole.
Remove the tap.
WARNING
WARNING
Check the capscrew hole for evidence of porosity and
cracks.
Clean the threads, and flush any debris from the tapped
hole using a solvent-degreasing agent.
WARNING
personal injury.
Remove the chips and solvent-degreasing agent from the
hole with a chip vacuum.
Install the thread insert on a cylinder head capscrew and

lock in place with a jam nut.
Temporarily install the thread insert and check the
protrusion. Make certain that the protrusion is 0 to 1 mm
[0 to 0.040 in] above the cylinder block surface.
Remove the insert.
Apply a light coat of primer, Part Number 3824715, to the

thread insert and the threaded hole. Allow three to five
minutes to dry.
Apply four beads of thread locking compound, Part
Number 3824038, to the circumference of the thread
insert.
Each bead must be 0.8 mm [0.03 in] wide down the entire
length of the thread insert and the beads must be 90
degrees apart.
Install the thread insert until it is flush with the cylinder

block surface or it bottoms in the hole.
Allow to dry for three hours.
Signature, ISX, and QSX15 Eng [...] Cylinder Block and Liner Seats
WARNING
personal injury.
Remove the capscrew and jam nut.
If necessary, file or machine the top of the thread insert so
it is flush with the cylinder block surface.
Make certain that the inner diameter of the thread insert
is free of burrs. Remove any file shavings or debris with
the chip vacuum.
For applications where the thread insert is recessed into

a counterbore, an end mill or a machine cutter will be
necessary to remove the excess length of the insert and
restore the alignment of counterbore.
Cylinder Block and Liner Seats

(001-027)
Leak Test
WARNING
WARNING
Drain the engine lubricating oil. Refer to Procedure
007-037.
007-025.
Cylinder Block and Liner Seats Signature, ISX, and QSX15 Eng [...]

Procedure 007-035.

001-089.
Pressurize the engine cooling system. Refer to Procedure

008-018.
NOTE: Apply the air pressure 15 minutes before
inspecting the cylinder liner seats. Be sure the system is
holding air pressure before beginning inspection.
Air Pressure: 138 kPa [ 20 psi ]
Inspect the outside circumference of the cylinder liners

and the area below the cylinder liner seats in the cylinder
block for coolant leaks.
If a leak is found:
Remove and inspect the cylinder liners. Refer to
Procedure 001-028.
Inspect the cylinder block liner bore area. If fretting
or wear is found, the cylinder block must be
replaced.
Signature, ISX, and QSX15 Eng [...] Cylinder Block and Liner Seats

001-089.

007-035.
Install the lubricating oil pan. Refer to Procedure 007-025.

007-037.
Cylinder Block and Liner Seats Signature, ISX, and QSX15 Eng [...]

007-037.
Operate engine to normal operating temperature and

check for leaks.
Procedure 014-013.

Preparatory Steps
WARNING
Wait until the coolant temperature is below 50 C
WARNING
WARNING
WARNING
WARNING
ingestion and prolonged contact with used engine oil.
If not reused, dispose of in accordance with local
Drain the cooling system. Refer to Procedure 008-018.
Remove the cylinder head. Refer to Procedure
002-004.
007-025.
Procedure 007-035.
001-089.
Procedure 001-046.
Remove the piston and connecting rod assemblies.
Remove
The cylinder liners can be removed by using either:
Cylinder liner puller (universal), Part Number 3163745
and puller plate (S600), Part Number 3162462.
Cylinder liner puller (universal), Part Number 3376015.
CAUTION
The cylinder puller must be installed and used as
described to reduce the possibility of damage to the
cylinder block. The puller plate must be parallel to the
main bearing saddles and must not overlap the
cylinder liner outside diameter.
Insert the cylinder liner puller onto the top of the cylinder
block.
The cylinder liner puller must be centered on the top of

the cylinder block.
Turn the puller jackscrew clockwise to loosen the cylinder
liner from the cylinder block.
Use both hands to remove the cylinder liner.
Remove and discard the o-ring seals.
Use Dykem, or equivalent, to place a mark on the intake

air side of the cylinder liner to show cylinder liner
orientation.
Use Dykem, or equivalent, to mark the cylinder number on

each cylinder liner.

CAUTION
silicon particles from emery cloth or sand paper can
be damaged.
Use a soft wire brush to clean the flange seating area.
7448, Part Number 3823258, or equivalent to remove the
remaining scale and rust.
WARNING
WARNING
Wear safety glasses or a face shield, as well as
protective clothing, to reduce the possibility of
personal injury when using a steam cleaner or high
pressure water.
WARNING
personal injury.
Use solvent or steam clean the cylinder liners and dry with
compressed air.
Use clean 15W-40 oil to lubricate the inside circumference
of the cylinder liners.
Allow oil to soak into the cylinder liner for 5 to 10 minutes.
Use lint-free paper towels to wipe the oil from the inside
of the cylinder liners.
Continue to lubricate the inside of the cylinder liners and
wipe clean until the paper towel shows no gray or black
residue.
Inspect the cylinder liners for cracks on the inside and

outside circumferences.
Inspect for cracks under the cylinder liner flange.

Cracks can also be detected by using either magnetic
inspection or dye method.
Inspect the outside circumference for excessive corrosion

or pitting.
Cylinder liners with pitting generally can not be used.
However, if the pitting is light and can be removed with
fine emery cloth, the cylinder liner can be used.
Cylinder Liner Pitting Depth

mm in
1.60 MAX 0.060
Inspect the inside circumference for vertical scratches

deep enough to be felt with a fingernail.
If a fingernail catches in the scratch, the cylinder liner
must be replaced.
Inspect the inside circumference for scuffing or scoring.
Inspect the inside diameter for cylinder liner bore

polishing.
A moderate polish (A) produces a mirror finish in the worn
area with traces of the original hone marks or an indication
of an etch pattern.
A heavy polish (B) produces a bright mirror finish in the
worn area with no traces of hone marks or an etch pattern.
Replace the cylinder liner if a heavy polish is present over

20 percent of the piston ring travel area or 30 percent of
the piston ring travel has both moderate and heavy polish
and one half (15 percent) is heavy polish.
Use a dial bore gauge to measure the cylinder liner inside

diameter in four places, 90 degrees apart at the top and
bottom of the piston travel area.
Cylinder Liner Inside Diameter

mm in
137.14 MAX 5.40
Measure the cylinder liner top press fit area outside

diameter.
Cylinder Top Press Fit Outside Diameter

mm in
160.98 MAX 6.34
Install
CAUTION
same design.
There are two different designs of cylinder liners used.
The design used in a particular engine is dependent on
the engine's production vintage.
Engines assembled prior to engine serial number
14022615 have groove-top cylinder liners. They are
characterized by a groove machined into the top surface
of the cylinder liner flange.
Engines with serial number 14022615 and after are
assembled with flat-top cylinder liners. They are
characterized by a cylinder liner flange that is flat, except
for the fire dam.
Make sure the cylinder block and all parts are clean before
assembly.
Lubricate the two cylinder liner o-ring seals with vegetable
oil prior to assembly.
Install the two o-ring seals onto the cylinder liner.
CAUTION
same design.
Install the cylinder liner into the cylinder block.
When acceptable and used cylinder liners are installed,
rotate the cylinder liner 90 degrees from its original
position in the engine. The thrust and anti-thrust surfaces
must face the front and back of the cylinder block.
Use cylinder liner installation kit, Part Number 3162461,
to seat the liner.
If the cylinder liner does not seat properly, remove it and
Inspect the cylinder liner bore seat and cylinder liner for
nicks, burrs, or dirt.
Install the cylinder liner again.
Measure
Liner Protrusion
Because of design differences, the cylinder liner's position
(relative to the cylinder top deck) will be different.
For groove-top cylinder liners, a recession measurement
is taken. This measures the depth of the groove relative
to the cylinder block deck regardless of the flange or fire
dam height.
For flat-top cylinder liners, a cylinder liner protrusion

measurement is taken which is the height of the cylinder
liner flange above the cylinder block surface regardless of
the flange or fire dam height.
Regardless of the cylinder liner design, the measurement
technique will be the same.
The cylinder liner measurement must be checked before

installing the pistons and connecting rods.
The cylinder liner measurement must be made with the
cylinder liners in the clamped state.
Install and tighten the cylinder liner installation tool.
Use depth gauge, Part Number 3823495, to measure the

clamped state at the intake side three times and average
the readings.
Measure the clamped state of the exhaust side three times
and average the readings.
Cylinder Liner Recession (Groove-Top Cylinder

Liners)
mm in
0.36 MIN 0.014
0.51 MAX 0.019
Cylinder Liner Protrusion (Flat-Top Cylinder Liners)

mm in
0.18 MIN 0.007
0.33 MAX 0.014
If the cylinder liner measurement on either the intake or
exhaust side is not within specifications, the cylinder liner
must be replaced.
For flat-top cylinder liners only:

The difference between the lowest cylinder liner and
the highest cylinder liner can not be greater than 0.102
mm [0.004 in].
The maximum allowable difference between adjacent
cylinders is 0.51 mm [0.002 in].
The protrusion must be within 0.0381 mm [0.0015 in]
around any cylinder.
Before installing the piston and connecting rod

assemblies, wipe the inside of the cylinder liners using a
clean cloth with 15W-40 oil.
Finishing Steps
WARNING
Install the piston and connecting rod assemblies. Refer
001-046.
001-089.
Install the oil suction tube. Refer to Procedure 007-035.
007-025.
Install the cylinder head. Refer to Procedure 002-004.
Procedure 007-037.
007-037.
Fill the cooling system. Refer to Procedure 008-018.
Operate the engine and check for leaks.

Preparatory Steps
WARNING
WARNING
Before removing gears, read Engine Base Timing.
Remove the water pump drive belt. Refer to
Procedure 008-003.
013-005.
Remove the fan hub assembly. Refer to Procedure
008-036.
Remove the crankcase breather tube. Refer to
Procedure 003-018.
Remove the alternator. Refer to Procedure 013-001.
Drain coolant. Refer to Procedure 008-018.
Remove the crankcase breather tube. Refer to
Procedure 003-001.
Remove the upper and lower gear covers. Refer to
Remove the water pump. Refer to Procedure
008-062.
Remove the valve and injector camshaft scissor
gear. Refer to Procedure 001-088.
Remove the adjustable idler gear. Refer to
Procedure 001-088.
Remove the air compressor. Refer to Procedure
012-014.
Remove the lower idler scissor gear. Refer to
Procedure 001-088.
Remove the crankshaft position sensor and
capscrews from front of oil pan.
Remove the retaining brace bracket. Refer to
Procedure 001-081.
Remove the accessory bracket. Refer to Procedure
001-082.
Remove
WARNING
Remove two capscrews and install two guides.

Remove the housing and gasket.
Discard the gasket.
Remove the guide studs.
CAUTION
Immediately upon removal of the front gear housing a
plug must be inserted into the cylinder block oil
passage drilling. Failure to insert the oil passage plug
can result in a bearing failure, crankshaft failure, or
both.
protective plug kit, Part Number 4918319. This plug is
Insert the plug into the front oil passage.
Firmly push the plug into the oil passage to prevent all
debris from entering the lubrication system when cleaning
the gasket surface.
WARNING
WARNING
When using a steam cleaner, wear protective clothing
and safety glasses, or a face shield. Hot steam can
cause serious personal injury.
WARNING
personal injury.
CAUTION
If the oil passages are not plugged before cleaning, a
crankshaft failure can occur.
Clean gasket surfaces by hand with a gasket scraper or
cleaning pad, Part Number 3823258. If the gasket material
residue can not be felt with a finger, the surface is ready
to accept the new gasket.
Use steam or solvent to clean the gear housing and dry
with compressed air.
WARNING
personal injury.
Use compressed air to clear the oil galley to the air
compressor and oil pump of any obstructions.
Inspect the gear housing for cracks or other damage.

Inspect the seal grooves of the housing for debris or
damage.
Install
Remove the protective plug from the cylinder block oil
passage. Make sure no debris enters the lubrication
system. Use a clean shop towel, carefully wipe out the oil
passages.

Install a new gear housing mounting gasket.
The gear housing has the words Special Capscrew cast

into the housing at the number 1 mounting location (see
illustration). This capscrew must be the short head
capscrew to prevent contact between the capscrew and
the idler gear.
WARNING
Install the gear housing.
Install the 18 mounting capscrews.

Four different length capscrews are utilized on the front
gear housing. Use the table below to identify the
capscrews and their mounting locations.
Capscrew Mounting Location
Location Size Quantity
14 M10 x 1.5 x 93 1
18, 19, 20 M10 x 1.5 x 70 3
1 M10 x 1.5 x 21.8 (Special 1
Short Head)
All remaining M10 x 1.5 x 2.5 15
Remove the guide studs and install two capscrews.

