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Copyright© 2007
Cummins Inc.
Bulletin 3666239
Printed in U.S.A. 09-AUGUST-2007 p41
Service Manual
Signature, ISX, and QSX15
Volume 2
Specifications ........................................................................................................................................... V
Service Tools
Injectors and Fuel Lines
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.
Sight Glass
Check for air in fuel suction line. Use Part Number ST-998 with
ST-998 Number 10 hose.
Filter Wrench
Used to remove or tighten spin-on fuel filters.
3376807
Pressure/Vacuum Module
Used with 3377161 Digital Multimeter or 3824648 Automotive Meter.
3824645 The pressure transducer range is 500 psi and the vacuum range is
29.92 in Hg.
ECM Cooling Plate, Fuel Cooled Signature, ISX, and QSX15 Engi [...]
Page 6-2 Section 6 - Injectors and Fuel Lines - Group 06
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.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the cooling plate mounting surfaces with solvent.
Dry with compressed air.
ECM Cooling Plate, Fuel Cooled Signature, ISX, and QSX15 Engi [...]
Page 6-4 Section 6 - Injectors and Fuel Lines - Group 06
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
NOTE: If the sealing bead or groove is dirty, a leak can
result.
Clean the ECM cooling plate gasket sealing bead with a
dry cloth.
Make sure no rust or soot has accumulated in the grooves
on either side of, or on top of, the sealing bead.
Use compressed air to remove debris from the grooves, if
necessary.
Check the cooling plate fuel supply and return line fittings
on the ECM cooling plate, integrated fuel system module,
and fuel pump to make sure the o-rings are installed
properly and are not damaged.
Replace the o-ring, fitting, or cooling plate if damaged.
Signature, ISX, and QSX15 Engi [...] ECM Cooling Plate, Fuel Cooled
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-5
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.
Torque Value: 20 N•m [ 15 ft-lb ]
Install the ECM.
Install and tighten the five ECM mounting capscrews.
Torque Value: 20 N•m [ 15 ft-lb ]
Finishing Steps
• Connect the ECM harness and engine wiring
harness. Refer to Procedure 019-031 in the
Troubleshooting and Repair Manual CM870
Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
• Start the engine and check for fuel leaks.
Fuel Filter (Spin-On Type) Signature, ISX, and QSX15 Engi [...]
Page 6-6 Section 6 - Injectors and Fuel Lines - Group 06
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.
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.
Disconnect the wiring harness from the water-in-fuel
sensor, if equipped.
Remove the fuel filter with filter wrench, Part Number
3400158.
Signature, ISX, and QSX15 Engi [...] Fuel Filter (Spin-On Type)
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-9
Clean
All Applications
Use a clean, lint-free cloth to clean the filter head gasket
surface.
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.
Refer to Procedure 018-024.
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 ¾ of a turn after the gasket
contacts the filter head surface, or as specified by the filter
manufacturer.
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 3/4 of a turn after the gasket
contacts the filter head surface, or as specified by the filter
manufacturer.
If the filter is equipped with a water-in-fuel sensor, rotate
the sensor to the desired location and connect the wiring
harness.
CAUTION
Mechanical overtightening of the filter can distort the
threads or damage the filter element seal.
NOTE: If the filter is equipped with a water-in-fuel sensor,
rotate the sensor on the filter to the desired location and
connect the wiring harness.
Fill the filter with clean fuel prior to installation.
Install the filter onto the filter head. Turn the filter until the
gasket contacts the filter head surface.
Tighten the filter an additional 3/4 of a turn after the gasket
contacts the filter head surface, or as specified by the filter
manufacturer.
Hold the vacuum gauge at the same level as the fuel inlet
connection.
Operate the engine at rated speed no load.
Observe the reading on the gauge.
Maximum Inlet Restriction (With Clean Suction Filter)
127 mm Hg [ 5 in Hg ]
If the restriction exceeds the specifications, correct the
restriction in the suction filter, lines, heaters, or fuel tank.
Refer to the OEM troubleshooting and repair manual.
Injector (006-026)
Leak Test
This test checks for combustion gas leaks back through the injector rail check valve or other failure modes that will
allow leakage through the injector into the fuel rail.
When the engine is barred over, back pressure is created against the injector by the piston coming up on the
compression stroke.
During the test if the rail check valve fails and is leaking, air is pushed through the rail check valve and into the fuel
rail where pressure is sensed at the test fixture which is in place of the metering actuator. If a manometer is connected
to the test fixture, pressure will be measured as air escapes through the failed rail check valve. If a container of water
is used instead of a manometer, bubbles will be seen as air escapes through the failed rail check valve.
Injector Signature, ISX, and QSX15 Engi [...]
Page 6-14 Section 6 - Injectors and Fuel Lines - Group 06
The overhead set marks on the damper are used to identify which cylinder is on the compression stroke and therefore
which injector has failed if a change in manometer pressure or bubbles are seen.
Verify the run-on after key-off complaint.
If the engine exhibits an excessive amount of run-on after
key-off (greater than 3 seconds), continue with this
procedure.
CAUTION
Use the engine barring device. Do not use the starting
motor to bar the engine during this test or engine
damage can result.
Bar the engine over while watching for bubbles in the
container.
The engine will need to be barred over two complete
revolutions to evaluate each bank.
There can be a few bubbles observed immediately before
reaching a timing mark. The failure indicator is if bubbles
occur for an extended duration between timing marks.
Bar the engine over and note between which two timing
marks the bubbles occur.
If the bubbles occur between:
A and B then number 4 injector has failed
B and C then number 6 injector has failed
C and A then number 5 injector has failed.
Preparatory Steps
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
• Drain coolant to below the cylinder head level. Refer
to Procedure 008-018.
• Remove the rocker lever cover. Refer to Procedure
003-011.
• Disconnect the engine brake solenoid wiring
harness. Refer to Procedure 020-015.
Signature, ISX, and QSX15 Engi [...] Injector
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-17
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 injector rocker lever adjusting screws.
Remove six capscrews and injector rocker lever shaft.
Do not let rocker levers come off shaft during removal.
Rotate the engine to the valve set mark for the injector
being removed. Refer to Procedure 003-004.
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.
Inspect the injector cup for missing plug balls. Replace the
injector if necessary.
Signature, ISX, and QSX15 Engi [...] Injector
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-19
Disassemble
Oil Seal
Thoroughly clean the oil and dirt from the outside of the
injector.
Place the injector holding fixture into a vise. Tighten the
vise to hold the fixture in place.
Place the injector into the injector holding fixture.
Align the load ring capscrew bracket with the cutout in the
fixture plate.
CAUTION
Its very important that a 3/32 inch punch be used so
that the barrel is not damaged during oil seal removal.
Use a 3/32 inch punch, place the punch at an upward
angle against the base of the oil seal.
Use a hammer to gently tap the punch against the base
of the oil seal. To prevent damage to the seal bore in the
barrel, alternate between the four holes in the barrel so
that the seal comes out evenly and does not score the
barrel.
Signature, ISX, and QSX15 Engi [...] Injector
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-21
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Slide the oil seal up the plunger.
Use a can of safety solvent to blow debris away from the
oil seal area before removing the plunger.
Assemble
Oil Seal
CAUTION
Do not install the oil seal upside down. Failure to
install the seal correctly will cause damage to the oil
seal.
The oil seal will fit on the tool tightly if installed correctly.
The spring side of the oil seal (as shown) faces up when
installed in the injector.
Install a new oil seal onto the installation tool.
With the new oil seal positioned on the tool, position the
tool over the seal bore.
Use the arbor press to gently place pressure onto the
installation tool until the outer diameter face of the tool
contacts the injector body.
When properly installed, the seal height will not be flush
with the injector body. The height will be approximately
0.5 mm [0.020 in] above the injector.
Injector Signature, ISX, and QSX15 Engi [...]
Page 6-22 Section 6 - Injectors and Fuel Lines - Group 06
Install a new roll pin into the load ring. By design, the roll
pin holes are a different size on each side so the roll pin
must be installed in the correct direction, as shown.
Use a 5/32 inch punch to gently tap the roll pin into both
holes in the load ring. Continue driving the roll pin into the
load ring until the pin is centered evenly in both holes and
is an equal distance from both sides.
Inspect the oil seal and plunger bore for debris. If debris
is present, clean with a lint free cloth.
Clean the injector coupling spring with a lint free cloth.
Assemble the spring onto the load ring.
Clean the plunger and coupling assembly with a lint free
cloth.
Install
Use clean 15W-40 lubricating oil. Lubricate the o-rings.
Injector Signature, ISX, and QSX15 Engi [...]
Page 6-24 Section 6 - Injectors and Fuel Lines - Group 06
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 injector clamp, and capscrew with washer.
Tighten the capscrew.
Torque Value: 80 N•m [ 59 ft-lb ]
Install the crossheads.
Finishing Steps
• Install the injector rocker lever and valve rocker lever
assemblies. Refer to Procedure 003-009.
• Connect the engine brake solenoid wiring harness,
if equipped. Refer to Procedure 020-015.
• Adjust the overhead set as needed. Refer to
Procedure 003-004.
• Install the rocker lever cover. Refer to Procedure
003-011.
• Fill the cooling system. Refer to Procedure 008-018.
• Operate engine to normal operating temperature
and check for leaks.
If damage 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.
Signature, ISX, and QSX15 Engi [...]
Section 7 - Lubricating Oil System - Group 07 Page 7-a
Clean..............................................................................................................................................................7-18
General Information.........................................................................................................................................7-17
Inspect for Reuse............................................................................................................................................7-18
Install..............................................................................................................................................................7-19
Remove.......................................................................................................................................................... 7-17
Lubricating Oil Filter Head Adapter ................................................................................................................7-20
Clean and Inspect for Reuse...........................................................................................................................7-21
Finishing Steps...............................................................................................................................................7-22
Install..............................................................................................................................................................7-21
Preparatory Steps...........................................................................................................................................7-20
Remove.......................................................................................................................................................... 7-20
Lubricating Oil High Pressure Relief Valve ....................................................................................................7-22
General Information.........................................................................................................................................7-22
Inspect for Reuse............................................................................................................................................7-23
Install..............................................................................................................................................................7-23
Remove.......................................................................................................................................................... 7-22
Lubricating Oil Leaks ......................................................................................................................................7-24
General Information.........................................................................................................................................7-24
Lubricating Oil Pan ..........................................................................................................................................7-26
Clean and Inspect for Reuse...........................................................................................................................7-27
Finishing Steps...............................................................................................................................................7-28
Install..............................................................................................................................................................7-27
Preparatory Steps...........................................................................................................................................7-26
Remove.......................................................................................................................................................... 7-26
Lubricating Oil Pressure Gauge ......................................................................................................................7-28
Test................................................................................................................................................................ 7-28
Lubricating Oil Pump ......................................................................................................................................7-29
Assemble........................................................................................................................................................7-37
Clean and Inspect for Reuse...........................................................................................................................7-31
Disassemble................................................................................................................................................... 7-29
Finishing Steps...............................................................................................................................................7-41
Install..............................................................................................................................................................7-39
Preparatory Steps...........................................................................................................................................7-29
Remove.......................................................................................................................................................... 7-29
Lubricating Oil Suction Tube (Block-Mounted) ..............................................................................................7-42
Finishing Steps...............................................................................................................................................7-43
Inspect for Reuse............................................................................................................................................7-42
Install..............................................................................................................................................................7-43
Preparatory Steps...........................................................................................................................................7-42
Remove.......................................................................................................................................................... 7-42
Lubricating Oil System ....................................................................................................................................7-44
Drain...............................................................................................................................................................7-44
Fill...................................................................................................................................................................7-46
Prime..............................................................................................................................................................7-44
Lubricating Oil Thermostat .............................................................................................................................7-47
Inspect for Reuse............................................................................................................................................7-47
Install..............................................................................................................................................................7-48
Remove.......................................................................................................................................................... 7-47
Service Tools ....................................................................................................................................................7-1
Lubricating Oil System......................................................................................................................................7-1
Signature, ISX, and QSX15 Engi [...] Service Tools
Section 7 - Lubricating Oil System - Group 07 Page 7-1
Service Tools
Lubricating Oil System
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.
Silicone Sealant
Used for sealing t-joints.
3823494
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Cooler
Section 7 - Lubricating Oil System - Group 07 Page 7-3
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
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
environmental regulations.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the lubricating oil filter. Refer to Procedure
007-013.
• Remove the variable geometry turbocharger. Refer
to Procedure 010-033.
• Remove the EGR valve. Refer to Procedure 011-022.
• Remove the EGR cooler connection. Refer to
Procedure 011-024.
• Remove the EGR cooler. Refer to Procedure
011-019.
Lubricating Oil Cooler Signature, ISX, and QSX15 Engi [...]
Page 7-4 Section 7 - Lubricating Oil System - Group 07
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
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
environmental regulations.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the lubricating oil filter. Refer to Procedure
007-013.
• Remove the turbocharger. This step is not required
with a die cast oil cooler. Refer to Procedure
010-033.
• Remove the alternator. Refer to Procedure 013-001.
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 oil passages.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Cooler
Section 7 - Lubricating Oil System - Group 07 Page 7-5
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 the remaining 18 capscrews, oil cooler, and
gasket. Discard the gasket.
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.
CAUTION
Do not reuse an oil cooler core after a debris related
engine failure since there is no practical method for
cleaning the cooler core. Metal particles which can
circulate through the lubricating system can remain in
the cooler core and cause engine damage. Do not
allow dirt to enter the oil passages when cleaning the
oil cooler.
Lubricating Oil Cooler Signature, ISX, and QSX15 Engi [...]
Page 7-6 Section 7 - Lubricating Oil System - Group 07
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to avoid
personal injury.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
CAUTION
Do not allow dirt or foreign material to enter oil
passages in the cooler housing when cleaning the
gasket sealing surfaces. Connecting rod bearing
failures can be caused if debris is introduced into the
cylinder block or lubricating oil cooler housing oil
passages.
Plug the oil cooler passages with rubber plugs, Part
Numbers 4918322, 4918323, and 4918340, included in
kit, Part Number 4918319, to prevent debris from entering
the cooler when cleaning the gasket surface.
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 solvent to clean and flush the oil cooler passages and
cores.
Blow dry with compressed air.
Remove the rubber plugs when cleaning is complete.
CAUTION
Do not allow dirt or foreign material to enter oil
passages in the cylinder block when cleaning the
gasket sealing surfaces. Connecting rod bearing
failures can be caused if debris is introduced into the
cylinder block or lubricating oil cooler housing oil
passages. Therefore, use of power tools combined
with abrasive pads to clean gasket surfaces is not
recommended.
Plug the oil passages in the cylinder block with rubber
plugs.
Clean the oil cooler to cylinder block gasket surface with
Scotch-Brite™ 7448 abrasive pad.