Torque Value:
All Capscrews Step1 20 Nm [ 15 ft-lb ]
Except (1)
Torque Value:
Capscrew (1) Step1 20 Nm [ 15 ft-lb ]
Piston Signature, ISX, and QSX15 Eng [...]
Finishing Steps
WARNING
Install the accessory bracket. Refer to Procedure
001-082.
Install the retaining brace bracket. Refer to
Procedure 001-081.
Install the crankshaft position sensor. Refer to
Procedure 019-042 in the Signature, ISX, and
QSX15 Service Manual, Bulletin 4021334. Install the
capscrews at the front of the oil pan.
Install the lower idler scissor gear. Refer to
Procedure 001-088.
Install the air compressor. Refer to Procedure
012-014.
Install the adjustable idler gear. Refer to Procedure
001-088.
Install the valve and injector camshaft scissor gear.
Install the water pump. Refer to Procedure 008-062.
Install the upper and lower gear covers. Refer to
Install the crankcase breather tube. Refer to
Procedure 003-001.
Fill coolant. Refer to Procedure 008-018.
Install the alternator. Refer to Procedure 013-001.
Install the crankcase breather tube. Refer to
Procedure 003-018.
Install the fan hub assembly. Refer to Procedure
008-036.
013-005.
Install the water pump drive belt. Refer to Procedure
008-003.
Operate the engine to normal operating temperature
and check for leaks.
Piston (001-043)
General Information
Some Signature, ISX, and QSX15 engines are equipped
with articulated pistons.
The articulated piston is a two-piece piston consisting of
a forged steel crown and an aluminum skirt.
An open chamber oil gallery is located on the underside
of the crown of the piston to provide more oil contact with
the piston and give better piston cooling. Piston cooling
nozzle targeting is critical because the oil is captured in
shaker trays.
Signature, ISX, and QSX15 Eng [...] Piston
Some engines are equipped with single-piece pistons.

The single-piece piston is a one-piece piston, that does
not have a bushing and is forged from a high-strength,
alloy steel.
A cover plate, that is not removable, is located on the
underside of the piston to capture oil and cool the piston.
Do not remove this cover plate under any circumstances.
CAUTION
All pistons within a given engine must be of the same
design - all are to be either the articulated design or
the single-piece design. Do not mix piston designs in
the same engine. Single-piece pistons must have
drilled rods and rod bearings. Articulated pistons can
Preparatory Steps
All Applications
Remove the piston and connecting rod assemblies from
the engine. Refer to Procedure 001-054 (Piston and
Connecting Rod Assembly) in Section 1.
Disassemble the piston and connecting rod assembly.

Refer to Procedure 001-054 (Piston and Connecting Rod

Articulated Piston
WARNING
CAUTION
To reduce the possibility of damage to the piston
crown, the cleaning solvent must be approved for
bushing material. If necessary, brush the piston
crowns with a soft non-metallic brush. A metallic
brush can damage the piston ring grooves.
It is only necessary to remove the carbon buildup. It is
not necessary to make the crown appear to be new.
CAUTION
When using walnut shell blast to clean steel piston
crowns, use the minimum recommended pressure
and do not concentrate the blast in any one area for
extended lengths of time. Make sure the pin bore area
is protected from the blast so as not to damage the
surface finish. Do not use walnut shell blast to clean
aluminum piston skirts.
Do not use glass or plastic bead media to clean the piston
crowns.
Carbon deposits can be cleaned from the piston crowns
by soaking in an approved solution and/or by blasting with
walnut shell media.
Soak steel pistons for at least 30 minutes in an approved
cleaning solvent for steel and for brushing material. Use
a hot soapy solution with a non-metallic brush to remove
carbon deposits.
For best results, soak the pistons several hours or
overnight.
WARNING
CAUTION
If necessary, brush the piston crowns with a soft non-
metallic brush. A metallic brush can damage the
surface finish. Do not use glass, plastic, or walnut
media to clean the aluminum piston skirts. This can
damage the pin bore surface finish or prevent the
rings from seating correctly in the ring grooves.
Soak aluminum pistons for a minimum of 30 minutes in a
tank containing an approved cleaning solvent for
aluminum. Use a hot soapy solution with a non-metallic
brush to remove carbon deposits. Anything more abrasive
will damage the surface finish.
WARNING
personal injury.
WARNING
Use steam to clean the pistons.
Single-Piece Piston
CAUTION
Never, under any circumstances, remove the flat, oil
cover plate located on the underside of the single-
piece pistons.
WARNING
CAUTION
To reduce the possibility of damage to the piston, the
cleaning solvent must be approved for bushing
material. If necessary, brush the pistons with a soft
non-metallic brush. A metallic brush can damage the
piston ring grooves.
It is only necessary to remove the carbon buildup. It is
not necessary to make the crown appear to be new.
CAUTION
When using walnut shell blast to clean steel pistons,
use the minimum recommended pressure and do not
concentrate the blast in any one area for extended
lengths of time. To prevent damage of the surface
finish, make sure the pin bore area is protected from
the blast.
Do not use glass or plastic bead media to clean the piston
crowns.
Carbon deposits can be cleaned from the pistons by
soaking in an approved solution and/or by blasting with
walnut shell media.
Soak steel pistons for at least 30 minutes in an approved
cleaning solvent for steel and for brushing material. Use
a hot soapy solution with a non-metallic brush to remove
carbon deposits.
For best results, soak the pistons several hours or
overnight.
WARNING
CAUTION
If necessary, brush the pistons with a soft non-
metallic brush. A metallic brush can damage the
surface finish.
WARNING
bodily injury.
WARNING
Use steam to clean the pistons.
Make certain there is not walnut shell blast media
remaining between the oil cover plate and the piston.
CAUTION
Do not use pistons with cracks. If the crown is
cracked, it must be replaced. Failure to replace the
damaged piston can cause serious engine damage.
Inspect the piston bowl for cracks or damage.
Inspect the piston pin bore for cracks, scratches, galling,
dents, or other damage.
Inspect the piston second land for scuffing. Refer to the
Single Piece, Open Skirt Piston Reuse Guidelines,
Service Bulletin 4021925.
CAUTION
Do not use pistons with cracks. If the skirt is cracked,
it must be replaced. Failure to replace the damaged
piston can cause serious engine damage.
Inspect the piston skirt pin bore (1) and sides (2) for cracks
or damage.
Also inspect the skirt for scratches. In general, if the
scratches can be felt with a fingernail, do not reuse the
skirts. Refer to Articulated Piston Skirt Reuse Guidelines
for Signature, ISX, and QSX15 Engines, Service Bulletin
4021468, if additional information is needed.
The ring groove can be inspected with a new ring and a

feeler gauge.
Hold a new ring in the groove even with the outside
diameter of the piston. Install a 0.15-mm [0.006-in] feeler
gauge. If the feeler gauge enters the groove without
resistance, there is too much wear. Replace the piston.
Measure the piston pin bore inside diameter on both the

crown and skirt on articulated pistons.
Articulated Piston Pin Bore Inside Diameter (Crown)

mm in
63.56 MIN 2.502
63.58 MAX 2.503
Articulated Piston Pin Bore Inside Diameter (Skirt)

mm in
63.513 MIN 2.5005
63.525 MAX 2.5010
The piston pin bore inside diameter is not a re-use criteria
measurement to be taken on single-piece pistons.
Inspect the piston pin for scratches, grooves, or other

damage. Do not reuse if visually unacceptable.
Measure the piston pin outside diameter. Piston pin
outside diameters are the same between articulated and
single-piece piston pins.
Piston Pin Outside Diameter

mm in
63.4670 MIN 2.4987
63.4999 MAX 2.5000
Also measure the piston pin lengths. Single-piece piston
pins are shorter than articulated piston pins.
Articulated Piston Pin Length

mm in
109.5 MIN 4.311
110.0 MAX 4.331
Single-Piece Piston Pin Length

mm in
84.6 MIN 3.331
85.1 MAX 3.350
Finishing Steps
All Applications
Assemble the piston and connecting rod. Refer to
Install the piston and connecting rod assembly. Refer to

Procedure 014-013 (Aftertreatment Testing) in Section 14.

Preparatory Steps
WARNING
WARNING
007-025.

Procedure 007-035.

001-089.
Piston Cooling Nozzle Signature, ISX, and QSX15 Eng [...]
Remove
The crankshaft must be rotated to allow access to remove
all the nozzles.
Remove the piston cooling nozzle capscrews and nozzles.
Install
CAUTION
Properly align the nozzles in the locator notch before
tightening the capscrews. Damage to the engine can
occur.
The crankshaft must be rotated to allow access to install
all the nozzles.
Install the nozzle, washers, and capscrews.
Finishing Steps
Install the block stiffener. Refer to Procedure 001-089.

007-035.

007-035.

007-037.

Procedure 007-037.
Operate the engine to normal operating temperature and

check for oil leaks.

Remove
Articulated Piston
Remove the piston rings.

Single-Piece Piston
CAUTION
Do not over-expand the second piston ring on single-
piece pistons.
Use a universal ring expander to remove the second
piston ring on single-piece pistons.

Measure
Articulated Piston
To check the ring gap, install the piston rings into the
cylinder liner in which they were used below the ring
reversal area.
Use the top part of the piston to correctly position the ring
in the liner.
Use a feeler gauge to inspect the ring end gap.
Articulated Piston Ring Gap

mm in
Top 0.33 MIN 0.013
0.53 MAX 0.021
Second 1.87 MIN 0.074
2.13 MAX 0.084
Oil 0.21 MIN 0.008
0.51 MAX 0.020
Single-Piece Piston
To check the ring gap, install the piston rings into the
cylinder liner in which they were used below the ring
reversal area.
Use the top part of the piston to correctly position the ring
in the liner.
Use a feeler gauge to inspect the ring end gap.
Single-Piece Piston Ring Gap

mm in
Top 0.33 MIN 0.013
0.53 MAX 0.021
Second 0.97 MIN 0.038
1.23 MAX 0.048
Oil 0.21 MIN 0.008
0.51 MAX 0.020
Install
Articulated Piston
CAUTION
Place the connecting rod in a vise to hold the assembly in

piston.
either orientation.

For articulated pistons, the top piston ring (1) is a keystone
ring with no twist or cutback notch.
The intermediate ring (2) is a positive twist design with a
cutback notch (3) on the topside and a two-degree taper
face.

Single-Piece Piston
CAUTION
Install the connecting rod in a vise to hold the assembly in

piston.
either orientation.
For single-piece pistons, use a universal piston ring
expander to install the second ring into the piston.

The single-piece ring set is similar to the articulated ring
set, with the exception of the second ring. The second ring
has a rectangular cross-section (2) with an angled cut (3)
on the upper side of the inner diameter to induce a positive
twist. This design improves the slobber-resistance of the
ring pack.


Procedure 014-013.

Preparatory Steps
Procedure 008-003.
013-005.

Fan or PTO
Remove the fan and water pump drive belts. Refer
013-005.

Fan or PTO
Remove the fan and water pump drive belts. Refer
013-005.
Remove the fan and water pump tensioner. Refer to
Procedure 008-080.
Remove
CAUTION
vibration damper(s). These tools can damage the
vibration damper(s).
Remove two of the vibration damper(s) and crankshaft
pulley retaining capscrews.
Remove the pulley and vibration damper(s).

Fan or PTO
Remove the crankshaft adapter (1) from the pulley (2).

CAUTION
vibration damper.
Remove the remaining four capscrews.
spacer (2) and second vibration damper (1).

Fan or PTO
Remove two of the pulley capscrews.
CAUTION
vibration damper.
spacer (2), and second vibration damper (1).

All Applications
WARNING
Clean the vibration damper(s) with a solvent cleaner.
Always replace the vibration damper(s) after a crankshaft

nose failure. Crankshaft nose breakages are primarily
caused by excessive torsional activity.
The vibration damper must always be measured after a
failure involving broken gears in the front gear train.
Check the mounting web for cracks.
Check the housing for dents or raised surfaces.
The vibration damper must be replaced if the mounting
web is cracked or the housing has dents or raised
surfaces.
Remove the paint on both sides of the vibration damper in

four locations spaced 90 degrees apart.
Measure and record the thickness at two points at each of

the four locations.
The difference between any two of the eight
measurements must not exceed 0.25 mm [0.010 in].
Spray the vibration damper with spot check developer,

Type SKD-NF, or equivalent.
Heat the vibration damper in an oven (rolled lip side down)
at 93C [200F] for two hours.
WARNING
Wear protective gloves when handling parts that have
been heated to reduce the possibility of personal
injury.
Remove the vibration damper from the oven and check for
fluid leakage.
If there is leakage, replace the vibration damper.
Install
vibration damper, and the pulley are clean, dry, and free
from burrs.
Align the dowel pin in the crankshaft wit the dowel hole in
the vibration damper.
Install the vibration damper, pulley, and clamping plate
onto the guide plate.

capscrews.

Fan or PTO

the guide studs.

Install four capscrews.
capscrews.
Tighten the six capscrews in a star pattern.
Install the crankshaft adapter (1).

Make sure the crank shaft adapter sets flush against the
pulley (2).

Fan or PTO

the guide studs.

capscrews.
Tighten the 12 capscrews in a star pattern.
Eccentricity Check
All Applications
Clean the outside surface of the vibration damper.
To measure the vibration damper eccentricity (out of
round), install a dial indicator onto the gear cover as
indicated.
Rotate the crankshaft with the accessory driveshaft one
complete revolution (360 degrees), and record the total
indicator movement.
Vibration Damper Eccentricity

mm in
0.28 MAX 0.011
must be replaced.
Wobble Check
All Applications
To measure wobble (face alignment), install a dial
indicator as shown.
Push the crankshaft to the front or rear of the engine and
set the indicator to 0 (zero).
Rotate the crankshaft one complete revolution (360
degrees) while maintaining the position of the crankshaft,
either toward the front or rear of the engine.
Record the total indicator movement.
Vibration Damper Wobble Measurement

mm in
0.28 MAX 0.011
must be replaced.
Finishing Steps
Procedure 008-002.
Install alternator drive belt. Refer to Procedure
013-005.
Operate the engine and check for proper operation.

Fan or PTO
013-005.
Procedure 008-002.

Fan or PTO
Install the fan and water pump belt. Refer to
Procedure 008-080.
013-005.
Procedure 008-002.

(001-054)
Preparatory Steps
WARNING
To reduce the possibility of personal injury, reduce
the possibility of direct contact of hot oil with your
skin.
WARNING
reproductive toxicity. Reduce the possibility of
inhalation of vapors, ingestion, and prolonged contact
with used engine oil. If not reused, dispose of in
accordance with local environmental regulations.
WARNING
WARNING
WARNING
Drain the cooling system. Refer to Procedure
008-018.
007-025.
Procedure 007-035.
001-089.
Procedure 001-046.
Remove the connecting rod cap. Refer to Procedure
001-005.
Remove the cylinder head. Refer to Procedure
002-004.
Remove
WARNING
cleaning, following the manufacturer's
recommendations for use. Wear goggles and
protective clothing to reduce the possibility of
personal injury.
WARNING
CAUTION
silicon particles from emery cloth or sandpaper can
be damaged.
7448, Part Number 3823258, or equivalent, and solvent to
remove the carbon.
Install two connecting rod guide pins, Part Number

3376038.
Use a T-handle piston pusher to push the connecting rod
away from the crankshaft.
Push the connecting rod until the piston rings are outside
of the top of the cylinder liner.
Remove the upper connecting rod bearing.

Mark the cylinder number and the letter U (upper) on the
flat surface of the bearing tang.
Use both hands to remove the piston and connecting rod

assembly.
reused.
CAUTION
To reduce the possibility of engine damage all pistons
within a given engine must be of the same design - all
are to be either the articulated design or the single-
piece design. Do not mix piston designs in the same
engine. Single-piece pistons must have drilled rods
and connecting rod bearings. Articulated pistons can
Place the connecting rod and piston assemblies in a

container to protect them from damage.
A unique number (not cylinder number) is stamped on the

connecting rod and matching connecting rod cap. When
the connecting rods and connecting rod cap are installed
in the engine, the numbers on the connecting rod and cap
must match and be installed on the same side (the
exhaust side) of the engine.
Disassemble
Articulated Piston
Use internal snap ring pliers to remove the snap rings from
both sides of the piston.
CAUTION
Do not use a hammer to remove the piston pins. The
piston can distort, causing it to seize in the liner.
If the piston pin can not be easily removed by hand, place
the piston and connecting rod assembly in a container of
water. Heat the piston in boiling water for 15 minutes.
Use a blunt tool to push the piston pin from the piston and
connecting rod assembly.
CAUTION
When the piston pin is removed from an articulated
piston, the skirt will separate from the crown. Use
care to prevent damage to the piston.
If they are to be reused, mark the number of the cylinder
that the piston, crown, skirt, and pin were removed from
on the parts to make sure they are installed in the correct
cylinder.
Single-Piece Piston
Use internal snap ring pliers to remove the snap rings from
both sides of the piston.
CAUTION
Do not use a hammer to remove the piston pins. The
If the piston pin can not be easily removed by hand, place
the piston and connecting rod assembly in a container of
water. Heat the piston in boiling water for 15 minutes.
Use a blunt tool to push the piston pin from the piston and
connecting rod assembly.

reused.
Assemble
Articulated Piston
All pistons (bushed and nonbushed) must be properly
lubricated prior to assembly.
For all pistons, use a clean, lint free cloth to apply a heavy
film of 85W-140 gear oil with EP additive to the following
locations:
Piston pin bore inside diameter in the piston crown
Piston pin bore inside diameter in the piston skirt
Rod bushing inside diameter
Piston pin.
Assemble the piston crown into the piston skirt.
CAUTION
The retainer snap ring must be seated completely in
the piston pin groove to prevent engine damage
during engine operation.
It is not necessary to heat the articulated pistons before
assembly. The piston pin is slip fitted.
The crown and skirt can only be assembled in one
position.
Install a new snap ring into one piston pin bore of each
piston skirt.
If the pistons are being reused, the crown, skirt, and pin
must be matched as they were when they were removed.
Position the skirt over the piston crown.
CAUTION
Do not use a hammer to install the piston pin. The
CAUTION
The lock tang on the connecting rod must be in line
with the cooling nozzle notch in the piston skirt and
on the side opposite the deep valve pocket of the
piston crown. Failure to follow this step will cause
CAUTION
The piston pin for the articulated piston is longer in
length than the pin for single-piece pistons. Do not
use articulated piston pins in single-piece pistons.
Likewise, do not use single-piece pins in articulated
pistons.
Align the pin bore of the connecting rod with the pin bore
of the piston skirt and crown, and install the piston pin.
On articulated pistons, make sure the locking tang on the
connecting rod is on the same side as the cooling nozzle
notch in the piston skirt and opposite the deep valve
pocket on the crown.
CAUTION
The snap ring must be seated completely in the piston
groove to prevent engine damage during engine
operation.
Install a new snap ring into the piston pin bore.
Install piston rings. Refer to Procedure 001-047.
Single-Piece Piston
CAUTION
The retainer snap ring must be seated completely in
the piston pin groove to prevent engine damage
during engine operation.
Install a new snap ring into one piston pin bore of each
single-piece piston.
If the pistons are being reused, the single-piece piston and
pin must be matched as they were when they were
removed.
CAUTION
Do not use a hammer to install the piston pin. The
CAUTION
The lock tang on the connecting rod must be in line
with the cooling nozzle notch in the piston skirt and
on the side opposite the deep valve pocket of the
piston crown. Failure to follow this step will cause
CAUTION
Generously coat both single-piece piston pin bores
with a heavy weight gear oil, such as 85W-140 EP,
when assembling single-piece pistons. Also lubricate
the connecting rod bushing. If gear oil is not available,
Lubriplate, Part Number 3163086, is permissible.
Failure to adequately lubricate the pin joint can result
in extensive engine damage, particularly with single-
piece pistons.
Use clean 85W-140 oil to coat the piston pin.
The single-piece piston requires a drilled connecting rod

and a drilled upper connecting rod bearing to lubricate the
pin joint. Do not assemble a single-piece piston with a
non-drilled connecting rod nor a non-drilled connecting
rod bearing. Make certain when assembling a single-piece
piston that the lubricating hole in the connecting rod
bearing lines up with lubricating hole in the connecting
rod.
CAUTION
The piston pin for single-piece pistons is shorter in
length than the pin for articulated pistons. Do not use
single-piece piston pins in articulated pistons.
Likewise, do not use articulated pins in single-piece
pistons.
On single-piece pistons, the locking tang on the

connecting rod is to be on the opposite side of the deep
valve pocket.
Install the piston pin.
CAUTION
The snap ring must be seated completely in the piston
groove to prevent engine damage during engine
operation.
Install a new snap ring into the piston pin bore.
Install the piston rings. Refer to Procedure 001-047.
Install
Immerse the piston in a container of clean 15W-40 oil.
Remove the piston from the container. Let the excess oil
drain from the piston.
Use piston ring compressor, Part Number 3164846, to

compress the rings.
The cylinder block and all parts must be clean before
assembly.
Inspect the cylinder liners for reuse. Refer to Procedure
001-028.
Use a clean, lint-free cloth to clean the connecting rods

and bearing shells.
Do not lubricate the backside of the bearing shells. The
operating clearance of the bearing will be reduced and the
bearing can be damaged during engine operation.
If new bearings are not used, the used bearings must be

installed on the same connecting rod from which they
were removed.
Install the upper bearing shell into the connecting rod.
The tang of the bearing shell (2) must be in the slot of the
cap (1). The end of the bearing shell must be even with
the cap mounting surface.
Use Lubriplate 105, Part Number 3163086, or

equivalent, to coat the entire inside circumference of the
bearing shell.
Apply a film of clean 15W-40 oil to the cylinder liner.
Install connecting rod guide pins, Part Number 3163097.
Use the compressor drive or barring device to rotate the

crankshaft so the connecting rod journal of the connecting
rod being installed is at bottom dead center.
CAUTION
Failure to align the deep valve pocket and the piston
skirt cooling nozzle notch correctly will result in
Align the piston crown deep valve pocket on the exhaust
side of the engine, and the piston skirt cooling nozzle
notch to the intake side of the engine.
If the deep valve pocket and the piston skirt cooling nozzle
notch are not on opposite sides, the piston and
connecting rod assembly are not assembled correctly.
Disassemble the piston and connecting rod and assemble
correctly.
Insert the connecting rod through the cylinder liner until
the ring compressor contacts the top of the liner.
Both articulated pistons and single-piece pistons have an

arrow on the top of the piston crown, which will point to
the front of the engine, when the piston is installed
properly.
CAUTION
Do not use a metal drift to push the piston into the
cylinder liner. The piston rings or cylinder liner can be
damaged.
Hold the ring compressor against the cylinder liner. Push
the piston through the ring compressor and into the
cylinder liner. Push the piston until the top ring is
completely in the cylinder liner.
If the piston does not move freely, remove the piston and
inspect for broken or damaged rings.
Use the nylon guide pins to align the connecting rod with
the crankshaft while pushing the piston and connecting
rod assembly into place.
Remove the nylon guide pins.
Finishing Steps
NOTE: When rebuilding an engine with single-piece
pistons that was originally built with articulated pistons,
stamp the dataplate with the letters SP. This will alert
future repair locations that this engine has been rebuilt
with single-piece pistons.
Install the connecting rod cap. Refer to Procedure
001-005.
001-046.
001-089.
Procedure 007-035.
007-025.
Install the cylinder head. Refer to Procedure
002-004.
007-037.
Fill the coolings system with coolant. Refer to
Procedure 008-018.
Procedure 007-037.
Operate the engine to normal operating temperature
and check for leaks.
Crankshaft Tone Wheel Signature, ISX, and QSX15 Eng [...]
Crankshaft Tone Wheel (001-069)

Preparatory Steps
Remove the vibration damper. Refer to Procedure
Remove the crankshaft adapter. Refer to Procedure
Remove the lower front gear cover. Refer to
Remove
Use care not to damage the crankshaft gear when
removing the tone wheel.
With a suitable pry bar or a lady's foot, remove the tone
wheel from the crankshaft and discard the tone wheel.
Inspect
Inspect the crankshaft, crankshaft gear, and the tone
wheel alignment dowel for damage and replace
components as necessary.
Inspect the machined surfaces for scratches or nicks.
Inspect the tone wheel alignment dowel hole for damage.
If the dowel hole or the area surrounding the dowel hole
has been damaged, the crankshaft must be replaced.
Use a crocus cloth to remove scratches or nicks. If
scratches or nicks can be felt with a fingernail after the
crankshaft has been polished with the crocus cloth, the
Inspect the crankshaft gear for excessive wear or damage.
Signature, ISX, and QSX15 Eng [...] Crankshaft Tone Wheel
Install
WARNING
heated.
Heat the tone wheel for 2 hours at 177C [350F] before
attempting the installation.
The tone wheel must be installed so the face labeled

"FRONT" faces away from the crankshaft gear.
The tone wheel is keyed to the crankshaft with a dowel.
The tone wheel alignment dowel slot on the inside
diameter of the tone wheel must align with the crankshaft
pin for proper installation.
The tone wheel must be installed within 30 seconds after
being removed from the oven.
Install the tone wheel so the slot on the inside diameter of
the tone wheel aligns with the tone wheel alignment pin.
Hold the tone wheel in position for approximately 90
seconds to allow the shrink fit to properly hold the
components.
Check the installation by attempting to insert a [0.25 mm]

0.010-inch feeler gauge between the crankshaft gear and
the tone wheel at 4 locations approximately 90 degrees
apart. If the feeler gauge can be inserted, the tone wheel
must be removed and replaced.
Finishing Steps
Install the lower front gear cover. Refer to Procedure
Install the crankshaft adapter. Refer to Procedure
Install the vibration damper. Refer to Procedure

General Information
Idler Gear, Adjustable (001-077)

General Information
NOTE: Before installation or removal of any gears, you
must read Engine Base Timing. Refer to Procedure
001-088.

Preparatory Steps
All Applications
Procedure 008-003.
013-005.
Remove the fan hub assembly. Refer to Procedure
008-036.
Remove the breather tube and hose. Refer to
Procedure 003-001.
Remove
WARNING
Remove 16 capscrews and the upper gear cover.
Signature, ISX, and QSX15 Eng [...] Gear Cover, Upper

Remove two capscrews and install two guide pins.
Remove the 14 vibration isolator capscrew assemblies.
WARNING
Remove the clamping plate and upper gear cover.

All Applications
WARNING
personal injury.
WARNING
WARNING
Use steam or solvent to clean the gear cover. Dry with
compressed air.
Clean the sealing surface on the rear face of the upper

gear cover and the seal groove on the gear housing.
Inspect the breather tube elbow and grommet. Refer to

Procedure 003-001.
Inspect the upper gear cover for cracks or damage.