Remove the rubber plugs when cleaning is complete.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Cooler
Section 7 - Lubricating Oil System - Group 07 Page 7-7
Leak Test
All Applications
It is important to leak test the oil cooler assembly as a unit
so leaks at the mounting joints can be identified. These
leaks can not be found when testing individual elements
that have been removed from the assembly. An element
is replaced only if it is found to be leaking.
This procedure is most effective when the oil cooler
assembly is tested in water below 7°C [44°F].
Use the mounting capscrews from the lubricating oil
cooler to attach the two plates and corresponding o-rings
from oil cooler leak test kit, Part Number 4918200, to the
lubricating oil cooler housing.
Insert the o-ring from the oil filter into the filter head cap,
Part Number 4918204.
Use engine oil to lubricate the gasket surface and install
the filter head cap.
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.
Place the oil cooler assembly under water.
If bubbles are observed, carefully determine the source of
the bubbles and replace the components as necessary.
If the element is suspected of leaking, refer to Procedure
007-007 for leak testing individual elements. Mounting
joint leaks are much more common than element leaks.
Do not replace components that do not leak.
If no leaks are found and the engine serial number is in
the range of 14023600 to 1405000 and 7900000 to
79012457, replace the capscrews and gaskets if the
elements are to be reused.
If no leaks are found and the engine serial number is not
in the above ranges the element does not get removed but
the capscrew torque is checked and tightened to the
specified torque.
Install
All Applications
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.
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 passage.
Install a new mounting gasket and the oil cooler housing
assembly.
Install the 18 capscrews.
Finishing Steps
Automotive with CM870
• Install the EGR cooler. Refer to Procedure 011-019.
• Install the EGR cooler connections. Refer to
Procedure 011-024.
• Install the EGR valve. Refer to Procedure 011-022.
• Install the lubricating oil filter. Refer to Procedure
007-013.
• Install the variable geometry turbocharger. Refer to
Procedure 010-033.
• Fill the cooling system. Refer to Procedure 008-018.
• Prime the lubricating oil system. Refer to Procedure
007-037.
• Fill the engine with clean oil.
• Operate engine to normal operating range and check
for oil and coolant leaks.
Disassemble
Single-Element
Remove the element from the lubricating oil filter head.
Discard the gaskets.
Lubricating Oil Cooler Element Signature, ISX, and QSX15 Engi [...]
Page 7-10 Section 7 - Lubricating Oil System - Group 07
Dual-Element
Remove the elements from the lubricating oil filter head.
Remove the oil cooler tube.
Discard the gaskets.
CAUTION
Do not damage the oil cooler tube when cutting the
vibration isolators to remove them. Engine damage
can occur.
Remove the vibration isolators by cutting a slit in them.
Discard the isolators.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
CAUTION
Do not allow dirt or foreign material to enter oil
passages in the cooler element when cleaning. Rod
bearing failures can be caused if debris is introduced
into the lube cooler housing oil passages.
Use solvent to clean the element.
Remove all old gasket material from the element.
Dry with compressed air.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Cooler Element
Section 7 - Lubricating Oil System - Group 07 Page 7-11
Inspect the oil cooler tube for cracks. Replace the cooler
tube if cracks are found.
Pressure Test
NOTE: An oil cooler element pressure test plate can be
constructed from a thin aluminum plate that allows the oil
cooler element to be mounted and air pressure applied to
the element inlet. An oil cooler pressure test tool does
not exist.
Install the oil cooler element and gaskets to the pressure
test plate.
Torque Value: 20 N•m [ 15 ft-lb ]
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
CAUTION
Do not allow dirt or foreign material to enter the oil
cooler element passages when cleaning. Engine
damage can result.
Remove the cooler element from the tank.
Remove the test equipment and dry with compressed air.
Lubricating Oil Cooler Element Signature, ISX, and QSX15 Engi [...]
Page 7-12 Section 7 - Lubricating Oil System - Group 07
Assemble
Single-Element
CAUTION
The single-element oil cooler assembly is for use only
on ISX1 and ISX2 engines. Engine oil overheating can
result if used on ISX3, and Signature 600 engines.
Install non-leaking lubricating oil cooler elements onto the
lubricating oil filter head with new gaskets and capscrews.
Assemble the cooler element(s) to the housing with the
following parts from the engine oil cooler kit.
Dual-Element
NOTE: The vibration isolators must be cut to allow
assembly over the cooler tube. Make sure the vibration
isolators are oriented so the slit is not tightened against
the oil cooler housing or the oil cooler elements.
Install two new vibration isolators onto the oil cooler tube
as shown.
Finishing Steps
Install the lubricating oil cooler. Refer to Procedure
007-003.
Operate the engine to normal operating temperature and
check for leaks.
CAUTION
Use care when marking the dipstick, or the dipstick
will break if the scribe mark is too deep.
Remove the dipstick and scribe a mark across the stick at
the oil level. Label the mark with an L to indicate the LOW
oil level.
If a new blank dipstick is being used, cut the dipstick off
approximately 38 mm [1.5 in] below the LOW oil level
mark.
Wipe off the dipstick and install it into the dipstick tube
housing.
Use the correct volume of oil to fill the oil pan to the
specified HIGH oil level. Refer to Lubricating Oil System
Specifications in this section for engine oil capacity.
Lubricating Oil Dipstick Tube Signature, ISX, and QSX15 Engi [...]
Page 7-14 Section 7 - Lubricating Oil System - Group 07
Install
Automotive with CM870
Install the dipstick tube and tighten the nut finger-tight.
Install the dipstick tube clamp, capscrew, and nut.
Tighten the dipstick tube nut.
Torque Value: 70 N•m [ 52 ft-lb ]
Tighten the clamp.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Filter (Spin-On)
Section 7 - Lubricating Oil System - Group 07 Page 7-15
Lubricating Oil
Use Valvoline Premium Blue® 15W-40 multiviscosity oil,
or its equivalent, which meets CES 20071 and CES 20076
oil classifications for turbocharged engines.
Lubricating Oil Filter (Spin-On) Signature, ISX, and QSX15 Engi [...]
Page 7-16 Section 7 - Lubricating Oil System - Group 07
CAUTION
Limited use of oils such as 5W-30 or 10W-30 can aid
in starting the engine and providing sufficient oil flow
at ambient temperatures below -5°C [23°F]. However,
the continuous use of low-viscosity oils can decrease
engine life.
Tthe accompanying chart to determine the best weight of
oil for the engine operating conditions.
Remove
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
environmental regulations.
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.
Use oil filter wrench, Part Number 3375049, 3397929, or
3400157 to remove the oil filter.
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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Filter Bypass Valve
Section 7 - Lubricating Oil System - Group 07 Page 7-17
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.
Operate the engine until the water temperature reaches
82°C [180°F].
Check the oil pressure and for leaks.
Remove
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
environmental regulations.
Loosen the retaining plug with a 7-millimeter Allen wrench.
Lubricating Oil Filter Bypass Valve Signature, ISX, and QSX15 Engi [...]
Page 7-18 Section 7 - Lubricating Oil System - Group 07
Remove the retaining plug (1), spring (2), and plunger (3)
from the lubricating oil cooler housing (4).
Clean
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.
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to avoid
personal injury.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
bodily injury.
Clean the spring, plunger, and retaining plug with solvent.
Dry with compressed air.
Install
CAUTION
The notched end of the bypass valve (3) must be
installed toward the spring (2). If the bypass valve is
installed incorrectly, it will bypass the filter
continuously which can cause engine damage.
Lubricate all pieces and the o-ring seal. Install the plunger
(3) with the notched end toward the spring into the
lubricating oil cooler housing (4).
Install the spring (2), and retaining plug (1) into the
lubricating oil cooler housing (4).
Tighten the retaining plug.
Torque Value: 45 N•m [ 33 ft-lb ]
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
environmental regulations.
NOTE: The oil filter head housing assembly does not
need to be removed to replace the oil filter head adapter.
Remove the lubricating oil filter. Refer to Procedure
007-013.
Remove
WARNING
To reduce the possibility of personal injury or
equipment damage. Use only a 3/4-inch drive
extension and ratchet for the removal of the adapter.
If the pinned adapter has come loose or if the staking pin
is missing, and the oil filter head adapter can be removed
by hand or without damaging the threads in the housing,
then follow the procedure as described below for cleaning
and installing the adapter. The missing staking pin will
not be replaced.
NOTE: If the housing threads are found damaged, the
housing must be replaced.
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.
Clean the threads of both the adapter and the oil filter head
housing with a clean towel and contact cleaner to remove
any residual Loctite™ and lubricating oil.
Inspect the adapter for cracks or other damage.
Install
WARNING
To reduce the possibility of personal injury or
equipment damage. Use only a 3/4-inch drive
extension and ratchet for the installation of the
adapter.
CAUTION
Do not use an impact wrench, to reduce the possibility
of damage to the oil filter head housing, adapter, or
tool.
Apply clean engine oil to the adapter-to-housing interface.
Apply service tool Loctite™ 2760, Part Number 3165083 to
the adapter. Apply Loctite™ to three threads, starting three
threads down from the top of the adapter and around the
entire circumference of adapter.
Finishing Steps
Fill the new oil filter with clean lubricating oil.
Install the lubricating oil filter. Refer to Procedure 007-013.
Operate the engine to normal operating temperature and
check for leaks.
Remove
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
environmental regulations.
Remove and disassemble the lubricating oil pump. Refer
to Procedure 007-031.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil High Pressure Relief Valve
Section 7 - Lubricating Oil System - Group 07 Page 7-23
Install
Assemble and install the lubricating oil pump. Refer to
Procedure 007-031.
Lubricating Oil Leaks Signature, ISX, and QSX15 Engi [...]
Page 7-24 Section 7 - Lubricating Oil System - Group 07
Once the quadrant has been determined, look at the following diagram to get a good indication of where the leak can
be coming from on the exhaust side of the engine.
1. Lower front gear cover gasket leak 6. Oil spill from oil filter change
2. Gear housing gasket leak 7. Oil slobber from exhaust manifold
3. Oil pan gasket leak 8. Cam cover gaskets leaks
4. Flywheel housing gasket leak 9. Valve cover gasket leak
5. Lube cooler gasket leak
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Leaks
Section 7 - Lubricating Oil System - Group 07 Page 7-25
Look at this diagram to get a good indication of where the leak can be coming from on the intake side of the engine.
1. Valve cover gasket leak 7. Crankshaft position sensor o-ring leak
2. Cam covers gaskets leaks 8. Gear cover gasket leak
3. Crankcase blowby tube 9. Air compressor or power steering pump gasket leak
4. Flywheel housing gasket leak 10. Oil fill tube cracked or leak
5. Dipstick tube leak 11. Upper front gear cover cracked or gasket leak
6. Gear housing gasket leak
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.
CAUTION
Protect all electrical components, openings, and
wiring from the full force of the cleaner spray nozzle.
Use a steam cleaner or a high-pressure washer to clean
the engine.
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
environmental regulations.
Drain the lubricating oil. Refer to Procedure 007-037.
Remove
Remove the oil pan mounting capscrews, oil pan, and
gasket.
Discard the oil pan gasket.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Pan
Section 7 - Lubricating Oil System - Group 07 Page 7-27
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.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
bodily injury.
Steam clean and dry with compressed air.
Inspect the inside and the outside of the oil pan for cracks.
Replace the oil pan if cracked or broken.
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.
Finishing Steps
Fill the lubricating oil pan. Refer to Procedure 007-037.
Operate the engine until the water temperature reaches
82°C [180°F], and check for leaks.
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
environmental regulations.
• Drain the lubricating oil. Refer to Procedure 007-037.
• Remove the lubricating oil pan. Refer to Procedure
007-025.
• Remove the lubricating oil suction tube. Refer to
Procedure 007-035.
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.
Disassemble
WARNING
The pressure regulator spring is under compression.
Slowly remove the cap to reduce the possibility of
personal injury.
Remove the lubricating oil pressure regulator and spring
by removing the split pin that secures the spring cap to the
lubricating oil pump.
Discard the o-ring.
Lubricating Oil Pump Signature, ISX, and QSX15 Engi [...]
Page 7-30 Section 7 - Lubricating Oil System - Group 07
WARNING
The high pressure relief valve is under compression.
Apply pressure to the cover while removing the
capscrews. Slowly release the pressure to reduce the
possibility of personal injury.
Remove the six assembly capscrews and the lube pump
cover.
Press off the external drive gear from the internal drive
gear shaft.
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.
CAUTION
Do not allow dirt or gasket material to enter the oil
passages. Bearing damage can result.
Clean the lubricating oil pump components with solvent.
Use a bristle brush to clean any internal ports.
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.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use a steam cleaner to rinse the components.
Dry with compressed air.
Lubricating Oil Pump Signature, ISX, and QSX15 Engi [...]
Page 7-32 Section 7 - Lubricating Oil System - Group 07
Assemble
Lubricate the drive shaft with clean 15W-40 lubricating oil.
Install the internal idler gear onto the shaft.
Insert the internal drive gear and shaft assembly into the
lubricating oil pump cover.
Press the external drive gear onto the shaft.
Turn the main drive gear by hand to check the gears for
freedom of rotation.
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.
Torque Value: 56 N•m [ 40 ft-lb ]
Using a dial indicator, check the oil pump idler gear back
lash.
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 block (2). Use the
following table to determine which shim should be used
according to the stamped number.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Pump
Section 7 - Lubricating Oil System - Group 07 Page 7-41
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]- 0.45 mm [0.018 in]-Black- 0.55 mm [0.022 in]- 0.35 mm [0.014 in]-
None- Purple- Yellow-
2 0.45 mm [0.018 in]- 0.65 mm [0.026 in]-Red- 0.75 mm [0.030 in]-Blue- 0.55 mm [0.022 in]-
Black- Purple-
3 0.55 mm [0.022 in]- 0.75 mm [0.030 in]-Blue- 0.85 mm [0.033 in]- 0.65 mm [0.026 in]-Red-
Purple- Green-
4 0.35 mm [0.014 in]- 0.55 mm [0.022 in]- 0.65 mm [0.026 in]-Red- 0.45 mm [0.018 in]-Black-
Yellow- Purple-
Finishing Steps
• 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 lubricating oil. Refer to Procedure
007-037.
Lubricating Oil Suction Tube (Block-Mounted) Signature, ISX, and QSX15 Engi [...]
Page 7-42 Section 7 - Lubricating Oil System - Group 07
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
environmental regulations.
Drain the lubricating oil. Refer to Procedure 007-037.
Remove the lubricating oil pan. Refer to Procedure
007-025.
Remove
Remove the lubricating oil suction tube capscrews,
suction tube, and o-ring. Discard o-ring.
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.
Torque Value: 47 N•m [ 35 ft-lb ]
Finishing Steps
Install the lubricating oil pan. Refer to Procedure 007-025.
Fill engine with oil. Refer to Procedure 007-037.
Lubricating Oil System Signature, ISX, and QSX15 Engi [...]
Page 7-44 Section 7 - Lubricating Oil System - Group 07
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
environmental regulations.
Operate the engine until the water temperature reaches
60°C [140°F].
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.
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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil System
Section 7 - Lubricating Oil System - Group 07 Page 7-45
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.
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]
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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Thermostat
Section 7 - Lubricating Oil System - Group 07 Page 7-47
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
environmental regulations.
Remove the alternator. Refer to Procedure 013-001.
Remove the water pump. Refer to Procedure 008-062.
Remove the thermostat plug.
Remove the tapered snap ring.
Remove the thermostat from lubricating oil cooler
housing.
WARNING
The flash point of new lubricating oil is approximately
221°C [430°F]. Do not allow the oil temperature in the
container to exceed 149°C [300°F]. Do not allow
water droplets to enter the container of hot oil. Water
droplets will cause a violent reaction that can cause
personal injury.
Suspend the thermostat and a 127°C [260°F]
thermometer in a container of new lubricating oil. Do not
allow the thermostat or the thermometer to touch the sides
of the container.
Heat the lubricating oil.
Install
Install the thermostat into lubricating oil cooler housing.
Install the tapered snap ring with the tapered side facing
away from the lubricating oil cooler housing.
Install and tighten the thermostat plug.
Torque Value: 100 N•m [ 74 ft-lb ]
Install the alternator. Refer to Procedure 013-001.
Install the water pump. Refer to Procedure 008-062.
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).
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.
Lubricating Oil Fill Tube Signature, ISX, and QSX15 Engi [...]
Page 7-50 Section 7 - Lubricating Oil System - Group 07
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.
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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Fill Tube
Section 7 - Lubricating Oil System - Group 07 Page 7-51
Inspect the oil fill tube and fill tube threads for cracks or
other damage.
Inspect the oil fill tube sealing surfaces for cracks or other
damage.
Inspect the oil fill tube extrusion for cracks or damage.
Inspect the oil fill tube and fill tube threads for cracks or
other damage.
Inspect the oil fill tube sealing surfaces for cracks or other
damage.
Lubricating Oil Fill Tube Signature, ISX, and QSX15 Engi [...]
Page 7-52 Section 7 - Lubricating Oil System - Group 07
Install
Automotive with CM870
Install a new oil fill connection ring seal.
Use clean engine oil to lubricate the oil fill connection ring
seal.
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.
Signature, ISX, and QSX15 Engi [...] Lubricating Oil Fill Tube
Section 7 - Lubricating Oil System - Group 07 Page 7-53
Install and tighten the tube brace gear cover capscrew (2).
Torque Value: 28 N•m [ 21 ft-lb ]
Tighten the tube brace capscrew (1).
Install the new o-rings on the bottom of the oil fill tube and
a new ring seal on the oil fill tube cap.
Lubricating Oil Fill Tube Signature, ISX, and QSX15 Engi [...]
Page 7-54 Section 7 - Lubricating Oil System - Group 07
Install the oil fill tube cap and the oil fill tube.
WARNING
Carefully cut open the upper section of the
combination filter. The filter element spring is under
compression and can cause personal injury.
Use the tube cutter, Part Number 3376579, to open the
upper section of the combination filter.
Drain...............................................................................................................................................................8-23
Fill...................................................................................................................................................................8-26
Flush...............................................................................................................................................................8-24
Pressure Test..................................................................................................................................................8-29
Cooling System - Air or Combustion Gas Test ..............................................................................................8-30
Initial Check....................................................................................................................................................8-30
Air in Cooling System...................................................................................................................................8-30
Leak Test........................................................................................................................................................8-31
Fan, Shutter, or Heater Air Control Valve......................................................................................................8-31
Air Compressor............................................................................................................................................8-32
Overflow Method..........................................................................................................................................8-33
Drive Belt, Cooling Fan .....................................................................................................................................8-3
Clean and Inspect for Reuse.............................................................................................................................8-3
Drives Alternator............................................................................................................................................8-3
Install................................................................................................................................................................8-3
Drives Alternator............................................................................................................................................8-3
Remove............................................................................................................................................................8-3
Drives Alternator............................................................................................................................................8-3
Drive Belt, Water Pump ....................................................................................................................................8-4
Adjust...............................................................................................................................................................8-5
Inspect for Reuse..............................................................................................................................................8-4
Install................................................................................................................................................................8-5
Remove............................................................................................................................................................8-4
Fan Clutch, On-Off ..........................................................................................................................................8-34
Initial Check....................................................................................................................................................8-34
With Low Temperature Fan-On Control.........................................................................................................8-34
With High Temperature Fan On....................................................................................................................8-35
Fan, Cooling ....................................................................................................................................................8-41
Inspect for Reuse............................................................................................................................................8-41
Install..............................................................................................................................................................8-42
Remove.......................................................................................................................................................... 8-41
Fan Hub, Belt Driven .......................................................................................................................................8-36
Clean and Inspect for Reuse...........................................................................................................................8-38
Automotive with CM870................................................................................................................................8-38
Automotive, Industrial with CM570 and Power Generation without CM570....................................................8-38
Finishing Steps...............................................................................................................................................8-40
Automotive with CM870................................................................................................................................8-40
Automotive with CM570................................................................................................................................8-40
Industrial CM570 and Power Generation without CM570...............................................................................8-40
Install..............................................................................................................................................................8-39
Automotive with CM870................................................................................................................................8-39
Automotive with CM570................................................................................................................................8-39
Industrial CM570 and Power Generation without CM570...............................................................................8-39
Preparatory Steps...........................................................................................................................................8-36
Automotive with CM870................................................................................................................................8-36
Automotive with CM570................................................................................................................................8-36
Industrial CM570 and Power Generation without CM570...............................................................................8-37
Remove.......................................................................................................................................................... 8-37
Automotive with CM870................................................................................................................................8-37
Automotive with CM570................................................................................................................................8-37
Industrial CM570 and Power Generation without CM570...............................................................................8-37
Fan Pulley ........................................................................................................................................................8-72
Inspect for Reuse............................................................................................................................................8-72
Install..............................................................................................................................................................8-73
Industrial and Power Generation...................................................................................................................8-73
Remove.......................................................................................................................................................... 8-72
Industrial and Power Generation...................................................................................................................8-72
Fan Shroud Assembly .....................................................................................................................................8-40
Initial Check....................................................................................................................................................8-40
Fan Support .....................................................................................................................................................8-69
Finishing Steps...............................................................................................................................................8-71
Industrial and Power Generation...................................................................................................................8-71
Install..............................................................................................................................................................8-70
Signature, ISX, and QSX15 Engi [...]
Section 8 - Cooling System - Group 08 Page 8-c
Service Tools
Cooling System
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.
Fluorescent Tracer
Used with black light, Part Number 3824754, to find coolant leaks.
3377438
Optical Tachometer
Used to measure engine rpm using reflective tape, Part Number
3377462 3377464.
Refractometer
Used to measure glycol (antifreeze) concentration.
CC-2800
Signature, ISX, and QSX15 Engi [...] Drive Belt, Cooling Fan
Section 8 - Cooling System - Group 08 Page 8-3
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.
Install
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 and hold the belt tensioner.
Install the drive belt and release the tensioner.
Drive Belt, Water Pump Signature, ISX, and QSX15 Engi [...]
Page 8-4 Section 8 - Cooling System - Group 08
Install
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.
Using a 1/2-inch square drive lift and hold the belt
tensioner. Install the drive belt and release the tensioner.
Adjust
Belt drive systems equipped with an automatic belt
tensioner can not be adjusted. A belt tension gauge will
not give an accurate measure of the belt tension. The
automatic belt tensioner is designed to maintain proper
belt tension over the life of the belt. Only inspection of the
tensioner is required.
The belt tensioner is designed to operate within the limit
of arm movement provided by the cast stops when the belt
length and geometry are correct.
If the tensioner is hitting either of the limits during
operation, check the mounting brackets and the belt
length. Loose brackets, bracket failure, alternator
movement, incorrect belt length, or belt failure can cause
the tensioner to hit the limits.
Remove
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Remove the cooling system pressure cap.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
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.
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 ½ to ¾ of a turn after initial
gasket contact, or as specified by the manufacturer.
Turn the coolant on/off valve to the ON position.
Signature, ISX, and QSX15 Engi [...] Coolant Filter Valve
Section 8 - Cooling System - Group 08 Page 8-7
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Operate the engine until the coolant temperature is above
82°C [180°F], and check for coolant leaks.
After the air has been purged from the system, check the
coolant level again.
Clean
WARNING
Use skin and eye protection when handling caustic
solutions to reduce the possibility of personal injury.
Clean the coolant filter valve and valve bore in the water
inlet connection with a filter brush and solvent.
Install
Install a new o-ring onto the valve.
Install the valve into the water inlet connection.
Signature, ISX, and QSX15 Engi [...] Coolant Thermostat
Section 8 - Cooling System - Group 08 Page 8-9
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
Drain the coolant to a level below the vent line in the
thermostat housing.
Disconnect and plug the vent line hose. Refer to
Procedure 008-017.
Remove the radiator hose from the radiator top tank.
Preparatory Steps
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
WARNING
Coolant is toxic. If not reused, dispose of in
accordance with local environmental regulations.
Drain the cooling system. Refer to Procedure 008-018.
Remove
Remove the upper radiator hose from the thermostat
housing cover.
Coolant Thermostat Signature, ISX, and QSX15 Engi [...]
Page 8-12 Section 8 - Cooling System - Group 08
Install
Install the two thermostats into the thermostat housing
cover by pushing on the outer rims.
Finishing Steps
Fill the cooling system. Refer to Procedure 008-018.
Operate the engine until the coolant temperature reaches
70°C [160°F]. Check for leaks.
Signature, ISX, and QSX15 Engi [...] Coolant Thermostat Housing
Section 8 - Cooling System - Group 08 Page 8-15
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the air intake piping. Refer to the OEM
service manual.
• Remove the charge air cooler piping. Refer to
Procedure 010-027.
• Remove the upper radiator hose. Refer to the OEM
service manual.
• Remove the vent line. Refer to the OEM service
manual.
• Remove the engine coolant temperature sensor.
Refer to Procedure 019-019 in the ISX CM871 and
ISM CM876 Electronic Control System
Troubleshooting and Repair Manual, Bulletin
4021560.
• Remove the turbocharger coolant return line. Refer
to Procedure 010-041.
• Remove the OEM coolant sensor(s). Refer to the
OEM service manual.
• Remove the exhaust gas pressure sensor. Refer to
019-376 in the ISX CM871 and ISM CM876
Electronic Control System Troubleshooting and
Repair Manual, Bulletin 4021560
• Remove the turbocharger actuator air line, if
required. Refer to Procedure 010-113.
• Remove the heat shield, if required. Refer to
Procedure 011-032.
• Remove the EGR valve. Refer to Procedure 011-022.
• Remove the EGR cooler connection tube, if required.
Refer to Procedure 011-024.
• Remove the EGR cooler coolant return tube, if
required. Refer to Procedure 011-031.
• Remove the refrigerant compressor. Refer to
Procedure 009-051.
• Remove the refrigerant compressor mounting
bracket. Refer to Procedure 009-055.
Coolant Thermostat Housing Signature, ISX, and QSX15 Engi [...]
Page 8-16 Section 8 - Cooling System - Group 08
Remove
Single Thermostat
Remove the four thermostat housing cover capscrews.
Remove the thermostat cover and gasket.
Discard the gasket.
Dual Thermostat
Remove the upper radiator hose from the thermostat
housing cover.
Signature, ISX, and QSX15 Engi [...] Coolant Thermostat Housing
Section 8 - Cooling System - Group 08 Page 8-17
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.
Torque Value: 45 N•m [ 33 ft-lb ]
Signature, ISX, and QSX15 Engi [...] Coolant Thermostat Housing
Section 8 - Cooling System - Group 08 Page 8-19
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.
Torque Value: 56 N•m [ 41 ft-lb ]
Remove the two thermostat housing cover capscrews
used as guides.
Finishing Steps
• Install the refrigerant compressor mounting bracket.
Refer to Procedure 009-055.
• Install the refrigerant compressor. Refer to
Procedure 009-051.
• Install the EGR cooler coolant return tube, if
required. Refer to Procedure 011-031.
• Install the EGR cooler connection tube, if required.
Refer to Procedure 011-024.
• Install the EGR valve, if required. Refer to Procedure
011-022.
• Install the heat shield, If required. Refer to Procedure
011-032.
• Install the turbocharger actuator air line. Refer to
Procedure 010-113.
• Install the exhaust gas pressure sensor. Refer to
Procedure 019-376 in the ISX CM871 and ISM
CM876 Electronic Control System Troubleshooting
and Repair Manual, Bulletin 4021560.
• Install the turbocharger coolant return line. Refer to
Procedure 010-041.
• Install the vent line. Refer to the OEM service
manual.
• Install the OEM coolant sensor(s). Refer to the OEM
service manual.
• Install the engine coolant temperature sensor. Refer
to Procedure 019-019 in the ISX CM871 and ISM
CM876 Electronic Control System Troubleshooting
and Repair Manual, Bulletin 4021560.
• Install the upper radiator hose. Refer to the OEM
service manual.
• Install the charge air cooler piping. Refer to
Procedure 010-027.
• Install the air intake piping. Refer to the OEM service
manual.
• Fill the cooling system. Refer to Procedure 008-018.
• Operate the engine until the coolant temperature
reaches 70°C [158°F] and check for leaks.
Dual Seal
NOTE: The Signature, ISX, and QSX engines have two
engine coolant thermostats.
Remove the thermostat housing cover. Refer to Procedure
008-014.
Remove the thermostat seal. Do not damage the
thermostat cover.
Install
Single Seal
NOTE: When installing a new seal, the flat side of the seal
must be toward the mandrel for correct installation.
Use thermostat seal mandrel, Part Number 3824716, and
a lead hammer to install the seal.
A counterbore in the housing bore locates the seal.
Dual Seal
NOTE: The Signature, ISX, and QSX engines have two
engine coolant thermostats.
NOTE: When installing a new seal, the flat side of the seal
must be toward the mandrel for correct installation.
Use thermostat seal mandrel, Part Number 3164350, and
a lead hammer to install the seal.
A counterbore in the housing bore locates the seal.
Install the thermostat housing cover. Refer to Procedure
008-014.
Signature, ISX, and QSX15 Engi [...] Cooling System
Section 8 - Cooling System - Group 08 Page 8-23
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Remove the radiator cap after the engine is cool.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Do not allow the cooling system to dry out.