If the cover is cracked, it must be replaced.
Put the upper gear cover on a flat surface and inspect it

for flatness.
Signature, ISX, and QSX15 Eng [...] Gear Cover, Upper
It is an acceptable practice to use a mallet to straighten

an upper gear cover with minor bends.
If necessary, lay the gear cover on a flat surface and hit
the upper gear to remove minor bends.
Install
seal.
WARNING
Install the cover with 16 capscrews.


seal.
WARNING
Install two guide pins in the gear housing.
Install the front gear cover over the guide pins.
Install the clamping plate, if used.
Remove the two guide pins and install the last two
capscrews.
Finishing Steps
All Applications
008-036.
008-003.
013-005.
Install the breather tube and hose. Refer to
Procedure 003-001.
Signature, ISX, and QSX15 Eng [...] Gear Cover, Lower

Preparatory Steps
Twist the oil filler connector counterclockwise and
remove
Section 8
013-005 (Drive Belt, Alternator) in Section 13
Remove the crankshaft pulley and vibration damper
(s). Refer to Procedure 001-022 (Crankshaft Pulley)
in Section 1
Remove the front crankshaft seal. Refer to
Procedure 001-023 (Crankshaft Seal, Front) in
Section 1.
Remove
NOTE: If the gear cover contains an o-ring seal groove for
the crankshaft seal and the seal needs to be replaced, the
lower gear cover must also be replaced. The new
crankshaft seal has the o-ring incorporated into the seal.
Remove the 15 capscrews and the lower gear cover.

NOTE: All lower gear covers have either a beveled half
groove or a full o-ring groove under the crankshaft seal
flange.
Full o-ring groove covers contain an o-ring in the lower
gear cover groove and were only used prior to June 5,
1999. The lower gear cover must be replaced if installing
a new seal.
Beveled half groove covers do not contain an o-ring and
only require replacement if damaged.
Gear Cover, Lower Signature, ISX, and QSX15 Eng [...]
WARNING
for use. Wear goggles and protective clothing to avoid
personal injury.
WARNING
WARNING
personal injury.
Clean the sealing surface on the rear face of the lower
gear cover and seal groove on the gear housing.
Use steam or solvent to clean the lower gear cover. Dry
with compressed air.
Inspect the lower gear cover for cracks or other damage.

If the cover is cracked, it must be replaced.
If the gear cover contains an o-ring groove for the
crankshaft seal and the cover is to be replaced, the
crankshaft seal must also be replaced.
Inspect the studs for damage. If the studs are damaged,
the cover must be replaced.
Place the lower gear cover on a flat surface and inspect it

for flatness.
Signature, ISX, and QSX15 Eng [...] Gear Cover, Lower
It is an acceptable practice to use a mallet to straighten a

lower gear cover with minor bends.
If necessary, lay the gear cover on a flat surface and hit
the cover to remove minor bends.
Install
Install a new strip seal.
Orient the overlap joint to the upper left of the gear
housing as shown.
Use a small amount of RTV at the overlap joint of strip
seal.
NOTE: Do not tighten the capscrews until the new

crankshaft seal is installed. The crankshaft seal must be
installed first to locate the gear cover properly.
Position the lower gear cover with the 15 capscrews.
Hand-tighten the capscrews.
Install a new crankshaft seal. Refer to Procedure 001-023

(Crankshaft Seal, Front) in Section 1.
Bracket, Retaining Brace Signature, ISX, and QSX15 Eng [...]
Tighten the 15 capscrews in the sequence shown.

Finishing Steps
WARNING
Install the crankshaft pulley and vibration damper(s).
Refer to Procedure 001-022 (Crankshaft Pulley) in
Section 1
008-036 (Fan Hub, Belt Driver) in Section 8
013-005 (Drive Belt, Alternator) in Section 13
008-003 (Drive Belt, Water Pump) in Section 8
Install the oil filler connector
Bracket, Retaining Brace (001-081)

Remove
Remove the two capscrews from the retaining brace
bracket and the gear housing.
Signature, ISX, and QSX15 Eng [...] Bracket, Retaining Brace
Remove the two remaining capscrews, washers, and

retaining brace bracket from the cylinder head.

Remove the engine lifting bracket from the retaining
bracket.
Remove the retaining brace bracket and mounting

spacers (1).
Inspect for Reuse

Inspect the retaining brace bracket for cracks.
Bracket, Retaining Brace Signature, ISX, and QSX15 Eng [...]
Install
NOTE: The two M10 x 1.5 x 25 capscrews attach the
bracket to the gear housing. The one M12 x 1.75 x 35
capscrew and washer attach the bracket to the cylinder
head through the engine lifting bracket. The one M12 x
1.75 x 30 capscrew and washer attach the bracket to the
cylinder head below the engine lifting bracket.
NOTE: Tighten the capscrews hand-tight.
Install the retaining brace bracket, four capscrews, and
two washers on the gear housing and cylinder head hand-
tight.
Tighten the two capscrews to the gear housing.

Tighten the two capscrews to the cylinder head.


Install the two mounting spacers (1) to the upper gear
cover.
Position the retaining brace bracket.
Install two capscrews into the threaded holes of the brace.
Hand tighten the capscrews.
Signature, ISX, and QSX15 Eng [...] Bracket, Retaining Brace
Install the capscrew into location (1) on the cylinder head.
Position the engine lifting bracket over the retaining brace

bracket and attach with the remaining capscrews (Nos. 2,
3, and 4).
Hand tighten the four capscrews.
Tighten the mounting spacer capscrews.

Tighten the four capscrews.

Bracket, Accessory Signature, ISX, and QSX15 Eng [...]
Bracket, Accessory (001-082)

Remove
NOTE: Each nylon cover is attached to the engine by a
combination of push on and slide in tabs. The top two
covers are removed by first pulling (at the location marked
Pull Here) the bottom of the covers away from the engine
until the tabs are released, then sliding the covers upward
to remove them from the accessory bracket. The lower
cover is removed by pulling (at the location marked Pull
Here) the top of the cover away from the engine until the
tabs are released, then sliding downward.
Remove the three composite nylon covers.
Remove the OEM wiring harness and accessories

attached to the accessory bracket.
Disconnect the camshaft position sensor.

Remove the camshaft position sensor and capscrew.
Remove the four capscrews, the studded capscrew, and

the accessory bracket.
Signature, ISX, and QSX15 Eng [...] Bracket, Accessory

NOTE: Each nylon cover is attached to the engine by a
combination of push on and slide in tabs. The top two
covers are removed by first pulling (at the location marked
Pull Here) the bottom of the covers away from the engine
until the tabs are released, then sliding the covers upward
to remove them from the accessory bracket. The lower
cover is removed by pulling (at the location marked Pull
Here) the top of the cover away from the engine until the
tabs are released, then sliding downward.
Remove the three composite nylon covers.
Remove the OEM wiring harness and accessories

attached to the accessory bracket.
Remove the camshaft position sensor and capscrew.
Remove the three capscrews from the accessory bracket.

Remove the two mounting spacers from the accessory

bracket and upper gear housing.
Inspect for Reuse

Inspect the bracket for cracks in the bend radius.
Install
Liberally apply a heavy moly grease, Part Number
3824759, or equivalent, to the area of contact between the
brace and the cylinder head.
Install the accessory bracket, four capscrews, and
studded capscrew to the cylinder head, hand-tight.
Tighten the two capscrews to the gear housing.

Signature, ISX, and QSX15 Eng [...] Bracket, Accessory
Tighten the two capscrews and the studded capscrew to

the cylinder head.
Install the camshaft position sensor and the capscrew.

Connect the camshaft position sensor.
Install the OEM wiring harness and accessories to the

accessory bracket
NOTE: The top two covers are installed by sliding the

cover down into the slots on the accessory bracket, then
pushing the bottom of the cover toward the engine onto
the cover mounting tabs. Install the bottom cover by
sliding the cover upward into the slots on the accessory
bracket, mounted on the IFSM, then pushing the top of the
cover toward the engine onto the cover mounting tabs.
Install the three composite nylon covers.

Install the two mounting spacers to the accessory bracket
and upper gear housing using two capscrews.
Install the accessory bracket to the engine using three

capscrews.
Tighten the mounting spacer capscrews.

Install the camshaft position sensor and capscrew.

Connect the camshaft position sensor.
Install the OEM wiring harness and accessories to the

accessory bracket
NOTE: This step may not apply to Power Generation
applications.
NOTE: The top two covers are installed by sliding the

cover down into the slots on the accessory bracket, then
pushing the bottom of the cover toward the engine onto
the cover mounting tabs. Install the bottom cover by
sliding the cover upward into the slots on the accessory
bracket, mounted on the IFSM, then pushing the top of the
cover toward the engine onto the cover mounting tabs.
Install the three composite nylon covers.
NOTE: This step does not apply to Power Generation
applications.

General Information
Front Gear Assembly Configuration
Two front gear train combinations are currently utilized on
the Signature, ISX, and QSX15 engines. Signature,
ISX3, ISX2, and QSX15 engines use a scissor gear for the
lower idler gear and the injector cam gear. ISX1 does
not use a scissor gear at the idler location.
ISX2 engines built between January, 1999 and January,
2000 utilized a scissor gear for the lower idler gear only.
The injector cam gear was a straight cut spur gear, similar
to the ISX1. After January, 2000, the ISX2 has scissor
gears for both the cam and lower idler.
This procedure describes the removal, inspection, and
installation of the different gear combinations.
Front Gear Assembly without Scissor Gear

View shown is from left to right and top to bottom.
Valve camshaft gear
Injector camshaft gear
Adjustable idler gear
Lower idler gear
Accessory gear
Crankshaft gear.
Front Gear Assembly with Scissor Gear

View shown is from left to right and top to bottom.
Valve camshaft gear
Injector camshaft scissor gear
Adjustable idler gear
Lower idler scissor gear
Accessory gear
Crankshaft gear.
Scissor Gear Definitions
WARNING
Do not attempt to remove any gears before reading
scissor gear definitions. Serious personal injury or
engine damage can result if instructions are not
followed.
The following terms describe the conditions of the scissor
gears for removal, installation, and operation.
Unloaded:
The gear will be unloaded when removing, installing, and
setting gear backlash.
Unload the gear by backing out two gear adjusting screws
until the gear teeth align.
The idler scissor gear is loaded when the gear backlash
is set.
Loaded:
The gear teeth are loaded (functional) and are spread
between the mating gear teeth.
The gear is loaded by tightening all of the adjusting
screws. The gear teeth will be spread and no movement
will be felt against the valve cam gear. The gear will be in
the loaded condition for engine operation.
Preparatory Steps
All Applications
QSX15 engines are equipped with dual vibration dampers.
The crank pin mark is located on the damper closest to
the engine.
Rotate the crankshaft clockwise until the insert pin
mark on the outside diameter of engine vibration damper
is aligned with the mark on the gear housing.
Insert the pin in the hole in the pin boss.

The green band on the timing pin will be lined up with the
surface of the timing pin boss of the block.
The pin is not correctly seated in the crank notch if the
green band is either completely visible outside the block,
or is not visible at all.
Lock the crankshaft in place with the crankshaft locking
pin, Part Number 3163020.
Remove the rocker lever cover and gasket.Refer to

Procedure 003-011 (Rocker Lever Cover) in Section 3.
Disconnect and remove the engine brake wiring

harness.Refer to Procedure 020-015 (Engine Brake
Wiring Harness) in Section 20.
Removing the rocker lever shafts removes the load from

the camshafts. This allows the camshafts to be rotated
when installing the timing wedges and the camshaft gears
are not installed.
Remove the rocker lever shafts.Refer to Procedure
003-009 (Rocker Lever Assembly) in Section 3.

plug.
It will be helpful to push the gear cover plug out from the
rear. It is not necessary to remove the lower gear cover to
push out the plug.
Remove the upper gear cover.Refer to Procedure 001-079

(Gear Cover, Upper) in Section 1.
Remove the lower gear cover, if needed.Refer to
Procedure 001-080 (Gear Cover, Lower) in Section 1.
Remove
Valve Camshaft Gear
during removal of the valve camshaft gear. To unload the
gear, two of the gear screws must be backed out far
enough to allow the teeth on the scissor gear to be aligned.
Unload the injector camshaft scissor gear.
Remove the valve camshaft gear mounting capscrew and
washer.
Early production engines were not equipped with puller

holes in the valve camshaft gear. A 3-jaw gear puller
must be used for gears that do not have puller holes. The
injector and valve gear puller, Part Number 3163069, can
be used for gears that have puller holes.
Install the gear puller, Part Number 3163069.
Install the valve camshaft gear mounting capscrew
completely.
Loosen the capscrew two turns.
Use the gear puller to remove the valve camshaft gear
from the camshaft nose.
Remove the puller.

Do not completely remove the camshaft gear mounting
capscrew when the 3-jaw puller is used. The capscrew
serves as a safety catch by preventing the gear from
shooting off of the camshaft nose.
Remove the valve camshaft gear mounting capscrew,
spacer, and valve camshaft gear.
WARNING
WARNING
CAUTION
Remove the injector camshaft scissor gear mounting

Install the injector camshaft scissor gear mounting
capscrew. Loosen the capscrew one turn.
Use the gear puller to force the injector camshaft scissor

gear off the camshaft taper.
Remove the injector camshaft scissor gear.
WARNING
WARNING
CAUTION
Remove the injector camshaft gear mounting capscrew

and washer.
Install the injector camshaft gear mounting capscrew.
Loosen the capscrew one turn.
Use the gear puller to force the injector camshaft gear off
the camshaft taper.
Remove the injector camshaft gear.
WARNING
WARNING

The adjustable idler gear shaft can fall out when the
adjustable idler gear is removed.
Remove the retainer capscrews, retainer, gear, and
adjustable idler gear shaft.
Remove the mounting spacer.

The lower idler scissor gear must be unloaded during
removal. To unload the gear, two of the gear screws
Unload the lower idler scissor gear.
Remove the idler scissor gear capscrews.
Remove the retainer, gear, shaft, and thrust bearing.