If the coolant is to be reused, the container must be free
of oil and dirt. Before pouring coolant back into the engine,
it must be tested for SCA concentration. Refer to
Procedure 018-004 in the Operation and Maintenance
Manual Signature and ISX Engines, Bulletin 3666251, the
Operation and Maintenance Manual Industrial and Power
Generation QSX15 Engines, Bulletin 3666423, or the
Operation and Maintenance Manual Signature and ISX
Engines, Bulletin 3666311.
Open the radiator draincocks.
Remove the lower radiator hose(s).
Do not remove the coolant filter.
Flush
CAUTION
Do not use caustic cleaners in the cooling system.
Aluminum components will be damaged.
The cooling system must be clean to work correctly and
to eliminate buildup of harmful chemicals.
Signature, ISX, and QSX15 Engi [...] Cooling System
Section 8 - Cooling System - Group 08 Page 8-25
CAUTION
Fleetguard® Restore™ contains no antifreeze. Do not
allow the cooling system to freeze during the cleaning
operation.
After draining the coolant, immediately add 3.8 liters [1
gal] of Fleetguard® Restore™, Restore Plus™, or
equivalent, for each 38 to 57 liters [10 to 15 gal] of cooling
system capacity, and fill the system with plain water.
Turn the cab heater temperature switch to high to allow
maximum coolant flow through the heater core. The
blower does not have to be on.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
Operate the engine at normal operating temperatures, at
least 85°C [185°F] for one to one and a half hours.
Shut off the engine and drain the cooling system.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
Operate the engine at high idle for five minutes with the
coolant temperature above 85°C [185°F].
Shut off the engine and drain the cooling system.
If the water being drained is still dirty, the system must be
continually flushed until the water is clean.
CAUTION
To reduce the possibility of engine damage, do not
add coolant while the engine is hot.
Fill the cooling system with fully-formulated coolant or a
50/50 mixture of fully-formulated antifreeze and good-
quality water. Use a service filter to bring the coolant to
the correct SCA concentration level. Refer to Procedure
018-004 in the Operation and Maintenance Manual
Signature and ISX Engines, Bulletin 3666251, the
Operation and Maintenance Manual Industrial and Power
Generation QSX15 Engines, Bulletin 3666423, or the
Operation and Maintenance Manual Signature and ISX
Engines, Bulletin 3666311.
Fill
Close the radiator draincocks.
Install the lower radiator hose(s).
Tighten the hose clamps.
Torque Value: 5 N•m [ 40 in-lb ]
Signature, ISX, and QSX15 Engi [...] Cooling System
Section 8 - Cooling System - Group 08 Page 8-27
Water Quality
Calcium Magnesium Maximum 170 ppm as (CaCO3 +
(Hardness) MgCO3)
Chloride 40 ppm as (CI)
Sulfate 100 ppm as (SO4)
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
CAUTION
Do not add cold coolant to a hot engine. This can
cause engine casting damage. Allow the engine to
cool to below 50°C [120°F] 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.
Signature, ISX, and QSX15 Engi [...] Cooling System
Section 8 - Cooling System - Group 08 Page 8-29
Pressure Test
Connect the air line in place of a vent line on the surge
tank.
Install an air regulator (2) between the ball valve (1) of the
air line and the surge tank connection.
Attach a hose to the radiator overflow connection (3).
Place the free end of the hose below the water level in a
container of water.
CAUTION
Do not apply more than 140 kPa [20 psi] air pressure
to the cooling system. The water pump seal can be
damaged.
Pressurize the cooling system slowly to the rated radiator
cap pressure until bubbles can be seen in the overflow
bottle.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Allow the engine to cool and remove the radiator cap.
Leak Test
Fan, Shutter, or Heater Air Control Valve
CAUTION
The engine can overheat with the fan control or the
shutter air control valve disconnected. Monitor the
engine coolant temperature while performing this
test. The coolant temperature must not exceed 100°
C [212°F] or engine damage can occur.
Disconnect the vehicle air supply hose from the fan, the
shutter, and the heater air control valve.
Install a plug into the air supply hose.
If the vehicle is equipped with more than one air control
valve, check only one valve at a time.
Cooling System - Air or Combustion Gas Test Signature, ISX, and QSX15 Engi [...]
Page 8-32 Section 8 - Cooling System - Group 08
Start the engine and run for five minutes before testing for
air in the coolant. This will allow any trapped air to purge
from the system.
Repeat the test for air in the cooling system, as previously
described.
If no air is found in the cooling system with the air control
valve(s) isolated, install a new control valve.
Air Compressor
CAUTION
The air compressor discharge line must be
disconnected at the compressor to allow the
compressor to discharge air to the atmosphere during
this next test to prevent the compressor from
overheating. Do not run the engine over 5 minutes
with components isolated from the cooling system.
Component damage can occur.
Overflow Method
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Allow the engine to cool and remove the radiator cap.
Install a radiator pressure cap that has had the spring and
the pressure relief valve removed to allow free flow from
the overflow tube.
The pressure cap must be tightly sealed in the top of the
radiator fill neck.
Attach a rubber hose to the radiator overflow connection.
Put the free end of the hose below the water level in a
container of water.
CAUTION
If the fan clutch logic is not set correctly, the ECM will
not be able to engage the fan for engine cooling and
engine protection. The engine can overheat and
damage is possible.
The fan clutches can be controlled by the ECM. The ECM
can be programmed for either 12 volts, fan ON or 12 volts,
fan OFF. Check the ECM program using INSITE™.
Return the engine to idle and remove the radiator air flow
restriction.
Signature, ISX, and QSX15 Engi [...] Fan Clutch, On-Off
Section 8 - Cooling System - Group 08 Page 8-35
Remove
Automotive with CM870
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.
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.
Install
Automotive with CM870
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.
Install the fan hub assembly and the capscrews.
Tighten the capscrews.
Torque Value: 113 N•m [ 83 ft-lb ]
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.
Tighten the capscrews.
Torque Value: 90 N•m [ 66 ft-lb ]
Install the belt tensioner bracket.
Finishing Steps
Automotive with CM870
• Install the automatic belt tensioner (water pump).
Refer to Procedure 008-080.
• Install the cooling fan drive belt. Refer to Procedure
008-002.
• Install the cooling fan. Refer to Procedure 008-040.
WARNING
Disconnect the batteries or air supply line to the air
starter to prevent accidental engine starting and
personal injury.
CAUTION
Do not pry or pull on the fan. The fan blades can be
damaged.
Remove the fan.
WARNING
Do not straighten a bent fan blade or continue to use
a damaged fan. A bent or damaged fan blade can fail
during operation and cause personal injury or
property damage.
Install
NOTE: Replace the original equipment fan with a fan of
the identical part number. Cummins Inc. must approve
any fan changes.
Radiator (008-042)
Initial Check
Inspect the radiator for plugged radiator fins.
Use 550-kPa [80-psi] air pressure to blow the dirt and
debris from the fins. Blow the air in the opposite direction
of the fan airflow.
Inspect the CAC and the clearance between the CAC and
the radiator for trapped debris. Remove the CAC if
necessary.
Remove any debris found.
Signature, ISX, and QSX15 Engi [...] Radiator Pressure Cap
Section 8 - Cooling System - Group 08 Page 8-43
WARNING
If a liquid refrigerant system must be removed before
removing the radiator, wear eye and face protection.
For environmental protection, federal law requires
that Freon be recycled and not vented into the
atmosphere. Wrap a cloth around the fittings before
removing. Liquid refrigerant can cause serious eye
and skin injury.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Remove the radiator pressure cap.
Radiator Shutter Assembly Signature, ISX, and QSX15 Engi [...]
Page 8-44 Section 8 - Cooling System - Group 08
Inspect the rubber inner seal and the brass outer seal of
the pressure cap for damage.
Inspect the radiator or expansion tank fill neck for cracks
or other damage.
Refer to the radiator manufacturer's or vehicle
manufacturer's instructions if the fill neck is damaged.
Make sure the correct pressure cap is used. Refer to the
Cooling System Specifications.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the water pump drive belt and tensioner.
Refer to Procedure 008-080.
• Remove the refrigerant compressor drive belt. Refer
to Procedure 009-052.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the water pump and fan drive belt. Refer to
Procedure 008-003.
• Remove the alternator drive belt. Refer to Procedure
013-005.
• Remove the alternator. Refer to Procedure 013-001.
• Remove the water pump belt tensioner bracket and
belt tensioner. Refer to Procedure 008-080.
• If necessary, remove the vibration dampers. Refer to
Procedure 001-052.
Water Pump Signature, ISX, and QSX15 Engi [...]
Page 8-46 Section 8 - Cooling System - Group 08
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
WARNING
Coolant is toxic. Keep children and pets away. If the
coolant is not going to be reused, dispose of it in
accordance with local environmental regulations.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the cooling fan and water pump belt. Refer
to Procedure 008-003.
• Remove the alternator drive belt. Refer to Procedure
013-005.
• Remove the alternator. Refer to Procedure 013-001.
• If required, remove the damper assembly. Refer to
Procedure 001-052.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the water pump drive belt and tensioner.
Refer to Procedure 008-080.
• Remove the refrigerant compressor drive belt. Refer
to Procedure 009-052.
• Remove the water pump cartridge. Refer to
Procedure 008-102.
Remove
Automotive with CM870
Remove two water pump mounting capscrews and install
two guide studs.
Signature, ISX, and QSX15 Engi [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-47
Clean
Clean the water pump and the water inlet connections.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the water pump components with solvent and dry
with compressed air.
Signature, ISX, and QSX15 Engi [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-49
Disassemble
WARNING
The retaining clip contains extreme amounts of
potential energy. To reduce the possibility of personal
injury from the clip slipping, place the water pump in
a box prior to removing the retaining clip.
Place the water pump in a box.
Remove the retaining clip securing the impeller cover.
Remove and discard the water pump outlet o-ring.
Position the water pump with the pulley end facing up.
Remove the bearing bore retaining clip.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the water pump components with solvent and dry
with compressed air.
Inspect the cast iron impeller for cracks, pitting and other
damage.
Continuous pitting deeper than 0.635 mm [0.025 in] or
individual pits deeper than 2.54 mm [0.100 in] are not
acceptable.
Replace the impeller if damaged or if pits are not within
specifications.
Measure
Measure the inside diameter of the water pump housing
large bearing bore.
Assemble
CAUTION
The mandrel must make contact on the inner race of
the bearing to prevent damage to the bearing.
Support the shaft in an arbor press.
Use an arbor press with water pump mandrel, Part
Number ST-658 (4), or equivalent to install the bearings.
Water Pump Signature, ISX, and QSX15 Engi [...]
Page 8-54 Section 8 - Cooling System - Group 08
Install the retaining clip with the beveled side of the clip
facing away from the bearing.
Install the retaining clip with the beveled side of the clip
facing away from the bearing.
CAUTION
To reduce the possibility of damage to the water pump
housing, make sure the impeller end of the shaft is
supported before pressing on the pulley.
Support the impeller end of the shaft in a press.
Press on the pulley until it is flush with the end of the shaft.
Make sure the pulley rotates freely.
Signature, ISX, and QSX15 Engi [...] Water Pump
Section 8 - Cooling System - Group 08 Page 8-55
CAUTION
Do not use petroleum based lubricants. Petroleum
based lubricants cause the o-ring seals to crack,
leading to a coolant leak.
CAUTION
Make sure the o-ring is seated properly. If the o-ring
is not seated properly it can be damaged during
impeller cover installation.
Lubricate the impeller cover o-ring with soapy water.
Install the cover o-ring into the water pump housing.
CAUTION
Do not use petroleum lubricant on the impeller cover,
o-ring damage can result from the use of petroleum
lubricant.
Lubricate the outside diameter of the impeller cover and
the o-ring bore with soapy water.
Support the water pump in a press.
Press the impeller cover into the bore until seated.
Water Pump Signature, ISX, and QSX15 Engi [...]
Page 8-56 Section 8 - Cooling System - Group 08
WARNING
The retaining clip contains extreme amounts of
potential energy. To reduce the possibility of personal
injury from the clip slipping, place the water pump in
a box prior to installing the retaining clip.
Place the water pump in a box.
Install the retaining clip.
Impeller Clearance
mm in
0.29 MIN 0.011
1.24 MAX 0.049
Install
Automotive with CM870
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.
CAUTION
Do not use petroleum based lubricants. Petroleum
based lubricants cause the o-ring seals to crack,
leading to a coolant leak.
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.
CAUTION
Do not use petroleum based lubricants. Petroleum
based lubricants cause the o-ring seals to crack,
leading to a coolant leak.
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.
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.
Tighten the capscrew.
Torque Value: 30 N•m [ 25 ft-lb ]
Install the dust seal.
Water Pump Signature, ISX, and QSX15 Engi [...]
Page 8-60 Section 8 - Cooling System - Group 08
CAUTION
Do not use petroleum based lubricants, petroleum
based lubricants cause the o-ring to crack or swell,
leading to a coolant leak.
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.
Tighten the capscrews.
Torque Value: 72 N•m [ 53 ft-lb ]
Install the two bracket capscrews.
Tighten the capscrews.
Torque Value: 30 N•m [ 25 ft-lb ]
Install the EGR tube outlet capscrew.
Tighten the capscrew.
Torque Value: 30 N•m [ 25 ft-lb ]
Finishing Steps
Automotive with CM870
• Fill the cooling system. Refer to Procedure 008-018.
• Install the water pump drive belt and tensioner. Refer
to Procedure 008-080.
• Install the refrigerant compressor drive belt. Refer to
Procedure 009-052.
Preparatory Steps
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 personal injury.
• Remove the cooling fan belt. Refer to Procedure
008-002.
Remove
Drives Alternator
Remove the mounting capscrew and the belt tensioner
from the bracket.
Signature, ISX, and QSX15 Engi [...] Belt Tensioner, Automatic (Water Pump)
Section 8 - Cooling System - Group 08 Page 8-63
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.
WARNING
The belt tensioner is spring loaded. Do not attempt to
disassemble the tensioner. Severe personal injury can
result.
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.
Check the tensioner for dirt buildup. If the tensioner has
dirt buildup, remove and clean with safety solvent.
CM570
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.
Check the tensioner for dirt buildup. If this condition
exists, the tensioner must be removed and steam-
cleaned.
Install
Drives Alternator
Install the belt tensioner and mounting capscrew.
Tighten the capscrew.
Torque Value: 50 N•m [ 37 ft-lb ]
Automotive Applications
For the low-mount belt tensioner:
Install the belt tensioner bracket to the water pump.
Tighten capscrew.
Torque Value: 34 N•m [ 25 ft-lb ]
Install the belt tensioner and capscrew.
Torque Value: 34 N•m [ 25 ft-lb ]
Finishing Steps
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 personal injury.