Remove the idler non-scissor gear capscrews and
retainer.
Remove the gear, shaft, and thrust bearing.
Inspect for Reuse

Inspect the gear teeth on all gears for pitting, heavy wear,
or breakage.
Inspect the gear for cracking around the puller holes.
Replace any pitted, heavily worn, or damaged gear and
inspect the mating gear for associated damage.
Inspect the lower idler shaft and adjustable idler shaft for
heavy wear.
Measure the idler shafts outside diameter.
Lower Idler Shaft Outside Diameter

mm in
88.88 MIN 3.4992
88.89 MAX 3.4997
Adjustable Idler Shaft Outside Diameter

mm in
88.88 MIN 3.4992
88.89 MAX 3.4997
Inspect the lower idler gear bore and adjustable idler gear
bore for heavy wear.
Measure the inside diameter of the lower idler and
adjustable idler gear bores.
Lower Idler Gear Bore Inside Diameter

mm in
88.962 MIN 3.5024
88.988 MAX 3.5035
Adjustable Idler Gear Bore Inside Diameter

mm in
88.962 MIN 3.5024
88.988 MAX 3.5035
Install
Timing Wedges:
The timing code is located on the engine dataplate.
First number - injector wedge
Second number - valve wedge.
position.
Insert the correct timing wedge to lock the injector
camshaft. Lightly tap the top of the timing wedge with a
mallet to be sure it is properly seated.
WARNING
Do not drive the wedges into place. Engine damage
can occur.
position.
Insert the correct timing wedge to lock the valve camshaft.
Lightly tap the top of the timing wedge with a mallet to be
sure it is properly seated.

The lower scissor idler gear must be unloaded during
installation. To unload the gear, two of the gear screws
scissor idler gear.
Install the thrust bearing, shaft, and lower scissor idler
the engine.
The lower idler scissor gear front retainer plate is larger in

diameter than the adjustable idler retainer plate. The slots
in the plate go toward the scissor gear
Torque Value:
above.
CAUTION
Load the lower idler scissor gear by tightening all of the
gear screws.

non-scissor idler gear.
Install the thrust bearing, shaft, and lower non-scissor idler
the engine.
The lower idler non-scissor gear front retainer plate is

larger in diameter than the adjustable idler retainer plate.
The slots in the plate go toward the scissor gear
Torque Value:
above.

The spacer plate is doweled to the block with two standard
dowels.
Install the mounting spacer plate.
Apply Lubriplate to the spacer, shaft, and adjustable idler

gear.
It is possible to install the shaft in an incorrect orientation;
however, it will not be possible to set the gear backlash
correctly.
Install the spacer, shaft and adjustable idler gear. The
shaft must be installed with the word TOP (stamped on
the front face of the shaft) oriented toward the top of the
engine.
The adjustable idler front retainer plate is smaller in

diameter than the lower idler scissor gear retainer plate.
The slots on the retainer plate go toward the gear.
The adjustable idler gear is installed loosely, because it is
moved into its final position later in the timing process.
Install the retainer and capscrews. Finger-tighten the
capscrews and then loosen by one flat, which is 60
degrees.

CAUTION
scissor gear must be clean and dry prior to assembly.
Wipe off the taper surface with a clean lint-free cloth
and apply a thin coat of Loctite 609, Part Number
3823718, to the inside diameter of the camshaft gear.
Use care not to contaminate the joint with oil prior to
assembly or engine damage may occur.
during installation. To unload the gear, two of the gear

The injector camshaft scissor gear needs to be fully

Install the injector camshaft scissor gear loosely on the
The injector camshaft scissor gear mounting washer is
larger in diameter than the valve camshaft mounting
washer.

The injector camshaft scissor gear is still loose at this
point, to allow the adjustable idler gear to be properly
positioned.

CAUTION
non-scissor gear must be clean and dry prior to
assembly. Wipe off the taper surface with clean a lint-
free cloth and apply a thin coat of Loctite 609, Part
Number 3823718, to the inside diameter of the
camshaft gear. Use care not to contaminate the joint
with oil prior to assembly or engine damage may
occur.

The injector camshaft non-scissor gear needs to be fully

Install the injector camshaft non-scissor gear loosely on
The injector camshaft non-scissor gear mounting washer
is larger in diameter than the valve camshaft mounting
washer.

The injector camshaft non-scissor gear is still loose at this
point to allow the adjustable idler gear to be properly
positioned.
Valve Camshaft Gear
CAUTION
The valve camshaft nose and valve camshaft gear
must be clean and dry prior to assembly. Wipe off the
taper surface with a clean lint-free cloth and apply a
thin coat of Loctite 609, Part Number 3823718, to the
inside diameter of the camshaft gear. Use care not to
contaminate the joint with oil prior to assembly or
engine damage may occur.

The valve camshaft gear needs to be fully engaged on the

camshaft nose taper, yet loose enough so it can rotate on
the camshaft nose.
Install the valve camshaft gear loosely on the camshaft
nose taper.
The valve camshaft mounting washer is smaller in
diameter than the injector camshaft scissor gear mounting
washer.

The valve camshaft gear is still loose at this point to allow
the adjustable idler gear to be properly positioned.
Adjust
Backlash (Scissor Gear Combinations)
CAUTION
Do not set backlash between the adjustable idler gear
and the lower scissor idler gear. Severe engine
damage can occur.
This backlash step works with the scissor type injector
camshaft gear and lower idler gear, and the non-scissor
injector camshaft gear with a scissor type lower idler gear.
The injector camshaft scissor gear must still be unloaded
during this step. To unload the gear, two of the gear
Insert, as shown, a narrow shim (0.25 mm [0.010 in]) into
the gear teeth mesh between the adjustable idler gear and
the wide (rear side) gear of the injector camshaft scissor
gear.
Shim Tolerance
mm in
0.225 MIN 0.009
0.275 MAX 0.011
NOTE: The gear backlash set procedure for engines that

have a non-scissor injector camshaft gear and a scissor
type lower idler gear is the same as that of engines that
utilize two scissor type gears.
gear toward the center of the engine (into mesh), so there
is no gap on either side of the shim.
in and out.
Backlash (Non-Scissor Gear Combinations)

plug. The plug can be pushed out from the rear side
without removing the gear cover.
The following procedure will be shown with the lower gear
cover removed.

teeth mesh between the adjustable idler gear and the
injector camshaft gear. The shim is inserted on the load
teeth mesh between the adjustable idler and the lower
non-scissor idler gear. The shim is inserted on the load
gear so there is no gap between the teeth and either side
of the shims.
in and out.

While holding the adjustable idler gear in position, tighten
the adjustable idler gear mounting capscrews.
Torque Value:
above.
CAUTION
Load the injector camshaft scissor gear by tightening all
of the gear screws.
The valve camshaft gear will rotate slightly on the valve
camshaft during this step.
Tighten the injector camshaft scissor gear retaining

capscrew.
Torque Value:
Step 1 136 Nm [ 100 ft-lb ]
Torque Value:
Step 1 136 Nm [ 100 ft-lb ]

Use hand pressure only to rotate the injector camshaft
gear clockwise until the gear train backlash is taken up.
Obtain tooth-to-tooth contact between the crankshaft gear
and the injector camshaft gear.
Tighten the injector camshaft non-scissor gear retaining

capscrew.
Torque Value:
Step 1 136 Nm [ 100 ft-lb ]
Torque Value:
Step 1 136 Nm [ 100 ft-lb ]
Valve Camshaft Scissor Gear

Tighten the valve camshaft scissor gear retaining
capscrew.
Valve Camshaft Non-Scissor Gear

Use hand pressure, only, to rotate the valve camshaft
gear counterclockwise until the backlash between the
injector camshaft gear is taken up. Obtain tooth-to-tooth
contact between the injector camshaft gear and the valve
camshaft gear.
Tighten the valve camshaft non-scissor gear retaining

capscrew.
Coat the entire gear train with clean 15W-40 oil.
Use the access hole in the lower gear cover to lubricate

the lower idler gear and crankshaft.
Finishing Steps
All Applications
Remove the injector and valve camshaft timing wedges.
A sudden jerking motion upwards is the most effective way
to remove wedges.
Remove the crankshaft locking pin.

Install the upper gear cover.Refer to Procedure 001-079

(Gear Cover, Upper) in Section 1.
Install the lower gear cover.Refer to Procedure 001-080
(Gear Cover, Lower) in Section 1.
Install the rocker lever shafts.Refer to Procedure 003-009

(Rocker Lever Assembly) in Section 3.
Install and connect the engine brake wiring harness.Refer

to Procedure 020-015 (Engine Brake Wiring Harness) in
Section 20.
Install the rocker lever cover and gasket.Refer to

Procedure 003-011 (Rocker Lever Cover) in Section 3.
If coolant, oil, excessive fuel, or excessive black smoke,
has entered the exhaust system, the aftertreatment
system must be inspected.Refer to Procedure 014-013
(Aftertreatment Testing) in Section 14.
Block Stiffener Plate Signature, ISX, and QSX15 Eng [...]

Preparatory Steps
WARNING
WARNING
Remove the oil pan. Refer to Procedure 007-025.

Procedure 007-035.
Remove
Remove the 10 capscrews and the block stiffener plate.
Signature, ISX, and QSX15 Eng [...] Block Stiffener Plate
Install
Install the block stiffener plate and the 10 capscrews.
Finishing Steps
007-035.
Install the oil pan. Refer to Procedure 007-025.

007-037.
Block Stiffener Plate Signature, ISX, and QSX15 Eng [...]

007-037.
Operate the engine until it reaches a temperature of 82

C [180F], and check for lubricating oil leaks.
Index
Page X-1
About the Manual ..........................................................................................i-1 Preparatory Steps.......................................................................................1-5