• Install the drive belt. Refer to Procedure 008-002.
Water Inlet Connection Signature, ISX, and QSX15 Engi [...]
Page 8-68 Section 8 - Cooling System - Group 08
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the coolant filter. Refer to Procedure
008-006.
• Remove the water pump. Refer to Procedure
008-062.
Remove
Remove the coolant hoses.
Remove the four capscrews, water inlet connection,
gasket, and o-ring.
Install
Replace the o-ring and gasket.
Install the gasket, water inlet connection, and the four
capscrews.
Tighten the capscrews.
Torque Value: 56 N•m [ 41 ft-lb ]
Install the coolant hoses.
Signature, ISX, and QSX15 Engi [...] Fan Support
Section 8 - Cooling System - Group 08 Page 8-69
Finishing Steps
• Install the water pump. Refer to Procedure 008-062.
• Install the coolant filter. Refer to Procedure 008-006.
• Fill the engine with heavy-duty coolant. Refer to
Procedure 008-018.
• Start the engine and check for leaks.
Remove
Industrial and Power Generation
Remove the belt tensioner support bracket from the fan
support.
Install
Industrial and Power Generation
Install two guide studs into the upper gear cover.
Finishing Steps
Industrial and Power Generation
• Install the fan pulley. Refer to Procedure 008-089.
• Install the alternator belt tensioner bracket. Refer to
Procedure 013-040.
• Install the alternator drive belt. Refer to Procedure
013-005.
• Install the fan and water pump drive belt. Refer to
Procedure 008-003.
Fan Pulley Signature, ISX, and QSX15 Engi [...]
Page 8-72 Section 8 - Cooling System - Group 08
Install
Industrial and Power Generation
Install the fan pulley using six capscrews.
Tighten the capscrews in a star pattern.
Torque Value: 95 N•m [ 70 ft-lb ]
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the water pump drive belt and tensioner.
Refer to Procedure 008-080.
• Remove the refrigerant compressor drive belt. Refer
to Procedure 009-052.
Finishing Steps
• Install the refrigerant compressor drive belt. Refer to
Procedure 009-052.
• Install the water pump drive belt and tensioner. Refer
to Procedure 008-080.
• Fill the cooling system. Refer to Procedure 008-018.
• Operate the engine and check for leaks.
Signature, ISX, and QSX15 Engi [...]
Section 9 - Drive Units - Group 09 Page 9-a
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.
NOTE: If the refrigerant compressor is only being
removed to access other components, refrigerant system
depressurization is not required. Leave hoses connected
and properly support the refrigerant compressor to other
vehicle components.
• Depressurize the refrigerant system, only if
complete removal of the refrigerant compressor is
required. Refer to the OEM service manual for the
proper procedure.
• Remove the cooling fan drive belt. Refer to
Procedure 008-002.
• Refrigerant compressor belt. Refer to Procedure
009-052.
Remove
Sanden
Remove the four refrigerant compressor mounting
capscrews.
Remove the refrigerant compressor.
Install
Sanden
Install the four mounting capscrews through the
refrigerant compressor and refrigerant compressor
bracket.
Tighten the capscrews.
Torque Value: 18 N•m [ 115 in-lb ]
Finishing Steps
With Water Pump and Refrigerant Compressor Belt
Routing
• Install the refrigerant compressor belt. Refer to
Procedure 009-052.
• Install the fan drive belt. Refer to Procedure 008-002.
• Fill the refrigerant system, if depressurized. Refer to
the OEM service manual.
Remove
With Water Pump and Refrigerant Compressor Belt
Routing
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 counterclockwise to
relieve tension on the belt.
Remove the belt.
Install
With Water Pump and Refrigerant Compressor Belt
Routing
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 counterclockwise and hold the belt tensioner.
Install the drive belt and relieve the tensioner.
Finishing Steps
With Water Pump and Refrigerant Compressor Belt
Routing
• Install the cooling fan drive belt. Refer to Procedure
008-002.
Signature, ISX, and QSX15 Engi [...] Belt Tensioner, Refrigerant Compressor, Automatic
Section 9 - Drive Units - Group 09 Page 9-5
WARNING
Tensioner is spring loaded. Do not attempt to
disassemble the tensioner. Severe bodily injury can
result.
With the tensioner installed on the engine, pivot the
tensioner through the full range of motion. Tensioner
must move with resistance while pivoting the tensioner
away from the belt. If no resistance, replace tensioner.
If this check is okay, check the belt part number. Make
sure that the belt is correct for this refrigerant compressor
option.
Preparatory Steps
With Water Pump and Refrigerant Compressor Belt
Routing
• Remove the fan drive belt. Refer to Procedure
008-002.
• Remove the refrigerant compressor belt. Refer to
Procedure 009-052.
Remove
With Water Pump and Refrigerant Compressor Belt
Routing
Remove the mounting capscrew and the refrigerant
compressor belt tensioner from the bracket.
Install
With Water Pump and Refrigerant Compressor Belt
Routing
Install the refrigerant compressor belt tensioner.
Install and tighten capscrew.
Torque Value: 45 N•m [ 33 ft-lb ]
Finishing Steps
With Water Pump and Refrigerant Compressor Belt
Routing
• Install the refrigerant compressor belt. Refer to
Procedure 009-052.
• Install the fan drive belt. Refer to Procedure 008-002.
Signature, ISX, and QSX15 Engi [...] Idler Pulley, Refrigerant Compressor
Section 9 - Drive Units - Group 09 Page 9-7
Remove
With Water Pump and Refrigerant Compressor Belt
Routing
Remove the pulley mounting capscrew.
Remove the refrigerant compressor idler pulley.
Install
With Water Pump and Refrigerant Compressor Belt
Routing
Install the refrigerant compressor idler pulley and the
mounting capscrew.
Torque Value: 36 N•m [ 27 ft-lb ]
NOTE: A special alignment procedure is not required for
the refrigerant compressor idler pulley to the alternator/
refrigerant compressor mounting bracket.
Refrigerant Compressor Mounting Bracket Signature, ISX, and QSX15 Engi [...]
Page 9-8 Section 9 - Drive Units - Group 09
Finishing Steps
With Water Pump and Refrigerant Compressor Belt
Routing
• Install the refrigerant compressor belt. Refer to
Procedure 009-051.
• Install the cooling fan drive belt. Refer to Procedure
008-002.
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 the cooling fan drive belt. Refer to
Procedure 008-002.
• Remove the refrigerant compressor belt. Refer to
Procedure 009-052.
• Remove the refrigerant compressor. Refer to
Procedure 009-051.
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 the refrigerant compressor and alternator
belt. Refer to Procedure 013-005.
• Remove the refrigerant compressor. Refer to
Procedure 009-051.
Signature, ISX, and QSX15 Engi [...] Refrigerant Compressor Mounting Bracket
Section 9 - Drive Units - Group 09 Page 9-9
Remove
Sanden
Remove the mounting capscrew from each refrigerant
compressor bracket.
Remove the refrigerant compressor brackets.
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protect clothing to reduce
the possibility of personal injury.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the refrigerant compressor mounting brackets with
solvents.
Dry with compressed air.
Inspect the refrigerant compressor mounting brackets.
Replace the refrigerant compressor mounting brackets if
cracked or damaged.
Inspect the roll pins. The roll pins must not be loose or
have any damage. Replace the refrigerant compressor
mounting brackets, if the roll pins are loose or damaged.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the bracket, links, and mounting capscrews with
solvent.
Dry the parts with compressed air.
Signature, ISX, and QSX15 Engi [...] Refrigerant Compressor Mounting Bracket
Section 9 - Drive Units - Group 09 Page 9-11
Install
Sanden
Install the two mounting capscrews and the refrigerant
compressor mounting bracket.
Tighten the capscrews.
Torque Value: 7 N•m [ 62 in-lb ]
Finishing Steps
Automotive with CM870
• Install the refrigerant compressor. Refer to
Procedure 009-051.
• Install the refrigerant compressor belt. Refer to
Procedure 009-052.
• Install the fan drive belt. Refer to Procedure 008-002.
Alternator/Refrigerant Compressor
Mounting Bracket (009-056)
Preparatory Steps
Automotive with CM870
• Remove the turbocharger control valve. Refer to
Procedure 019-388 in the Troubleshooting and
Repair Manual CM870 Electronic Control System
Signature and ISX Engines, Bulletin 4021334.
• Remove the alternator drive belt. Refer to Procedure
013-005.
• Remove the alternator. Refer to Procedure 013-001.
• Remove the alternator spacers. Refer to Procedure
013-036.
• Remove the refrigerant compressor drive belt. Refer
to Procedure 009-052.
• Remove the refrigerant compressor. Refer to
Procedure 009-051.
• Remove the refrigerant compressor mounting
bracket. Refer to Procedure 009-055.
• Remove the refrigerant compressor belt tensioner.
Refer to Procedure 009-053.
• Remove the refrigerant idler pulley. Refer to
Procedure 009-054.
• Remove the water pump belt tensioner. Refer to
Procedure 008-080.
Remove
Automotive with CM870
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/
refrigerant compressor mounting bracket.
Alternator/Refrigerant Compressor Mounting Bracket Signature, ISX, and QSX15 Engi [...]
Page 9-14 Section 9 - Drive Units - Group 09
Install
Automotive with CM870
Install the wire harness jumper to the alternator/refrigerant
compressor mounting bracket.
Torque Value: 18 N•m [ 14 ft-lb ]
Tap the split washers out slightly. This will ease the
installation.
Install the alternator/refrigerant compressor mounting
bracket to the gear housing.
Finishing Steps
Automotive with CM870
• Install the water pump belt tensioner. Refer to
Procedure 008-080.
• Install the refrigerant compressor idler pulley. Refer
to Procedure 009-054.
• Install the refrigerant compressor belt tensioner
Refer to Procedure 009-053.
• Install the refrigerant compressor mounting bracket.
Refer to Procedure 009-055.
• Install the refrigerant compressor. Refer to
Procedure 009-051.
• Install the refrigerant compressor drive belt. Refer to
Procedure 009-052.
• Install the alternator spacers. Refer to Procedure
013-036.
• Install the alternator. Refer to Procedure 013-001.
• Install the alternator drive belt. Refer to Procedure
013-005.
• Install the turbocharger control valve. Refer to
Procedure 019-388 in the Troubleshooting and
Repair Manual CM870 Electronic Control System
Signature and ISX Engines, Bulletin 4021334.
Service Tools
Air Intake System
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.
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.
The noise can be caused by an air leak from the following:
Turbocharger-to-charge-air cooler elbow connection.
• Inspect the connection and o-ring for damage.
• Tighten the v-band clamps.
Torque Value: 9 N•m [ 80 in-lb ]
Air Leaks, Air Intake and Exhaust Systems Signature, ISX, and QSX15 Engi [...]
Page 10-4 Section 10 - Air Intake System - Group 10
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 used.
Turbine housing sealing surface air leak.
• Tighten the v-band clamp.
Torque Value: 14 N•m [ 124 in-lb ]
• Check for an air leak.
• If an air leak is still present, remove and replace the
turbocharger.
Check for soot streaks from the EGR valve gasket and
seal rings.
• Inspect for signs of leakage such as soot streaks. If
signs of leakage are present, replace the EGR valve
gaskets. Refer to Procedure 011-022.
Air Leaks, Air Intake and Exhaust Systems Signature, ISX, and QSX15 Engi [...]
Page 10-6 Section 10 - Air Intake System - Group 10
CAUTION
Do not use caustic cleaners to clean the charge-air
cooler. Damage to the charge-air cooler will result.
Flush the charge-air cooler internally with solvent in the
opposite direction of normal airflow. Shake the charge-air
cooler and lightly tap on the end tanks with a rubber mallet
to dislodge trapped debris. Continue flushing until all
debris or oil is removed.
NOTE: Be sure the tubes are in the vertical direction when
flushing.
If the debris can not be totally removed from the charge-
air cooler, the charge-air cooler must be replaced.
CAUTION
The charge-air cooler must be rinsed, dried, and free
of solvent, oil, and debris or engine damage will
result.
After the charge-air cooler has been thoroughly cleaned
of all oil and debris with solvent, wash the charge-air
cooler internally with hot soapy water to remove the
remaining solvent. Rinse thoroughly with clean water.
Blow compressed air through the inside of the charge-air
cooler in the opposite direction of normal air flow until the
charge-air cooler is dry internally.
Leak Test
To check the charge-air cooler for cracked tubes or
header, remove the inlet and outlet hoses from the cooler.
The charge-air cooler does not have to be removed from
the chassis.
WARNING
To prevent possible injury if either plug blows off
during the test, secure safety chains on the test plugs
to any convenient capscrew on the radiator assembly.
This test must not be performed without securely
fastened safety chains.
Install the charge-air cooler tester, Part Number 3824556.
Apply 207 kPa [30 psi] of air pressure to the cooler. Close
the air pressure regulator.
Determine if pressure decay is caused by a leak in the
charge-air cooler or from a leaky connection. Use a spray
bottle filled with soapy water and apply to all hose
connections. Watch for bubbles to appear at the location
of the leak.
Turbocharger (010-033)
Initial Check
Automotive with CM870 and CM871
Add one unit of fluorescent tracer, Part Number 3376891,
to each 38 liters [10 gal] of engine lubricating oil.
If a bearing housing coolant leak is suspected, use the
turbocharger coolant leak test kit, Part Number 3164682.
Operate the engine at low idle for 10 minutes.
Test
Flourescent Tracer Dye Test
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Variable Geometry
• Drain the cooling system. Refer to Procedure
008-018.
• Inspect the bearing housing for external oil or
coolant leaks.
• Remove the oil supply, oil drain, coolant inlet, and
coolant outlet tubes from the turbocharger.
• Disconnect the variable geometry turbocharger
actuator air supply line (CM870 engines).
• Discard the oil drain tube gasket.
• Check for evidence of coolant in the oil supply and
oil drain fittings.
Leak Test
All Applications
Remove the air intake and charge air cooler piping from
the turbocharger.
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-18 Section 10 - Air Intake System - Group 10
Install the air intake and charge air cooler piping to the
turbocharger and tighten the clamp.
Torque Value: 8.5 N•m [ 75 in-lb ]
Operate the engine at full throttle and maximum load, and
check for air leaks.
Preparatory Steps
Automotive, Industrial with CM570 and Power
Generation without CM570
• Remove the wastegate actuator hose. Refer to
Procedure 010-050.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
• Drain the coolant. Refer to Procedure 008-018.
• Disconnect the turbocharger speed sensor. See
Procedure 019-390 in the Troubleshooting and
Repair Manual, CM870 Electronic Control System
Signature and ISX Engines, Bulletin 4021334.