General Information.....................................................................................i-1 Remove......................................................................................................1-5
Acronyms and Abbreviations ......................................................................i-15 Bearings, Main .........................................................................................DS-83
General Information...................................................................................i-15 Remove.................................................................................................DS-83
Aftertreatment Adapter Pipe ...................................................................DS-26 Bearings, Main ...........................................................................................AS-4
Remove.................................................................................................DS-26 Install.......................................................................................................AS-4
Aftertreatment Adapter Pipe .................................................................AS-122 Bearings, Main ............................................................................................1-11
Install...................................................................................................AS-122 Clean and Inspect for Reuse.....................................................................1-12
Aftertreatment Diesel Particulate Filter Excessive Ash Cleaning.........TS-12 Finishing Steps.........................................................................................1-19
Aftertreatment Diesel Particulate Filter - Excessive Automatic and/or Stationary Install........................................................................................................1-14
Regeneration..............................................................................................TS-90 Preparatory Steps.....................................................................................1-11
Aftertreatment Diesel Particulate Filter Excessive Soot Loading..........TS-11 Remove....................................................................................................1-12
Aftertreatment Fuel Injector ....................................................................DS-27 Bearings, Thrust ......................................................................................DS-82
Remove.................................................................................................DS-27 Remove.................................................................................................DS-82
Aftertreatment Fuel Injector ..................................................................AS-122 Bearings, Thrust .........................................................................................1-19
Install...................................................................................................AS-122 Finishing Steps.........................................................................................1-22
Aftertreatment Fuel Shutoff Manifold .....................................................DS-23 Inspect for Reuse......................................................................................1-21
Remove.................................................................................................DS-23 Install........................................................................................................1-21
Aftertreatment Fuel Shutoff Manifold ...................................................AS-126 Preparatory Steps.....................................................................................1-19
Install...................................................................................................AS-126 Remove....................................................................................................1-20
Aftertreatment Injector Lines ..................................................................DS-19 Belt Tensioner, Automatic (Water Pump) .................................................DS-9
Remove.................................................................................................DS-19 Remove...................................................................................................DS-9
Aftertreatment Injector Lines ................................................................AS-127 Drives Alternator..................................................................................DS-9
Install...................................................................................................AS-127 Automotive Applications.....................................................................DS-10
Air Compressor ........................................................................................DS-62 Industrial and Power Generation........................................................DS-10
Remove.................................................................................................DS-62 Belt Tensioner, Automatic (Water Pump) .............................................AS-140
Air Compressor ........................................................................................AS-57 Install...................................................................................................AS-140
Install.....................................................................................................AS-57 Drives Alternator..............................................................................AS-140
Air Compressor Air Pressure Rises Slowly ...............................................TS-3 Automotive Applications...................................................................AS-140
Air Compressor Coolant Lines ................................................................DS-62 Industrial and Power Generation.......................................................AS-141
Finishing Steps......................................................................................DS-62 Belt Tensioner, Refrigerant Compressor, Automatic .............................DS-13
Remove.................................................................................................DS-62 Remove.................................................................................................DS-13
Air Compressor Coolant Lines ................................................................AS-58 With Water Pump and Refrigerant Compressor Belt Routing..............DS-13
Finishing Steps......................................................................................AS-60 Belt Tensioner, Refrigerant Compressor, Automatic ...........................AS-137
Install.....................................................................................................AS-58 Install...................................................................................................AS-137
Air Compressor Cycles Frequently............................................................TS-4 With Water Pump and Refrigerant Compressor Belt Routing.............AS-137
Air Compressor Noise is Excessive...........................................................TS-5 Block Stiffener Plate ................................................................................AS-42
Air Compressor Pumping Excess Lubricating Oil into the Air System .......TS-6 Install.....................................................................................................AS-42
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Block Stiffener Plate ................................................................................1-178
Continuously)...............................................................................................TS-8 Finishing Steps.......................................................................................1-179
Air Compressor Will Not Pump Air............................................................TS-9 Install......................................................................................................1-179
Air Compressor Will Not Stop Pumping...................................................TS-10 Preparatory Steps...................................................................................1-178
Air Intake Connection ..............................................................................DS-18 Remove..................................................................................................1-178
Remove.................................................................................................DS-18 Block Stiffener Plate ................................................................................DS-71
Automotive with CM870......................................................................DS-18 Remove.................................................................................................DS-71
Automotive With CM871.....................................................................DS-18 Bracket, Accessory ..................................................................................1-152
Automotive, Industrial with CM570 and Power Generation without CM570.... Inspect for Reuse....................................................................................1-154
DS-18 Install......................................................................................................1-154
Air Intake Connection ............................................................................AS-131 Automotive Applications......................................................................1-154
Install...................................................................................................AS-131 Industrial and Power Generation.........................................................1-156
Automotive, Industrial with CM570 and Power Generation without CM570.... Remove..................................................................................................1-152
AS-131 Automotive Applications......................................................................1-152
Automotive with CM870....................................................................AS-131 Industrial and Power Generation.........................................................1-153
Automotive With CM871...................................................................AS-131 Bracket, Retaining Brace .........................................................................1-148
Air Intake System - Overview ....................................................................F-34 Inspect for Reuse....................................................................................1-149
General Information..................................................................................F-34 Install......................................................................................................1-150
Variable Geometry................................................................................F-34 Automotive Applications......................................................................1-150
Automotive with CM870........................................................................F-34 Industrial and Power Generation.........................................................1-150
Automotive With CM871.......................................................................F-35 Remove..................................................................................................1-148
All Applications.....................................................................................F-36 Automotive Applications......................................................................1-148
Alternator .................................................................................................DS-52 Industrial and Power Generation.........................................................1-149
Remove.................................................................................................DS-52 Complete Engine - Overview .......................................................................F-1
Driven by Cooling Fan Drive Belt........................................................DS-52 General Information....................................................................................F-1
Automotive with CM870......................................................................DS-52 Compressed Air System - Overview ..........................................................F-51
Alternator .................................................................................................AS-92 General Information..................................................................................F-51
Install.....................................................................................................AS-92 Single Cylinder.....................................................................................F-51
Driven by Cooling Fan Drive Belt........................................................AS-92 Connecting Rod ..........................................................................................1-23
Automotive with CM870......................................................................AS-92 Bend and Twist Inspect.............................................................................1-27
Alternator Not Charging or Insufficient Charging.....................................TS-13 Calibration Procedure...........................................................................1-27
Alternator/Refrigerant Compressor Mounting Bracket ...........................DS-53 Test......................................................................................................1-29
Remove.................................................................................................DS-53 Clean and Inspect for Reuse.....................................................................1-23
Automotive with CM870......................................................................DS-53 Finishing Steps.........................................................................................1-33
Automotive with CM570......................................................................DS-53 Magnetic Crack Inspect.............................................................................1-30
Alternator/Refrigerant Compressor Mounting Bracket ...........................AS-91 Preparatory Steps.....................................................................................1-23
Install.....................................................................................................AS-91 Coolant Filter .............................................................................................DS-7
Automotive with CM870......................................................................AS-91 Remove...................................................................................................DS-7
Automotive with CM570......................................................................AS-91 Coolant Filter .........................................................................................AS-147
Bearings, Connecting Rod ......................................................................DS-74 Install...................................................................................................AS-147
Remove.................................................................................................DS-74 Coolant in the Lubricating Oil..................................................................TS-26
Bearings, Thrust ........................................................................................AS-9 Coolant Loss - External...........................................................................TS-15
Install.......................................................................................................AS-9 Coolant Loss - Internal............................................................................TS-17
Bearings, Connecting Rod ......................................................................AS-36 Coolant Temperature Above Normal - Gradual Overheat.........................TS-19
Install.....................................................................................................AS-36 Coolant Temperature Above Normal - Sudden Overheat.........................TS-22
Bearings, Connecting Rod ...........................................................................1-5 Coolant Temperature Below Normal.......................................................TS-24
Clean and Inspect for Reuse.......................................................................1-6 Coolant Thermostat .................................................................................DS-51
Finishing Steps.........................................................................................1-11 Remove.................................................................................................DS-51
Install..........................................................................................................1-8 Coolant Thermostat .................................................................................AS-92
Index
Page X-2
Install.....................................................................................................AS-92 Remove..................................................................................................1-138
Coolant Thermostat Housing ..................................................................DS-49 Cylinder Block ............................................................................................1-77
Remove.................................................................................................DS-49 Inspect for Reuse......................................................................................1-77
Single Thermostat..............................................................................DS-49 Repair.......................................................................................................1-78
Dual Thermostat................................................................................DS-49 Cylinder Block - Overview ...........................................................................F-3
Coolant Thermostat Housing ..................................................................AS-94 General Information....................................................................................F-3
Install.....................................................................................................AS-94 Cylinder Block and Liner Seats .................................................................1-87
Single Thermostat..............................................................................AS-94 Leak Test..................................................................................................1-87
Dual Thermostat.................................................................................AS-95 Cylinder Head ..........................................................................................DS-69
Cooling System .........................................................................................DS-1 Remove.................................................................................................DS-69
Drain........................................................................................................DS-1 Cylinder Head ..........................................................................................AS-44
Cooling System ......................................................................................AS-153 Install.....................................................................................................AS-44
Fill........................................................................................................AS-153 Cylinder Head - Overview ............................................................................F-4
Cooling System - Overview .......................................................................F-24 General Information....................................................................................F-4
General Information..................................................................................F-24 Cylinder Liner ..........................................................................................DS-84
Crankcase Breather (External) ................................................................DS-14 Remove.................................................................................................DS-84
Remove.................................................................................................DS-14 Cylinder Liner ............................................................................................AS-1
Automotive with CM870......................................................................DS-14 Install.......................................................................................................AS-1
Automotive With CM871.....................................................................DS-15 Measure...................................................................................................AS-2
Crankcase Breather (External) ..............................................................AS-135 Cylinder Liner .............................................................................................1-91
Install...................................................................................................AS-135 Clean and Inspect for Reuse.....................................................................1-93
Automotive with CM870....................................................................AS-135 Finishing Steps.........................................................................................1-99
Automotive With CM871...................................................................AS-136 Install........................................................................................................1-96
Crankcase Coalescing Filter - Frequent Replacement.............................TS-28 Measure...................................................................................................1-97
Crankcase Gases (Blowby) Excessive.....................................................TS-27 Preparatory Steps.....................................................................................1-91
Crankshaft ...............................................................................................DS-82 Remove....................................................................................................1-92
Remove.................................................................................................DS-82 Drive Belt, Cooling Fan .............................................................................DS-9
Crankshaft ................................................................................................AS-10 Remove...................................................................................................DS-9
Install.....................................................................................................AS-10 Drives Alternator..................................................................................DS-9
Crankshaft ..................................................................................................1-34 Drive Belt, Cooling Fan .........................................................................AS-142
Bend and Twist Inspect.............................................................................1-40 Install...................................................................................................AS-142
Clean and Inspect for Reuse.....................................................................1-36 Drives Alternator..............................................................................AS-142
Finishing Steps.........................................................................................1-51 Drive Belt, Refrigerant Compressor ........................................................DS-13
Install........................................................................................................1-50 Remove.................................................................................................DS-13
Magnetic Crack Inspect.............................................................................1-46 With Water Pump and Refrigerant Compressor Belt Routing..............DS-13
Preparatory Steps.....................................................................................1-35 Drive Belt, Refrigerant Compressor ......................................................AS-137
Remove....................................................................................................1-36 Install...................................................................................................AS-137
Rotation Check.........................................................................................1-34 With Water Pump and Refrigerant Compressor Belt Routing.............AS-137
Crankshaft Adapter ....................................................................................1-51 ECM Cooling Plate, Fuel Cooled .............................................................DS-19
Clean and Inspect for Reuse.....................................................................1-56 Remove.................................................................................................DS-19
Finishing Steps.........................................................................................1-58 ECM Cooling Plate, Fuel Cooled ...........................................................AS-130
Install........................................................................................................1-56 Install...................................................................................................AS-130
Preparatory Steps.....................................................................................1-51 EGR Connection Tubes ...........................................................................DS-43
Remove....................................................................................................1-52 Remove.................................................................................................DS-43
Crankshaft Gear, Front (Crankshaft Installed) ...........................................1-58 EGR Connection Tubes .........................................................................AS-101
Clean and Inspect for Reuse.....................................................................1-62 Install...................................................................................................AS-101
Finishing Steps.........................................................................................1-63 EGR Cooler ..............................................................................................DS-45
Install........................................................................................................1-62 Remove.................................................................................................DS-45
Preparatory Steps.....................................................................................1-58 EGR Cooler ..............................................................................................AS-97
On-Engine Repair.................................................................................1-58 Install.....................................................................................................AS-97
Remove....................................................................................................1-59 EGR Cooler Coolant Lines .......................................................................DS-38
Crankshaft Pulley .......................................................................................1-64 Remove.................................................................................................DS-38
Inspect for Reuse......................................................................................1-65 EGR Cooler Coolant Lines .....................................................................AS-109
Install........................................................................................................1-66 Install...................................................................................................AS-109
Automotive Applications........................................................................1-66 EGR Mixer ................................................................................................DS-17
Industrial and Power Generation...........................................................1-66 Remove.................................................................................................DS-17
Remove....................................................................................................1-64 EGR Mixer ..............................................................................................AS-132
Automotive Applications........................................................................1-64 Install...................................................................................................AS-132
Industrial and Power Generation...........................................................1-64 EGR Valve ................................................................................................DS-40
Crankshaft Seal, Front ............................................................................DS-61 Remove.................................................................................................DS-40
Remove.................................................................................................DS-61 EGR Valve ..............................................................................................AS-107
Crankshaft Seal, Front .............................................................................AS-61 Install...................................................................................................AS-107
Install.....................................................................................................AS-61 EGR Valve Coolant Lines ........................................................................DS-40
Crankshaft Seal, Front ...............................................................................1-68 Remove.................................................................................................DS-40
Clean and Inspect for Reuse.....................................................................1-70 EGR Valve Coolant Lines .......................................................................AS-108
Finishing Steps.........................................................................................1-73 Install...................................................................................................AS-108
Install........................................................................................................1-70 EGR Valve Mounting Bracket ..................................................................DS-41
Preparatory Steps.....................................................................................1-68 Remove.................................................................................................DS-41
Remove....................................................................................................1-69 EGR Valve Mounting Bracket ................................................................AS-106
Crankshaft Seal, Rear ..............................................................................DS-76 Install...................................................................................................AS-106
Measure.................................................................................................DS-77 Electrical Equipment - Overview ...............................................................F-54
Remove.................................................................................................DS-76 General Information..................................................................................F-54
Crankshaft Seal, Rear ..............................................................................AS-31 Engine Base Timing ................................................................................DS-63
Install.....................................................................................................AS-31 Remove.................................................................................................DS-63
Measure.................................................................................................AS-32 Engine Base Timing .................................................................................AS-46
Crankshaft Seal, Rear ................................................................................1-73 Adjust.....................................................................................................AS-53
Clean and Inspect for Reuse.....................................................................1-75 Install.....................................................................................................AS-46
Finishing Steps.........................................................................................1-77 Engine Base Timing .................................................................................1-157
Install........................................................................................................1-75 Adjust.....................................................................................................1-172
Measure...................................................................................................1-76 Finishing Steps.......................................................................................1-176
Preparatory Steps.....................................................................................1-73 General Information................................................................................1-157
Remove....................................................................................................1-74 Inspect for Reuse....................................................................................1-165
Crankshaft Tone Wheel ............................................................................1-138 Install......................................................................................................1-166
Finishing Steps.......................................................................................1-139 Preparatory Steps...................................................................................1-159
Inspect....................................................................................................1-138 Remove..................................................................................................1-161
Install......................................................................................................1-139 Engine Brake - Low Retarding Power or Slow to Activate........................TS-32
Preparatory Steps...................................................................................1-138
Index
Page X-3
Engine Brake One or More Cylinders Braking with Power Switch Off.....TS- Remove.................................................................................................DS-11
35 Automotive with CM870......................................................................DS-11
Engine Brake Does Not Operate.............................................................TS-29 Automotive with CM570......................................................................DS-11
Engine Decelerates Slowly.....................................................................TS-37 Industrial CM570 and Power Generation without CM570....................DS-12
Engine Diagrams ..........................................................................................E-3 Fan Hub, Belt Driven .............................................................................AS-139
Engine Views.............................................................................................E-3 Install...................................................................................................AS-139
Automotive with CM870..........................................................................E-4 Automotive with CM870....................................................................AS-139
Automotive With CM871.........................................................................E-7 Automotive with CM570....................................................................AS-139
Industrial CM570 and Power Generation without CM570.......................E-11 Industrial CM570 and Power Generation without CM570...................AS-139
Engine Identification ....................................................................................E-1 Fan Support .............................................................................................DS-12
ECM Dataplate...........................................................................................E-1 Remove.................................................................................................DS-12
Automotive with CM870 and CM871.......................................................E-1 Industrial and Power Generation........................................................DS-12
Automotive, Industrial with CM570 and Power Generation without CM570.... Fan Support ...........................................................................................AS-137
E-1 Install...................................................................................................AS-137
Power Generation...................................................................................E-2 Industrial and Power Generation.......................................................AS-137
Engine Dataplate........................................................................................E-1 Flow Diagram, Air Intake System ..............................................................F-37
Engine Installation .......................................................................................0-7 Flow Diagram...........................................................................................F-37
Finishing Steps...........................................................................................0-9 Automotive, Industrial with CM570 and Power Generation without CM570....
All Applications.......................................................................................0-9 F-37
Install..........................................................................................................0-7 With CM870..........................................................................................F-38
Automotive and Industrial.......................................................................0-7 Automotive With CM871.......................................................................F-39
Power Generation...................................................................................0-8 Flow Diagram, Compressed Air System ....................................................F-52
Engine Installation .................................................................................AS-148 Flow Diagram...........................................................................................F-52
Install...................................................................................................AS-148 Flow Diagram, Cooling System .................................................................F-26
Automotive and Industrial.................................................................AS-148 Flow Diagram...........................................................................................F-26
Power Generation.............................................................................AS-149 Automotive, Industrial with CM570 and Power Generation without CM570....
Engine Lifting Brackets ...........................................................................DS-48 F-26
Remove.................................................................................................DS-48 Automotive with CM870........................................................................F-29
Engine Lifting Brackets ...........................................................................AS-96 Automotive With CM871.......................................................................F-31
Install.....................................................................................................AS-96 Single Thermostat................................................................................F-33
Engine Noise Excessive.........................................................................TS-38 Flow Diagram, Exhaust System .................................................................F-44
Engine Noise Excessive Combustion Knocks.....................................TS-41 Flow Diagram...........................................................................................F-44
Engine Noise Excessive Connecting Rod...........................................TS-42 Automotive, Industrial with CM570 and Power Generation without CM570....
Engine Noise Excessive Main Bearing................................................TS-43 F-44
Engine Noise Excessive Piston..........................................................TS-45 With CM870..........................................................................................F-46
Engine Noise Excessive Turbocharger...............................................TS-46 Automotive With CM871.......................................................................F-48
Engine Performance Troubleshooting Tree - ISX with CM871 ...............TT-61 Automotive With CM871.......................................................................F-49
Engine Performance Troubleshooting Tree - Signature and ISX CM870 ..... Automotive With CM871.......................................................................F-50
TT-1 Flow Diagram, Fuel System .........................................................................F-9
Engine Removal ...........................................................................................0-2 Flow Diagram.............................................................................................F-9
Preparatory Steps.......................................................................................0-2 Automotive with CM570..........................................................................F-9
All Applications.......................................................................................0-2 Automotive with CM870........................................................................F-11
Remove......................................................................................................0-3 Automotive With CM871.......................................................................F-12
Automotive and Industrial.......................................................................0-3 Industrial CM570 and Power Generation without CM570.......................F-13
Power Generation...................................................................................0-5 Flow Diagram, Lubricating Oil System ......................................................F-18
Engine Removal .........................................................................................DS-2 Flow Diagram...........................................................................................F-18
Remove...................................................................................................DS-2 Automotive, Industrial with CM570 and Power Generation without CM570....
Automotive and Industrial.....................................................................DS-2 F-18
Power Generation................................................................................DS-5 Automotive with CM870........................................................................F-20
Engine Shuts Off Unexpectedly or Dies During Deceleration...................TS-47 All Applications.....................................................................................F-21
Engine Speed Surges in PTO or Cruise Control......................................TS-49 Automotive With CM871.......................................................................F-23
Engine Starts But Will Not Keep Running...............................................TS-51 Flywheel ...................................................................................................DS-76
Engine Storage - Long Term ......................................................................0-11 Remove.................................................................................................DS-76
General Information..................................................................................0-11 Flywheel ...................................................................................................AS-32
Engine Support Bracket, Front ...............................................................DS-70 Install.....................................................................................................AS-32
Remove.................................................................................................DS-70 Flywheel Housing ....................................................................................DS-78
Engine Support Bracket, Front ...............................................................AS-43 Remove.................................................................................................DS-78
Install.....................................................................................................AS-43 Flywheel Housing ....................................................................................AS-14
Engine Testing - Overview .........................................................................F-56 Install.....................................................................................................AS-14
Fuel Flow Measurement on Engine or Chassis Dynamometer...................F-57 Measure.................................................................................................AS-15
General Information..................................................................................F-56 Bore Alignment..................................................................................AS-15
Engine Will Not Crank or Cranks Slowly (Air Starter)...............................TS-54 Face Alignment..................................................................................AS-17
Engine Will Not Crank or Cranks Slowly (Electric Starter)........................TS-55 Flywheel Housing, REPTO ......................................................................DS-79
Engine Will Not Shut Off.........................................................................TS-57 Remove.................................................................................................DS-79
Exhaust Gas Pressure Sensor Adapter ..................................................DS-42 Flywheel Housing, REPTO ......................................................................AS-19
Remove.................................................................................................DS-42 Install.....................................................................................................AS-19
All Applications..................................................................................DS-42 Measure.................................................................................................AS-27
Exhaust Gas Pressure Sensor Adapter .................................................AS-106 Bore Alignment..................................................................................AS-27
Install...................................................................................................AS-106 Face Alignment..................................................................................AS-29
All Applications.................................................................................AS-106 Fuel Consumption Excessive..................................................................TS-58
Exhaust Gas Pressure Sensor Tube .......................................................DS-42 Fuel Economy Troubleshooting Tree ....................................................TT-110
Remove.................................................................................................DS-42 Fuel Economy Troubleshooting Tree ....................................................TT-141
Exhaust Gas Pressure Sensor Tube .....................................................AS-107 Fuel Filter (Spin-On Type) .........................................................................DS-8
Install...................................................................................................AS-107 Remove...................................................................................................DS-8
Exhaust Manifold, Dry .............................................................................DS-43 Fuel Filter (Spin-On Type) .....................................................................AS-144
Remove.................................................................................................DS-43 Install...................................................................................................AS-144
Exhaust Manifold, Dry ...........................................................................AS-103 Fuel in Coolant.......................................................................................TS-63
Install...................................................................................................AS-103 Fuel in the Lubricating Oil.......................................................................TS-64
Automotive with CM870 and CM871.................................................AS-103 Fuel System - Overview ...............................................................................F-5
Automotive, Industrial with CM570 and Power Generation without CM570.... General Information....................................................................................F-5
AS-104 Automotive with CM870..........................................................................F-6
Exhaust System - Overview .......................................................................F-40 Automotive With CM871.........................................................................F-7
General Information..................................................................................F-40 Installation Recommendations....................................................................F-7
Automotive With CM871.......................................................................F-40 Gear Cover, Lower ..................................................................................DS-62
Automotive With CM871.......................................................................F-40 Remove.................................................................................................DS-62
Automotive with CM870........................................................................F-43 Gear Cover, Lower ...................................................................................AS-60
Fan Hub, Belt Driven ...............................................................................DS-11 Install.....................................................................................................AS-60
Index
Page X-4
Gear Cover, Lower ...................................................................................1-145 Remove.................................................................................................DS-24