• Disconnect the turbocharger compressor air inlet
temperature sensor. See Procedure 019-395 in the
Troubleshooting and Repair Manual, CM870
Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
• Disconnect the variable geometry actuator air supply
line. Refer to Procedure 010-113.
• Remove the turbocharger coolant hoses. Refer to
Procedure 010-041.
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-20 Section 10 - Air Intake System - Group 10
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
• Drain the coolant. Refer to Procedure 008-018.
• Disconnect the turbocharger speed sensor. See
Procedure 019-390 in the ISX CM871 and ISM
CM876 Electronic Control System, Troubleshooting
and Repair Manual, Bulletin 4021560.
• Disconnect the turbocharger compressor air inlet
temperature sensor. See Procedure 019-395 in the
ISX CM871 and ISM CM876 Electronic Control
System, Troubleshooting and Repair Manual,
Bulletin 4021560.
• Remove the turbocharger coolant hoses. Refer to
Procedure 010-041.
• Remove the charge air piping. Refer to Procedure
010-027.
• Disconnect the aftertreatment adapter pipe. Refer to
Procedure 011-043.
Remove
Automotive, Industrial with CM570 and Power
Generation without CM570
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.
Remove the oil supply, oil drain tube, and brace (if
equipped) from the turbocharger.
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.
CAUTION
When installing a lifting eye, be sure the shoulder of
the lifting eye is bottomed against bearing housing.
Failure to do so can result in failure of the lifting eye
and personal injury.
CAUTION
If the lifting eye is installed in the 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.
Remove the oil supply and the oil drain tube from the
turbocharger.
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-22 Section 10 - Air Intake System - Group 10
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.
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 removing the turbocharger.
Remove the four turbocharger mounting nuts.
NOTE: If the turbocharger mounting nuts do not loosen
freely, split the nuts to avoid breaking a mounting stud.
Remove the turbocharger and discard the gaskets.
Disassemble
Turbine Housing Replacement for ISX Automotive with
CM570, QSX15 with CM570 and Power Generation with
CM570
Place turbocharger outlet on a clean flat surface. Create
an alignment mark on the turbine housing, bearing
housing and the V-band clamp. This mark will make
certain the components are oriented correctly during the
assembly process.
CAUTION
Turbine blades can be easily damaged and care is
required for the turbine housing removal process.
Use a soft hammer to tap the turbine housing down
against a soft bench surface.
As the bearing housing and compressor housing
assembly loosen, gently lift the assembly out of the turbine
housing.
Wastegate mounting is not affected by this disassembly
process.
Always clean the turbine housing before assembly,
paying particular attention to the surface close to the
turbine housing and the bearing housing location.
Clean
Turbocharger Turbine Housing Cleaning
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.
CAUTION
Wear appropriate eye and face protection when using
non-corrosive metal cleaner.
Soak the turbocharger turbine housing in a non-corrosive,
low flash point metal cleaner to loosen deposits.
CAUTION
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
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.
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-25
CAUTION
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
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, leading to spindle seizure.
It is permissible to bead blast the turbocharger turbine
housing if chemical and brush cleaning is not effective.
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.
Push the rotor assembly toward the gauge and record the
reading.
Assemble
ISX Automotive with CM570, QSX15 with CM570 and
Power Generation with CM570
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.
Install
Automotive, Industrial with CM570 and Power
Generation without CM570
Apply a film of high-temperature anti-seize compound,
Part Number 3823097, to the turbocharger mounting
studs.
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-31
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.
NOTE: If the exhaust manifold and turbocharger were
removed together in order for the turbocharger to clear the
lubricating oil cooler assembly, refer to Procedure
011-007 for installation of the exhaust manifold.
Install a new mounting gasket, the turbocharger, and the
four mounting nuts.
Tighten the mounting nuts.
Torque Value: 60 N•m [ 44 ft-lb ]
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.
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.
Torque Value: 9 N•m [ 80 in-lb ]
Torque Value: 12 N•m [ 106 in-lb ]
If installing a new turbocharger, install the male union
elbow.
Torque Value: 30 N•m [ 22 ft-lb ]
Install the turbocharger oil supply tube on the elbow.
Torque Value: 30 N•m [ 22 ft-lb ]
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-33
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.
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.
Torque Value: 88 N•m [ 65 ft-lb ]
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-34 Section 10 - Air Intake System - Group 10
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.
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.
Torque Value: 30 N•m [ 22 ft-lb ]
Install the turbocharger actuator coolant supply and return
fittings into the electronic actuator. Refer to Procedure
010-041.
WARNING
This component weighs 23 kg [50 lb] or more. To
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.
Torque Value: 88 N•m [ 65 ft-lb ]
Turbocharger Signature, ISX, and QSX15 Engi [...]
Page 10-36 Section 10 - Air Intake System - Group 10
Finishing Steps
Automotive, Industrial with CM570 and Power
Generation without CM570
• Install the wastegate actuator hose. Refer to
Procedure 010-050.
• Start and operate the engine until the coolant
temperature reaches 82°C [180°F] and check for air,
coolant, and oil leaks.
Signature, ISX, and QSX15 Engi [...] Turbocharger
Section 10 - Air Intake System - Group 10 Page 10-37
CAUTION
Turbocharger speed sensor harness and turbocharger
compressor inlet air temperature sensor harnesses
must be tied securely and away from heat sources,
such as the exhaust manifold and exhaust pressure
sensor tube. Failure to do so can cause damage to the
sensor harness.
CAUTION
The turbocharger compressor inlet air temperature
sensor must be positioned so the sensor body is
pointing up and away from the exhaust manifold.
Failure to do so can cause sensor damage.
CAUTION
Do not twist coolant lines while tightening. Failure to
do so will damage coolant lines.
• Install the turbocharger coolant hoses. Refer to
Procedure 010-041.
• Connect the variable geometry actuator air supply
line. Refer to Procedure 010-113.
• Connect the electrical connectors on the
turbocharger speed sensor and the turbocharger
compressor air inlet temperature sensor. Refer to
Procedures 019-395 and 019-390 in the
Troubleshooting and Repair Manual, CM870
Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
• Fill the cooling system with coolant. Refer to
Procedure 008-018.
• Start and operate the engine until the coolant
temperature reaches 82°C [180°F] and check for air,
coolant, and oil leaks.
Turbocharger Coolant Hoses Signature, ISX, and QSX15 Engi [...]
Page 10-38 Section 10 - Air Intake System - Group 10
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 50°C
[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
environmental regulations.
• Disconnect the batteries. Refer to Procedure
013-009 (Battery Cables and Connections) in Section
13.
• Drain the coolant. Refer to Procedure 008-018
(Cooling System) in Section 8.
• Remove the turbocharger oil supply and oil drain
lines from the turbocharger. Refer to Procedure
010-033 (Turbocharger) in Section 10.
Signature, ISX, and QSX15 Engi [...] Turbocharger Coolant Hoses
Section 10 - Air Intake System - Group 10 Page 10-39
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 50°C
[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
environmental regulations.
• Disconnect the batteries. Refer to Procedure
013-009 (Battery and Cable Connections) in Section
13.
• Drain the coolant. Refer to Procedure 008-018
(Cooling System) in Section 8.
• Remove the turbocharger oil drain line from the
turbocharger. Refer to Procedure 010-033
Turbocharger) in Section 10.
Remove
Automotive with CM870
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.
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.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the turbocharger coolant hoses with solvent.
Dry with compressed air.
Signature, ISX, and QSX15 Engi [...] Turbocharger Coolant Hoses
Section 10 - Air Intake System - Group 10 Page 10-41
Install
Automotive with CM870
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.
Use a second wrench to hold the coolant hose coupling
while tightening the line.
Torque Value: 46 N•m [ 34 ft-lb ]
CAUTION
Do not bend or kink hoses while tightening. Doing so
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.
Use a second wrench to hold the coolant hose coupling
while tightening the line.
Torque Value: 46 N•m [ 34 ft-lb ]
Turbocharger Coolant Hoses Signature, ISX, and QSX15 Engi [...]
Page 10-42 Section 10 - Air Intake System - Group 10
CAUTION
Do not bend or kink hoses while tightening. Doing so
can damage the hoses.
CAUTION
Do not use petroleum products on the turbocharger
coolant hose o-rings. The o-rings will swell and cause
the connection to leak.
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).
Torque Value: 41 N•m [ 30 ft-lb ]
Install the turbocharger coolant supply hose to the
turbocharger actuator (2).
Torque Value: 15 N•m [ 133 in-lb ]
Install the turbocharger coolant supply hose to the
lubricating oil filter head (1).
Torque Value: 54 N•m [ 40 ft-lb ]
NOTE: Use a second wrench to hold the coolant hose
coupling while tightening the hose.
Tighten the fittings.
Signature, ISX, and QSX15 Engi [...] Turbocharger Coolant Hoses
Section 10 - Air Intake System - Group 10 Page 10-43
CAUTION
Do not bend or kink hoses while tightening. Doing so
can damage the lines.
CAUTION
Do not use petroleum products on the turbocharger
coolant line o-rings. The o-rings will swell and cause
the connection to leak.
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.
Torque Value: 46 N•m [ 34 ft-lb ]
Install the turbocharger coolant return hose in the
thermostat housing. Tighten the banjo fitting.
Torque Value: 24 N•m [ 18 ft-lb ]
Install the turbocharger actuator coolant hose to the
thermostat housing. Tighten the fitting.
Torque Value: 16 N•m [ 142 in-lb ]
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.
Torque Value: 24 N•m [ 18 ft-lb ]
Finishing Steps
Automotive with CM870
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.
• Install the turbocharger oil supply and oil drain hoses
from the turbocharger. Refer to Procedure 010-033
(Turbocharger) in Section 10.
• Fill the engine with coolant. Refer to Procedure
008-018 (Coolant System) in Section 8.
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
• Start the engine and check for leaks.
Turbocharger Wastegate Actuator Signature, ISX, and QSX15 Engi [...]
Page 10-44 Section 10 - Air Intake System - Group 10
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.
• Install the turbocharger oil drain line from the
turbocharger. Refer to Procedure 010-033.
• Fill the engine with coolant. Refer to Procedure
008-018.
• Connect the batteries. Refer to Procedure 013-009.
• Start the engine and check for leaks.
CAUTION
A bent wastegate mounting bracket, actuator rod, or
lever can cause improper operation.
Inspect the wastegate mounting bracket, actuator rod,
and lever for damage.
If the wastegate mounting bracket, actuator rod, or lever
is bent, it must be replaced.
Signature, ISX, and QSX15 Engi [...] Turbocharger Wastegate Actuator
Section 10 - Air Intake System - Group 10 Page 10-45
WARNING
Exhaust and turbocharger components could be hot.
Use caution and wear protective clothing when
handling these components.
To verify the wastegate actuator travel, install Service Tool
Part Number 3165168 on the wastegate cover with the
magnetic base and the dial indicator resting on the end of
the actuator end link.
Preparatory Steps
Remove the turbocharger. Refer to Procedure 010-033.
Signature, ISX, and QSX15 Engi [...] Turbocharger Wastegate Actuator
Section 10 - Air Intake System - Group 10 Page 10-47
Inspect
To obtain an accurate measurement, do not remove the
wastegate valve cover or take the measurement from the
top of the capscrew that secures the wastegate valve
cover.
Using a micrometer depth gauge, take a measurement
from the face of the wastegate valve cover to the end of
the wastegate actuator end link. Do not apply air pressure
to the wastegate actuator.
If the wastegate wear measurement is less than 25.654
mm [1.010 in] then the turbocharger wastegate actuator
can be recalibrated and the turbocharger returned to
service. If the wastegate wear measurement is greater
than 25.654 mm [1.010 in], replace the turbocharger
turbine housing.
Remove
Remove the retaining clip from the control lever.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
bodily injury.
CAUTION
Be careful not to bend the control lever.
Air Regulator with Pressure Gauge
Slowly apply regulated air pressure to the boost capsule,
a maximum of 310 kPa [45 psi] can be used. Disconnect
the boost capsule actuator rod end from the turbocharger
wastegate lever rod when the rod is loose on the lever.
Turbocharger Wastegate Actuator Signature, ISX, and QSX15 Engi [...]
Page 10-48 Section 10 - Air Intake System - Group 10
Adjust
CAUTION
To reduce the possibility of breaking the wastegate
pivot pin, use a wrench on the end link to support it
while loosening and/or tightening the actuator end-
link locknut.
Leave the setting pressure air supply connected to the
wastegate capsule.
Loosen the actuator end-link locknut.
Install
If a new actuator is being installed, install the adjusting
end link onto the shaft of the precalibrated wastegate
actuator assembly.
Thread the new end link several turns onto the shaft of the
new pre-set actuator assembly.
Signature, ISX, and QSX15 Engi [...] Turbocharger Wastegate Actuator
Section 10 - Air Intake System - Group 10 Page 10-51
Finishing Steps
Reinstall the turbocharger. Refer to Procedure 010-033.
Rotate the lever by hand to verify that the shaft turns freely
and is not seized.
Check for excessive movement between the shaft and
bushing.
Replace the turbine housing if the shaft and bushing are
damaged or seized.
Refer to the Turbocharger Master Repair Manual, Bulletin
3580555.
Signature, ISX, and QSX15 Engi [...] Intake Manifold Pressure
Section 10 - Air Intake System - Group 10 Page 10-53
Remove
Automotive with CM870
Remove the four capscrews holding the air intake
connection to the cylinder head.
Remove and discard the gasket.
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.
Inspect the air intake connection for the amount of carbon
on the inside of the air intake connection.
Air Intake Connection Signature, ISX, and QSX15 Engi [...]
Page 10-56 Section 10 - Air Intake System - Group 10
Install
Automotive, Industrial with CM570 and Power
Generation without CM570
Install the four mounting capscrews, air inlet connection,
and new gasket.
Finishing Steps
Automotive, Industrial with CM570 and Power
Generation without CM570
Connect the air pipe from the charge air cooler to the air
inlet connection.
Connect the boost sensor wire.
Install the four-step wastegate controller wires, hose,
mounting capscrews, and controller.
Resistance
12-VDC 6 to 10 ohms
24-VDC 24 to 40 ohms
Install
Assemble the valve as shown.
Install these parts as follows:
• Install a new o-ring between the spacer and the
control valve body.
• Install the spacer o-ring groove toward the coil.
• Install the spring washer with the cup side toward the
coil.
Preparatory Steps
Variable Geometry
CAUTION
The keyswitch must be in the OFF position to make
sure no air pressure is present at the actuator.
• Remove the air line from the actuator.
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.
Turbocharger, Variable Geometry Actuator Signature, ISX, and QSX15 Engi [...]
Page 10-62 Section 10 - Air Intake System - Group 10
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.
Test
Variable Geometry
Attach a dial indicator as shown, so the shaft is in line with
the actuator rod.
Set the dial indicator to zero, with no air pressure applied
to the actuator.
Connect clean, regulated air pressure and a pressure
gauge to the actuator.
Apply a minimum of 414 kPa [60 psi] to make sure the
actuator is functioning properly.
The rod must move without any sticking.
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.
Torque Value: 17 N•m [ 150 in-lb ]
Finishing Steps
Variable Geometry
• Install actuator air line.
• Start and operate the engine.
• Verify proper operation and check for air leaks.
If a 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.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
WARNING
Air pressure must be released from the system before
removing the turbocharger control shutoff valve. The
turbocharger control shutoff valve is under pressure
and can cause personal injury.
• Release the air pressure from the compressed air
system.
Remove
Variable Geometry
Use filter wrench and remove the air filter from the
turbocharger control shutoff valve.
Signature, ISX, and QSX15 Engi [...] Turbocharger Air Shutoff Valve Filter
Section 10 - Air Intake System - Group 10 Page 10-65
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the turbocharger control shutoff valve filter head
threads with a lint free cloth.
Inspect the threads for damage. If damage is found,
replace the turbocharger control shutoff valve filter head.
Refer to Procedure 010-115.
Inspect the filter head for signs of water entrapment or
contamination. If water entrapment or contamination is
found, inspect the turbocharger control shutoff valve lines,
turbocharger control shutoff valve, and turbocharger
control valve. Replace if signs of corrosion are found.
Use compressed air to clean fittings, lines, and
turbocharger control shutoff valve.
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.
Finishing Steps
Variable Geometry
• Start the engine and verify proper operation.
• Inspect for air leaks and proper variable geometry
turbocharger operation.
Turbocharger Control Shutoff Valve Filter Head Signature, ISX, and QSX15 Engi [...]
Page 10-66 Section 10 - Air Intake System - Group 10
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
WARNING
Air pressure must be released from the system before
removing the turbocharger control shutoff valve. The
turbocharger control shutoff valve is under pressure
and can cause personal injury.
• Remove the turbocharger control shutoff valve filter.
Refer to Procedure 010-114.
• Remove the air line from the turbocharger control
valve. Refer to Procedure 019-388 in the
Troubleshooting and Repair Manual CM870
Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
• Disconnect the air line from the air tank.
• Disconnect the electrical harness from the
turbocharger air control shutoff valve.
• Remove the air shutoff valve. Refer to Procedure
019-386 in the Troubleshooting and Repair Manual
CM870 Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
Remove
Variable Geometry
Remove the two mounting capscrews.
Remove the turbocharger control shutoff valve filter head.
Signature, ISX, and QSX15 Engi [...] Turbocharger Control Shutoff Valve Filter Head
Section 10 - Air Intake System - Group 10 Page 10-67
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the turbocharger control shutoff valve filter head
threads with a lint free cloth.
Inspect the threads for damage. If damage is found,
replace the turbocharger control shutoff valve filter head.
Inspect the fittings and lines for signs of water entrapment
or contamination. If water entrapment or contamination is
found, inspect the turbocharger control shutoff valve.
Use compressed air to clean the fittings, lines, and
turbocharger control shutoff valve and the turbocharger
control valve.
Inspect the vehicle air drier for proper operation.
Replace the lines and turbocharger control shutoff valve,
if necessary.
Repair the cause of water entrapment or contamination.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
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.
Clean the turbocharger control shutoff valve filter head
mounting surfaces with solvent.
Dry with compressed air.
Check for cracks or damage. Replace the turbocharger
control shutoff valve filter head, if cracks or damage are
found.
Install
Variable Geometry
Install the two mounting capscrews and the turbocharger
control shutoff valve filter head.
Torque Value: 45 N•m [ 33 ft-lb ]
Turbocharger, Variable Geometry Actuator Air Supply Lin [...] Signature, ISX, and QSX15 Engi [...]
Page 10-68 Section 10 - Air Intake System - Group 10
Finishing Steps
Variable Geometry
• Install the air shutoff valve. Refer to Procedure
019-386 in the Troubleshooting and Repair Manual
CM870 Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
• Connect the air line from the air tank.
• Install the air line from the turbocharger control
valve. Refer to Procedure 019-388 in the
Troubleshooting and Repair Manual CM870
Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
• Install the turbocharger control shutoff valve filter.
Refer to Procedure 010-114.
• Connect the electrical harness to the turbocharger
control shutoff valve.
• Operate the engine and check for leaks.
Install
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.
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.
Install
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.
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.
Preparatory Steps
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
• Clean the area around the turbocharger actuator and
dry with compressed air.
• Drain the engine coolant. Refer to Procedure
008-018.
• Disconnect the turbocharger actuator coolant supply
and return lines from the turbocharger actuator.
Refer to Procedure 010-041.
• Remove the turbocharger actuator wiring harness
zip ties.
Remove
Disconnect the wiring harness from the turbocharger
actuator by sliding the locking tang to the open position,
and then pushing down on the release lever and pulling
the connection apart.
Time
CAUTION
During the turbocharger actuator install test, the
pinion gear on the actuator will move. Keep hands and
tools away from the pinion gear during the test.
Signature, ISX, and QSX15 Engi [...] Variable Geometry Turbocharger Actuator, Electric
Section 10 - Air Intake System - Group 10 Page 10-75
Grasp the sector gear by hand and rotate the sector gear
toward the turbocharger compressor cover until the
through hole in the sector gear lines up with the blind hole
in the bearing housing. Verify the sector gear is aligned
by inserting the alignment pin included in the actuator kit
or a 3/16” or 5mm drill bit through the sector gear and into
the bearing housing.
Coat the teeth on the sector gear with the high-
temperature grease from the packet supplied in the
installation kit.
NOTE: It is critical for smooth reliable operation of the
actuator to use the full amount of the Holset® supplied
high-temperature grease.
Install
CAUTION
Do not attempt to force the actuator onto the bearing
housing by using the capscrews. Misalignment can
cause damage to the actuator or turbocharger.
Align the actuator and gasket assembly with the
turbocharger bearing housing face with the two lower
capscrews. Be sure to use the new capscrews available
in the turbocharger actuator mounting kit.
Align the actuator to the bearing housing and slide the
actuator into place. The actuator pinion gear and the
turbocharger sector gear must engage smoothly. If not,
verify that the sector gear through-hole and the bearing
housing blind-hole are aligned.
You could possibly have to twist the actuator housing in
order to align it with the mounting holes.
Signature, ISX, and QSX15 Engi [...] Variable Geometry Turbocharger Actuator, Electric
Section 10 - Air Intake System - Group 10 Page 10-77
Calibrate
The turbocharger actuator must be calibrated to the
turbocharger. This step must be performed to make sure
proper turbocharger operation is achieved.
With the keyswitch in the ON position, connect the
turbocharger actuator into the engine wiring harness.
Calibration instructions:
Within the INSITE™ electronic service tool screen labeled
“VGT Electric Actuator Install and Calibrate”, locate the
column labeled “Value” and left click on the down arrow.
Select “Calibrate Actuator”.
Follow the instruction on the screen in order to calibrate
the new turbocharger actuator to the turbocharger.
INSITE™ electronic service tool will indicate when this step
is complete.
If INSITE™ electronic service tool status message
indicates the test was stopped or failed, turn the keyswitch
OFF for 30 seconds and key back ON. Then start over
beginning with the Timing Step.
It is normal to have an active Fault Code 2387 at this point.
Turn the keyswitch in the OFF position for 30 seconds.
Then key ON and refresh the fault code screen. All
turbocharger actuator fault codes can be inactive. Use
INSITE™ electronic service tool to clear all fault codes.
Finishing Steps
• Install the turbocharger actuator coolant supply and
return lines. Refer to Procedure 010-041.
• Fill the cooling system. Refer to Procedure 008-018.
Variable Geometry Turbocharger Actuator, Electric Signature, ISX, and QSX15 Engi [...]
Page 10-78 Section 10 - Air Intake System - Group 10
Pressure Test................................................................................................................................................11-24
Automotive with CM870..............................................................................................................................11-24
Automotive With CM871.............................................................................................................................11-25
Remove.........................................................................................................................................................11-16
Automotive with CM870..............................................................................................................................11-16
Automotive With CM871.............................................................................................................................11-17
EGR Cooler Connection ................................................................................................................................11-40
Clean and Inspect for Reuse.........................................................................................................................11-40
Finishing Steps.............................................................................................................................................11-42
Install............................................................................................................................................................11-42
Preparatory Steps.........................................................................................................................................11-40
Remove.........................................................................................................................................................11-40
EGR Cooler Coolant Lines ............................................................................................................................11-60
Clean and Inspect for Reuse.........................................................................................................................11-63
Automotive with CM870..............................................................................................................................11-63
Automotive With CM871.............................................................................................................................11-64
Finishing Steps.............................................................................................................................................11-67
Automotive with CM870..............................................................................................................................11-67
Automotive With CM871.............................................................................................................................11-67
Install............................................................................................................................................................11-64
Automotive with CM870..............................................................................................................................11-64
Automotive With CM871.............................................................................................................................11-65
Preparatory Steps.........................................................................................................................................11-60
Automotive with CM870..............................................................................................................................11-60
Automotive With CM871.............................................................................................................................11-61
Remove.........................................................................................................................................................11-61
Automotive with CM870..............................................................................................................................11-61
Automotive With CM871.............................................................................................................................11-61
EGR Differential Pressure Sensor Adapter ...................................................................................................11-57
Clean and Inspect for Reuse.........................................................................................................................11-58
Finishing Steps.............................................................................................................................................11-58
Install............................................................................................................................................................11-58
Preparatory Steps.........................................................................................................................................11-57
Remove.........................................................................................................................................................11-57
EGR Differential Pressure Sensor Tubes .....................................................................................................11-51
Clean and Inspect for Reuse.........................................................................................................................11-52
Automotive with CM870..............................................................................................................................11-52
Automotive With CM871.............................................................................................................................11-54
Finishing Steps.............................................................................................................................................11-55
Automotive with CM870..............................................................................................................................11-55
Automotive With CM871.............................................................................................................................11-55
Install............................................................................................................................................................11-54
Automotive with CM870..............................................................................................................................11-54
Automotive With CM871.............................................................................................................................11-55
Preparatory Steps.........................................................................................................................................11-51
Automotive With CM871.............................................................................................................................11-51
Remove.........................................................................................................................................................11-51
Automotive with CM870..............................................................................................................................11-51
Automotive With CM871.............................................................................................................................11-52
EGR Mixer ......................................................................................................................................................11-30
Clean and Inspect for Reuse.........................................................................................................................11-31
Finishing Steps.............................................................................................................................................11-32
Install............................................................................................................................................................11-31
Preparatory Steps.........................................................................................................................................11-30
Remove.........................................................................................................................................................11-30
EGR Valve ......................................................................................................................................................11-32
Assemble......................................................................................................................................................11-37
Automotive With CM871.............................................................................................................................11-37
Clean and Inspect for Reuse.........................................................................................................................11-35
Automotive with CM870..............................................................................................................................11-35
Automotive With CM871.............................................................................................................................11-35
Disassemble..................................................................................................................................................11-34
Automotive With CM871.............................................................................................................................11-34
Signature, ISX, and QSX15 Engi [...]
Page 11-d Section 11 - Exhaust System - Group 11
Finishing Steps.............................................................................................................................................11-39
Automotive with CM870..............................................................................................................................11-39
Automotive With CM871.............................................................................................................................11-39
Install............................................................................................................................................................11-38
Automotive with CM870..............................................................................................................................11-38
Automotive With CM871.............................................................................................................................11-38
Preparatory Steps.........................................................................................................................................11-32
Automotive with CM870..............................................................................................................................11-32
Automotive With CM871.............................................................................................................................11-33
Remove.........................................................................................................................................................11-33
Automotive with CM870..............................................................................................................................11-33
Automotive With CM871.............................................................................................................................11-34
EGR Valve Coolant Lines ..............................................................................................................................11-59
Clean and Inspect for Reuse.........................................................................................................................11-59
Finishing Steps.............................................................................................................................................11-60
Install............................................................................................................................................................11-60
Preparatory Steps.........................................................................................................................................11-59
Remove.........................................................................................................................................................11-59
EGR Valve Mounting Bracket ........................................................................................................................11-81
Clean and Inspect for Reuse.........................................................................................................................11-82
Finishing Steps.............................................................................................................................................11-82
Install............................................................................................................................................................11-82
Preparatory Steps.........................................................................................................................................11-81
Automotive With CM871.............................................................................................................................11-81
Remove.........................................................................................................................................................11-81
Exhaust Gas Pressure Sensor Adapter ........................................................................................................11-69
Finishing Steps.............................................................................................................................................11-70
Automotive with CM870..............................................................................................................................11-70
Inspect for Reuse..........................................................................................................................................11-70
All Applications...........................................................................................................................................11-70
Install............................................................................................................................................................11-70
All Applications...........................................................................................................................................11-70
Preparatory Steps.........................................................................................................................................11-69
Automotive with CM870..............................................................................................................................11-69
Remove.........................................................................................................................................................11-70
All Applications...........................................................................................................................................11-70
Exhaust Gas Pressure Sensor Tube .............................................................................................................11-55
Clean and Inspect for Reuse.........................................................................................................................11-56
Finishing Steps.............................................................................................................................................11-57
Install............................................................................................................................................................11-56
Preparatory Steps.........................................................................................................................................11-55
Remove.........................................................................................................................................................11-56
Exhaust Manifold, Dry .....................................................................................................................................11-1
Assemble........................................................................................................................................................11-9
Automotive with CM870................................................................................................................................11-9
Automotive, Industrial with CM570 and Power Generation without CM570....................................................11-9
Automotive With CM871...............................................................................................................................11-9
Clean and Inspect for Reuse...........................................................................................................................11-5
Automotive, Industrial with CM570 and Power Generation without CM570....................................................11-5
Automotive with CM870 and CM871.............................................................................................................11-6
Disassemble...................................................................................................................................................11-4
Automotive with CM870................................................................................................................................11-4
Automotive, Industrial with CM570 and Power Generation without CM570....................................................11-5
Automotive With CM871...............................................................................................................................11-5
Finishing Steps.............................................................................................................................................11-13
Automotive with CM870..............................................................................................................................11-13
Automotive, Industrial with CM570 and Power Generation without CM570..................................................11-13
Automotive With CM871.............................................................................................................................11-13
Initial Check....................................................................................................................................................11-1
Automotive with CM870................................................................................................................................11-1
Automotive With CM871...............................................................................................................................11-1
Install............................................................................................................................................................11-10
Automotive with CM870 and CM871...........................................................................................................11-10
Signature, ISX, and QSX15 Engi [...]
Section 11 - Exhaust System - Group 11 Page 11-e
Repair
Automotive with CM870
WARNING
To reduce the possibility of personal injury from hot
surfaces, allow the engine to cool before beginning
work. Wear appropriate hand and eye protection.