Clean and Inspect for Reuse...................................................................1-145 Lubricating Oil Consumption Excessive..................................................TS-71
Finishing Steps.......................................................................................1-148 Lubricating Oil Contaminated..................................................................TS-74
Install......................................................................................................1-147 Lubricating Oil Cooler .............................................................................DS-47
Preparatory Steps...................................................................................1-145 Remove.................................................................................................DS-47
Remove..................................................................................................1-145 All Applications..................................................................................DS-47
Gear Cover, Upper ...................................................................................DS-60 Lubricating Oil Cooler .............................................................................AS-97
Remove.................................................................................................DS-60 Install.....................................................................................................AS-97
Automotive Applications.....................................................................DS-60 All Applications..................................................................................AS-97
Industrial and Power Generation........................................................DS-60 Lubricating Oil Dipstick Tube .................................................................DS-17
Gear Cover, Upper ...................................................................................AS-64 Remove.................................................................................................DS-17
Install.....................................................................................................AS-64 Automotive with CM870......................................................................DS-17
Automotive Applications.....................................................................AS-64 Automotive With CM871.....................................................................DS-17
Industrial and Power Generation.........................................................AS-64 Lubricating Oil Dipstick Tube ................................................................AS-132
Gear Cover, Upper ....................................................................................1-140 Install...................................................................................................AS-132
Clean and Inspect for Reuse...................................................................1-141 Automotive with CM870....................................................................AS-132
All Applications...................................................................................1-141 Automotive With CM871...................................................................AS-132
Finishing Steps.......................................................................................1-144 Lubricating Oil Fill Tube ..........................................................................DS-15
All Applications...................................................................................1-144 Remove.................................................................................................DS-15
Install......................................................................................................1-143 Automotive with CM870......................................................................DS-15
Automotive Applications......................................................................1-143 Automotive With CM871.....................................................................DS-16
Industrial and Power Generation.........................................................1-144 Lubricating Oil Fill Tube ........................................................................AS-132
Preparatory Steps...................................................................................1-140 Install...................................................................................................AS-132
All Applications...................................................................................1-140 Automotive with CM870....................................................................AS-132
Remove..................................................................................................1-140 Automotive With CM871...................................................................AS-134
Automotive Applications......................................................................1-140 Lubricating Oil Filter (Spin-On) .................................................................DS-7
Industrial and Power Generation.........................................................1-141 Remove...................................................................................................DS-7
Gear Housing, Front ................................................................................DS-81 Lubricating Oil Filter (Spin-On) .............................................................AS-147
Remove.................................................................................................DS-81 Install...................................................................................................AS-147
Gear Housing, Front ................................................................................AS-12 Lubricating Oil Filter Plugged..................................................................TS-75
Install.....................................................................................................AS-12 Lubricating Oil in the Fuel.......................................................................TS-70
Gear Housing, Front .................................................................................1-100 Lubricating Oil Pan ..................................................................................DS-70
Clean and Inspect for Reuse...................................................................1-101 Remove.................................................................................................DS-70
Finishing Steps.......................................................................................1-104 Lubricating Oil Pan ..................................................................................AS-42
Install......................................................................................................1-102 Install.....................................................................................................AS-42
Preparatory Steps...................................................................................1-100 Lubricating Oil Pressure High.................................................................TS-78
Remove..................................................................................................1-100 Lubricating Oil Pressure Low..................................................................TS-79
General Cleaning Instructions ....................................................................i-10 Lubricating Oil Pump ...............................................................................DS-82
Abrasive Pads and Abrasive Paper.............................................................i-10 Remove.................................................................................................DS-82
Definition of Clean......................................................................................i-10 Lubricating Oil Pump ...............................................................................AS-10
Fuel System...............................................................................................i-13 Install.....................................................................................................AS-10
Gasket Surfaces........................................................................................i-11 Lubricating Oil Sludge in the Crankcase Excessive.................................TS-81
Plastic Bead Cleaning................................................................................i-12 Lubricating Oil Suction Tube (Block-Mounted) ......................................DS-71
Solvent and Acid Cleaning.........................................................................i-11 Remove.................................................................................................DS-71
Steam Cleaning.........................................................................................i-12 Lubricating Oil Suction Tube (Block-Mounted) ......................................AS-42
General Repair Instructions ..........................................................................i-8 Install.....................................................................................................AS-42
General Information.....................................................................................i-8 Lubricating Oil System ..............................................................................DS-2
Welding on a Vehicle with an Electronic Controlled Fuel System..................i-9 Drain........................................................................................................DS-2
General Safety Instructions ..........................................................................i-6 Lubricating Oil System ..........................................................................AS-151
Important Safety Notice................................................................................i-6 Fill........................................................................................................AS-152
Heat Shield ..............................................................................................DS-37 Prime...................................................................................................AS-151
Remove.................................................................................................DS-37 Lubricating Oil System - Overview ............................................................F-15
Automotive with CM870......................................................................DS-37 General Information..................................................................................F-15
Automotive With CM871.....................................................................DS-37 Lubricating Oil......................................................................................F-15
Heat Shield .............................................................................................AS-111 Lubricating Oil Filters............................................................................F-16
Install...................................................................................................AS-111 Lubricating Oil System..............................................................................F-16
Automotive with CM870....................................................................AS-111 New Engine Break-in Oils.........................................................................F-17
Automotive With CM871...................................................................AS-112 Oil Drain Intervals.....................................................................................F-17
How to Use the Manual .................................................................................i-2 Lubricating Oil Temperature Above Specification....................................TS-83
General Information.....................................................................................i-2 Lubricating or Transmission Oil in the Coolant........................................TS-85
Idler Gear, Lower Scissor ........................................................................AS-43 Overhead Camshaft, Injector ..................................................................DS-68
General Information................................................................................AS-43 Remove.................................................................................................DS-68
Idler Gear, Adjustable ..............................................................................1-140 Overhead Camshaft, Injector ..................................................................AS-45
General Information................................................................................1-140 Install.....................................................................................................AS-45
Idler Gear, Lower Scissor ........................................................................DS-70 Overhead Camshaft, Valve ......................................................................DS-67
General Information...............................................................................DS-70 Remove.................................................................................................DS-67
Idler Gear, Lower Scissor ........................................................................1-140 Overhead Camshaft, Valve ......................................................................AS-46
General Information................................................................................1-140 Install.....................................................................................................AS-46
Idler Pulley, Refrigerant Compressor .....................................................DS-13 Overhead Set ...........................................................................................AS-73
Remove.................................................................................................DS-13 Adjust.....................................................................................................AS-77
With Water Pump and Refrigerant Compressor Belt Routing..............DS-13 Measure.................................................................................................AS-73
Idler Pulley, Refrigerant Compressor ....................................................AS-137 General Information............................................................................AS-73
Install...................................................................................................AS-137 Piston ........................................................................................................1-104
With Water Pump and Refrigerant Compressor Belt Routing.............AS-137 Clean and Inspect for Reuse...................................................................1-106
Illustrations ....................................................................................................i-5 Articulated Piston................................................................................1-106
General Information.....................................................................................i-5 Single-Piece Piston.............................................................................1-107
Injector .....................................................................................................DS-57 Finishing Steps.......................................................................................1-110
Remove.................................................................................................DS-57 All Applications...................................................................................1-110
Injector .....................................................................................................AS-68 General Information................................................................................1-104
Install.....................................................................................................AS-68 Preparatory Steps...................................................................................1-105
Injectors and Fuel Lines - Overview ..........................................................F-15 All Applications...................................................................................1-105
General Information..................................................................................F-15 Piston and Connecting Rod Assembly ...................................................DS-72
Intake Manifold Air Temperature Above Specification.............................TS-66 Remove.................................................................................................DS-72
Intake Manifold Pressure (Boost) is Below Normal..................................TS-68 Piston and Connecting Rod Assembly ...................................................AS-39
Integrated Fuel System Module (IFSM) .................................................AS-125 Install.....................................................................................................AS-39
Install...................................................................................................AS-125 Piston and Connecting Rod Assembly ....................................................1-127
Integrated Fuel System Module (IFSM) ...................................................DS-24 Assemble................................................................................................1-131
Index
Page X-5
Articulated Piston................................................................................1-131 Service History Review.....................................................................TS-104

Single-Piece Piston.............................................................................1-133 ECM Data Review:...........................................................................TS-104
Disassemble...........................................................................................1-130 Driveability - General Information............................................................TS-93
Articulated Piston................................................................................1-130 Driveability/Low Power - Customer Complaint Form................................TS-95
Single-Piece Piston.............................................................................1-130 Driveability/Low Power/Excessive Fuel Consumption - Checklist.............TS-96
Finishing Steps.......................................................................................1-137 Engine Noise Diagnostic Procedures - General Information.....................TS-93
Install......................................................................................................1-134 Fuel Consumption - Customer Complaint Form.......................................TS-99
Preparatory Steps...................................................................................1-127 Fuel Consumption - General Information.................................................TS-98
Remove..................................................................................................1-128 Main Bearing Noise................................................................................TS-93
Piston Cooling Nozzle .............................................................................DS-71 Oil Consumption...................................................................................TS-101
Remove.................................................................................................DS-71 Piston Noise...........................................................................................TS-93
Piston Cooling Nozzle .............................................................................AS-41 ....................................................................................................................TS-1
Install.....................................................................................................AS-41 General Information..................................................................................TS-1
Piston Cooling Nozzle ..............................................................................1-111 Troubleshooting Symptoms Charts ..........................................................TS-2
Finishing Steps.......................................................................................1-112 General Information..................................................................................TS-2
Install......................................................................................................1-112 Turbocharger ...........................................................................................DS-29
Preparatory Steps...................................................................................1-111 Clean.....................................................................................................DS-30
Remove..................................................................................................1-112 Inspect for Reuse...................................................................................DS-31
Piston Rings ............................................................................................DS-75 Remove.................................................................................................DS-29
Remove.................................................................................................DS-75 Turbocharger .........................................................................................AS-112
Articulated Piston...............................................................................DS-75 Assemble.............................................................................................AS-112
Single-Piece Piston............................................................................DS-75 Install...................................................................................................AS-113
Piston Rings .............................................................................................AS-34 Turbocharger Air Shutoff Valve Filter ....................................................DS-24
Install.....................................................................................................AS-34 Remove.................................................................................................DS-24
Articulated Piston...............................................................................AS-34 Variable Geometry.............................................................................DS-24
Single-Piece Piston............................................................................AS-35 Turbocharger Air Shutoff Valve Filter ...................................................AS-124
Piston Rings .............................................................................................1-114 Install...................................................................................................AS-124
Install......................................................................................................1-116 Variable Geometry............................................................................AS-124
Articulated Piston................................................................................1-116 Turbocharger Control Shutoff Valve Filter Head ....................................DS-25
Single-Piece Piston.............................................................................1-117 Remove.................................................................................................DS-25
Measure..................................................................................................1-115 Variable Geometry.............................................................................DS-25
Articulated Piston................................................................................1-115 Turbocharger Coolant Hoses ..................................................................DS-28
Single-Piece Piston.............................................................................1-115 Remove.................................................................................................DS-28
Remove..................................................................................................1-114 Automotive with CM870......................................................................DS-28
Articulated Piston................................................................................1-114 Automotive With CM871.....................................................................DS-28
Single-Piece Piston.............................................................................1-114 Turbocharger Coolant Hoses ................................................................AS-119
Refrigerant Compressor ..........................................................................DS-13 Install...................................................................................................AS-119
Remove.................................................................................................DS-13 Automotive with CM870....................................................................AS-119
Sanden..............................................................................................DS-13 Automotive With CM871...................................................................AS-120
Climate Control Incorporated..............................................................DS-14 Turbocharger Leaks Engine Oil or Fuel...................................................TS-86
Refrigerant Compressor ........................................................................AS-136 Turbocharger Control Shutoff Valve Filter Head ..................................AS-123
Install...................................................................................................AS-136 Install...................................................................................................AS-123
Sanden............................................................................................AS-136 Variable Geometry............................................................................AS-123
Climate Control Incorporated............................................................AS-136 Turbocharger, Variable Geometry Actuator ..........................................AS-121
Refrigerant Compressor Mounting Bracket ............................................DS-53 Install...................................................................................................AS-121
Remove.................................................................................................DS-53 Variable Geometry............................................................................AS-121
Sanden..............................................................................................DS-53 Turbocharger, Variable Geometry Actuator ...........................................DS-27
Climate Control Incorporated..............................................................DS-54 Remove.................................................................................................DS-27
Automotive, Industrial with CM570 and Power Generation without CM570.... Variable Geometry.............................................................................DS-27
DS-54 Turbocharger, Variable Geometry Actuator Air Supply Line .................DS-26
Refrigerant Compressor Mounting Bracket ............................................AS-89 Remove.................................................................................................DS-26
Install.....................................................................................................AS-89 Turbocharger, Variable Geometry Actuator Air Supply Line ...............AS-123
Sanden..............................................................................................AS-89 Install...................................................................................................AS-123
Climate Control Incorporated..............................................................AS-90 Turbocharger, Variable Geometry Control Valve Air Supply Line .........DS-25
Automotive, Industrial with CM570 and Power Generation without CM570.... Remove.................................................................................................DS-25
AS-90 Turbocharger, Variable Geometry Control Valve Air Supply Line .......AS-124
Rocker Lever Assembly ..........................................................................DS-56 Install...................................................................................................AS-124
Remove.................................................................................................DS-56 Vehicle Braking - Overview .......................................................................F-59
Rocker Lever Assembly ...........................................................................AS-69 General Information..................................................................................F-59
Install.....................................................................................................AS-69 Vibration Damper, Viscous .....................................................................DS-58
Rocker Lever Cover ...................................................................................DS-8 Remove.................................................................................................DS-58
Remove...................................................................................................DS-8 Automotive Applications.....................................................................DS-58
Rocker Lever Cover ...............................................................................AS-143 Industrial and Power Generation with Crank-Driven Fan or PTO.........DS-58
Install...................................................................................................AS-143 Industrial and Power Generation without Crank-Driven Fan or PTO.....DS-
Rocker Levers - Overview ............................................................................F-5 59
General Information....................................................................................F-5 Vibration Damper, Viscous ......................................................................AS-65
General Information................................................................................F-5 Eccentricity Check..................................................................................AS-68
Service Tools ...............................................................................................0-1 All Applications..................................................................................AS-68
Engine Removal and Installation.................................................................0-1 Install.....................................................................................................AS-65
Service Tools ...............................................................................................1-1 Automotive Applications.....................................................................AS-65
...................................................................................................................1-1 Industrial and Power Generation with Crank-Driven Fan or PTO.........AS-66
Starting Motor ............................................................................................DS-9 Industrial and Power Generation without Crank-Driven Fan or PTO.....AS-
Remove...................................................................................................DS-9 67
All Except 50MT With Aluminum Flywheel Housing..............................DS-9 Wobble Check........................................................................................AS-68
50MT With Aluminum Flywheel Housing..............................................DS-9 All Applications..................................................................................AS-68
Starting Motor ........................................................................................AS-142 Vibration Damper, Viscous ......................................................................1-118
Install...................................................................................................AS-142 Clean and Inspect for Reuse...................................................................1-121
All Except 50MT With Aluminum Flywheel Housing..........................AS-142 All Applications...................................................................................1-121
50MT With Aluminum Flywheel Housing...........................................AS-142 Eccentricity Check..................................................................................1-125
Stationary Regeneration Will Not Activate...........................................TS-87 All Applications...................................................................................1-125
Stationary Regeneration - Will Not Complete..........................................TS-91 Finishing Steps.......................................................................................1-126
Symbols .........................................................................................................i-4 Automotive Applications......................................................................1-126
General Information.....................................................................................i-4 Industrial and Power Generation with Crank-Driven Fan or PTO..........1-126
Troubleshooting Overview ......................................................................TS-93 Industrial and Power Generation without Crank-Driven Fan or PTO.....1-
Connecting Rod Bearing Noise...............................................................TS-93 126
Coolant Loss Pre-Troubleshooting Guide..............................................TS-102 Install......................................................................................................1-123
Driver Interview Questions................................................................TS-103 Automotive Applications......................................................................1-123
Index
Page X-6
Industrial and Power Generation with Crank-Driven Fan or PTO..........1-123

Industrial and Power Generation without Crank-Driven Fan or PTO.....1-
124
Preparatory Steps...................................................................................1-118
Automotive Applications......................................................................1-118
119
Remove..................................................................................................1-119
Automotive Applications......................................................................1-119
120
Wobble Check.........................................................................................1-125
All Applications...................................................................................1-125
Vibration Excessive ................................................................................TT-146
Water Inlet Connection ............................................................................DS-54
Remove.................................................................................................DS-54
Water Inlet Connection ............................................................................AS-89
Install.....................................................................................................AS-89
Water Pump .............................................................................................DS-54
Remove.................................................................................................DS-54
Automotive with CM870......................................................................DS-54
Automotive with CM570......................................................................DS-55
Industrial CM570 and Power Generation without CM570....................DS-55
Water Pump .............................................................................................AS-85
Install.....................................................................................................AS-85
Automotive with CM870......................................................................AS-85
Automotive with CM570......................................................................AS-86
Industrial CM570 and Power Generation without CM570.....................AS-87
Automotive With CM871.....................................................................AS-89
NOTES
Cummins Inc.
Service Manual
Service Manual Signature, ISX and QSX15 Volume 1

Box 3005
Columbus, Indiana, U.S.A., 47202 Signature, ISX and QSX15
Registered Office Volume 1
Cummins Ltd.
49 - 51 Gresham Road,
Staines,
Middlesex TW18 2BD,
England
Registration 573951 England
Copyright 2010
Cummins Inc.
Bulletin 3666239
Printed in U.S.A. 27-APRIL-2010 p41
302158_Cummins_Vol1.indd 1 5/11/10 9:35 AM

Vol1

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Vol1

Загружено:

Авторское право:

Доступные форматы

Cummins Inc.

Service Manual Signature, ISX and QSX15 Volume 1

302158_Cummins_Vol1.indd 1 5/11/10 9:35 AM

Copyright 2010 Bulletin 3666239

Engine and System Identification ............................................................................................................ E

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

Back .......................................................................................................................................................... back

This Page Left Intentionally Blank

About the Manual

How to Use the Manual

(Step 1) Locate the symptom on the Section Contents pages of

The illustrations are intended to show repair or

General Safety Instructions

General Repair Instructions

Follow all safety instructions noted in the procedures

Welding on a Vehicle with an Electronic Controlled Fuel System

General Cleaning Instructions

Fuel system tools are to be kept as clean as possible.

Acronyms and Abbreviations

psi Pounds Per Square Inch

Section E - Engine and System Identification

This Page Left Intentionally Blank

Automotive, Industrial with CM570 and Power

Automotive with CM870

ISX Automotive with CM870 - Left Side View

Automotive with CM870

ISX Automotive with CM870 - Right Side View

Automotive with CM870

ISX Automotive with CM870 - Front View

Automotive With CM871

ISX Automotive with CM871 - Front View

Automotive With CM871

ISX Automotive with CM871 - Left Side View

Automotive With CM871

ISX Automotive with CM871 Rear View

Automotive With CM871

ISX Automotive with CM871 - Right Side View

Industrial CM570 and Power Generation without CM570

QSX15 Industrial with CM570 - Front View

Industrial CM570 and Power Generation without CM570

QSX15 Industrial with CM570 - Left Side View

Industrial CM570 and Power Generation without CM570

QSX15 Industrial with CM570 - Right Side View

Industrial CM570 and Power Generation without CM570

QSX15 Power Generation without CM570 - Front View

Industrial CM570 and Power Generation without CM570

QSX15 Power Generation without CM570 - Left Side View

Industrial CM570 and Power Generation without CM570

QSX15 Power Generation without CM570 - Right Side View

Industrial CM570 and Power Generation without CM570

Fuel System - Left Side View

Industrial CM570 and Power Generation without CM570

Fuel System - Left Side View (continued)

Industrial CM570 and Power Generation without CM570

Fuel Delivery Housing - Front View

Industrial CM570 and Power Generation without CM570

QSX15 with CM570 Fuel Delivery Housing - Rear View

All Applications............................................................................................................................................ F-21