CAUTION
To reduce the possibility of damage to the EGR cooler
bellows, do not use the cooler bellows as a pivot point
for a pry bar when compressing the covers.
NOTE: The EGR water return tube was removed in the
illustration in order to show the seal kit installation. The
seal kit can be installed without removing the EGR water
return tube.
Compress the two covers together. The use of a pry bar
and/or mallet to accommodate the T bolt clamp will
possibly be necessary.
The T bolt of the clamp can be removed to aid in
installation.
Separate the clamp and place it over the two covers.
Tighten the clamp.
Torque Value: 11 N•m [ 100 in-lb ]
Or until the ends of the cover make contact.
Preparatory Steps
Automotive with CM870
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the charge air cooler piping. Refer to the
manufacturer's instructions.
• Remove the variable geometry turbocharger. Refer
to Procedure 010-033.
• Remove the heat shield. Refer to Procedure
011-032.
• Remove the EGR valve. Refer to Procedure 011-022.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Drain the cooling system. Refer to Procedure 008-018.
Remove the following:
• Charger air cooler piping. Refer to the OEM
troubleshooting and repair manual.
• Variable geometry turbocharger. Refer to Procedure
010-033
• Exhaust gas pressure sensor tube. Refer to
Procedure 011-027.
Remove
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.
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.
Disassemble
Automotive with CM870
Disassemble the exhaust manifold end sections.
Discard the exhaust seal ring on the slip-joint, if equipped.
Signature, ISX, and QSX15 Engi [...] Exhaust Manifold, Dry
Section 11 - Exhaust System - Group 11 Page 11-5
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use a 240-grit emery cloth to remove carbon deposits from
the sealing surfaces.
Steam-clean and dry with compressed air.
Exhaust Manifold, Dry Signature, ISX, and QSX15 Engi [...]
Page 11-6 Section 11 - Exhaust System - Group 11
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Steam clean and dry with compressed air.
Grasp the portion of the seal between the cuts with a pair
of pliers.
Twist and pull the seal off of the exhaust manifold end
sections.
NOTE: Take care not to damage the seal carrier surface.
Discard the exhaust seal rings.
Signature, ISX, and QSX15 Engi [...] Exhaust Manifold, Dry
Section 11 - Exhaust System - Group 11 Page 11-9
Assemble
Automotive with CM870
The exhaust manifold sections must be assembled on a
flat surface for proper alignment.
Install exhaust seal rings, if equipped.
Install the exhaust manifold end sections to the center
section.
Position the seal installer and seal ring in line with the
sealing surface on the exhaust manifold and strike with a
lead or dead blow hammer until the seal is fully seated.
Install
Automotive with CM870 and CM871
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.
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.
Install the exhaust manifold over the guide studs.
Apply a film of high-temperature anti-seize compound to
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.
Remove the two guide studs and install the two remaining
capscrews.
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.
Install the exhaust manifold assembly on the guide pins.
Finishing Steps
Automotive with CM870
• Install the EGR valve. Refer to Procedure 011-022.
• Install the heat shield. Refer to Procedure 011-032.
• Install the variable geometry turbocharger. Refer to
Procedure 010-033.
• Install the charge air cooler piping. Refer to the
manufacturer's instructions.
• Fill the cooing system. Refer to Procedure 008-018.
• Start and operate the engine. Listen and feel for air
leaks and exhaust gas leaks.
Exhaust Restriction
mm Hg in Hg
Without Aftertreatment 75.0 MAX 3.0
With Aftertreatment 305.0 MAX 12.0
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
• Drain the engine coolant. Refer to Procedure
008-018.
• Remove the air intake pipe to turbocharger. Refer to
the OEM service manual.
• Remove the turbocharger. Refer to Procedure
010-033.
• Remove the exhaust gas pressure sensor tube.
Refer to Procedure 011-027.
• Remove the EGR cooler coolant lines. Refer to
Procedure 011-031.
EGR Cooler Signature, ISX, and QSX15 Engi [...]
Page 11-16 Section 11 - Exhaust System - Group 11
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
• Drain the engine coolant. Refer to Procedure
008-018.
• Remove the air intake pipe to turbocharger. Refer to
the OEM service manual.
• Remove the aftertreatment adapter pipe and
aftertreatment injector lines. Refer to Procedures
011-051 and 011-043.
• Remove the turbocharger. Refer to Procedure
010-033.
• Remove the EGR cooler coolant lines. Refer to
Procedure 011-031.
Remove
Automotive with CM870
Loosen the v-band clamp between the EGR cooler and the
EGR cooler connection.
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.
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.
Cap the outlet end of the EGR cooler with parts supplied
in the EGR cooler leak check kit, Part Number 3164225.
Completely fill the EGR cooler with mineral spirits.
Cap the gas inlet end of the EGR cooler with parts
supplied in the EGR cooler leak check kit, Part Number
3164225.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Drain the mineral spirits from the EGR cooler and properly
dispose of the liquid.
Use compressed air to dry the inside of the EGR cooler
and remove any loose debris or particles.
Cap the outlet end of the EGR cooler with parts supplied
in service kit, Part Number 3164225.
Completely fill the EGR cooler with water.
Cap the gas inlet end of the EGR cooler with parts
supplied in service kit, Part Number 3164225.
Drain the water from the EGR cooler and properly dispose
of the liquid.
Use compressed air to dry the inside of the EGR cooler.
Clean the EGR valve, with safety solvent, where the EGR
cooler connection attaches to the EGR valve. Refer to
Procedure 011-022.
Clean the EGR cooler connection with safety solvent and
dry with compressed air.
Inspect the EGR valve where the EGR cooler connection
attaches to the EGR valve. Replace the EGR valve if
cracks or other damage is found. Refer to Procedure
011-022.
Replace the EGR cooler if cracks or other damage is found
on the EGR cooler.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
With the EGR connection tube attached, clean the cooler
end of the EGR connection tube with safety solvent.
Dry with compressed air.
Inspect the EGR connection tube for cracks or other
damage, while still attached to the block. Replace the
EGR connection tube, if necessary. Refer to Procedure
011-025.
EGR Cooler Signature, ISX, and QSX15 Engi [...]
Page 11-20 Section 11 - Exhaust System - Group 11
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the EGR cooler connection with safety solvent and
dry with compressed air.
Inspect the EGR cooler connection for cracks or other
damage. Replace the EGR cooler connection if cracks or
other damage is found. Refer to Procedure 011-024.
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.
Clean the mounting surfaces with safety solvent to remove
debris or other deposits.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
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.
Inspect the v-band clamp threads for damage. Replace
the clamp if damage is found.
WARNING
Do not use chlorinated water to clean or rinse the EGR
cooler. Chlorides are very corrosive to the stainless
alloys internal and external to the EGR cooler.
Cap the outlet end of the EGR cooler with the plastic caps
supplied in the service kit, Part Number 4918655.
Completely fill the EGR cooler with safety solvent.
Cap the gas inlet end of the EGR cooler with the plastic
cap supplied in the service kit.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
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.
Drain the safety solvent from the EGR cooler and properly
dispose of the liquid.
Use compressed air to dry the inside of the EGR cooler
and remove any loose debris or particles.
Cap the outlet end of the EGR cooler with the plastic cap
supplied in the service kit, Part Number 4918655.
Completely fill the EGR cooler with water.
Cap the gas inlet end of the EGR cooler with the plastic
cap supplied in the service kit.
Shake the cooler by hand, from end to end, for
approximately 30 seconds.
Drain the water from the EGR cooler and properly dispose
of the liquid.
Use compressed air to dry the inside of the EGR cooler.
Clean the exhaust manifold with safety solvent, where the
EGR cooler connection attaches to the exhaust manifold.
Refer to Procedure 011-007.
Inspect the exhaust manifold where the EGR cooler
connection attaches to the exhaust manifold. Replace the
exhaust manifold if cracks or other damage is found. Refer
to Procedure 011-007.
Replace the EGR cooler, if cracks or other damage is
found.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris or dirt can cause
personal injury.
Clean the EGR cooler exhaust gas outlet with safety
solvent.
Dry with compressed air.
Inspect the EGR cooler exhaust gas outlet for signs of
fretting, cracks, or other damage.
Replace the EGR cooler if damage is found. Refer to
Procedure 011-025.
Signature, ISX, and QSX15 Engi [...] EGR Cooler
Section 11 - Exhaust System - Group 11 Page 11-23
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
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.
Clean the EGR cooler bellows with safety solvent and dry
with compressed air.
Inspect the EGR cooler bellows for cracks or other
damage.
Replace the EGR cooler bellows if cracks or other damage
is found.
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.
Clean the mounting surfaces with safety solvent to remove
debris or other deposits.
Pressure Test
Automotive with CM870
Cap off the coolant inlet and vents of the cooler with the
parts supplied in the EGR cooler leak check kit, Part
Number 3164225. Jumper tube, Part Number 3683068,
and jumper tube, Part Number 3682540, from the cooler,
are also used.
Cap off the coolant outlet with the plugged jumper tube
and pressure regulator assembly. Secure the jumper tube
with a hose clamp.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Drain all of the water from the gas side of the EGR cooler
before reuse.
Dry the cooler with compressed air.
Install the collet and cap over the pipe coupling and
coolant outlet and secure with the hose clamp provided in
Service Kit, Part Number 4918655.
EGR Cooler Signature, ISX, and QSX15 Engi [...]
Page 11-26 Section 11 - Exhaust System - Group 11
Install
Automotive with CM870
Install a new hose onto the rear EGR connection tube and
install the hose clamps.
Signature, ISX, and QSX15 Engi [...] EGR Cooler
Section 11 - Exhaust System - Group 11 Page 11-27
Connect the EGR cooler to the new hose on the rear EGR
connection tube.
EGR Cooler Signature, ISX, and QSX15 Engi [...]
Page 11-28 Section 11 - Exhaust System - Group 11
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.
Torque Value: 17 N•m [ 150 in-lb ]
Finishing Steps
Automotive with CM870
• Install the EGR cooler coolant lines. Refer to
Procedure 011-031.
• Install the exhaust gas pressure sensor tube. Refer
to Procedure 011-027.
• Install the turbocharger. Refer to Procedure 010-033.
• Install the air intake pipe to the turbocharger. Refer
to OEM service manual.
• Fill the engine cooling system. Refer to Procedure
008-018.
• Start the engine, check for leaks, and verify proper
operation.
EGR Mixer Signature, ISX, and QSX15 Engi [...]
Page 11-30 Section 11 - Exhaust System - Group 11
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.
Signature, ISX, and QSX15 Engi [...] EGR Mixer
Section 11 - Exhaust System - Group 11 Page 11-31
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
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.
Use compressed air to blow out any debris or soot buildup
inside the EGR mixer.
Clean all mounting surfaces with solvent.
Dry with compressed air.
Inspect the EGR mixer for cracks. Replace the EGR mixer
if cracks are found.
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.
Torque Value: 34 N•m [ 25 ft-lb ]
EGR Valve Signature, ISX, and QSX15 Engi [...]
Page 11-32 Section 11 - Exhaust System - Group 11
Finishing Steps
• Install the v-band clamp on the inlet adapter and the
EGR mixer.
• Install the air compressor supply line. Refer to
Procedure 012-014.
• Install the charge air cooler connection. Refer to
Procedure 010-027.
• Start and operate the engine and check for leaks at
the air connections.
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.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulators.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
• Drain the engine coolant. Refer to Procedure
008-018.
• Remove the water pump drive belt. Refer to
Procedure 008-003.
• On some applications, removal of the alternator is
required. Refer to Procedure 013-001.
• Remove the air intake pipe to the turbocharger.
Refer to the OEM troubleshooting and repair
manual.
• Remove the heat shield. Refer to Procedure
011-032.
• Disconnect the EGR valve motor and position sensor
connectors from the harness.
• Remove the EGR valve coolant lines. Refer to
Procedure 011-030.
Signature, ISX, and QSX15 Engi [...] EGR Valve
Section 11 - Exhaust System - Group 11 Page 11-33
Remove
Automotive with CM870
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.
Disassemble
Automotive With CM871
Remove the pipe seal from the EGR valve inlet port.
Pry the lip of the pipe seal up from the EGR valve, use a
small flat headed screwdriver. Take care not to nick the
EGR valve housing when removing the seal.
Discard the pipe seal.
Signature, ISX, and QSX15 Engi [...] EGR Valve
Section 11 - Exhaust System - Group 11 Page 11-35
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
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 injury.
Clean the mounting surfaces with a shop towel wetted with
a safety solvent to remove any deposits or debris.
Dry with compressed air.
Inspect the mounting surfaces for cracks, fretting, or other
damage. Inspect the EGR motor and position sensor for
damage.
Replace the valve if damage is found.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the EGR valve mounting and sealing surfaces with
a shop towel wetted with safety solvent to remove any
deposits or debris.
EGR Valve Signature, ISX, and QSX15 Engi [...]
Page 11-36 Section 11 - Exhaust System - Group 11
Clean the accumulated soot from the EGR valve inlet port
using a wire brush, then soaking with carburetor cleaner
and cleaning again with a wire brush. Be sure the loose
soot is removed from the EGR valve housing. This can be
done by vacuuming the soot out of the EGR valve inlet
port.
Dry with compressed air.
Inspect the mounting surfaces for cracks, fretting, or other
damage.
Assemble
Automotive With CM871
Use a light coat of clean engine oil to lubricate the outer
diameter of the EGR valve seal during assembly on to the
EGR valve. Push the EGR valve seal into the EGR valve
inlet port by hand. The EGR seal must remain square in
the EGR valve inlet port during installation.
Install
Automotive with CM870
Before installing the v-band clamp, coat the clamping
surface with high temperature anti-seize compound.
Finishing Steps
Automotive with CM870
• Install the EGR valve coolant lines. Refer to
Procedure 011-030.
• Connect the EGR valve motor and position sensor
connectors to the harness (clean off the wiring
harness and connector before connecting to the
valve).
• Install the heat shield. Refer to Procedure 011-032.
• Install the air intake pipe to the turbocharger. Refer
to the OEM troubleshooting and repair manual.
• Install the alternator, if removed. Refer to Procedure
013-001.
• Install the water pump drive belt. Refer to Procedure
008-003.
Fill the engine cooling system. Refer to Procedure
008-018.
Start and operate the engine. Check for exhaust and
coolant leaks.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulators.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
Drain the cooling system. Refer to Procedure 008-018.
Remove or loosen the following:
• Air intake pipe to the turbocharger. Refer to the OEM
service manual.
• Heat shield. Refer to Procedure 011-032.
• EGR cooler coolant line. Refer to Procedure
011-031.
• V-band clamp that holds the EGR valve to the
exhaust manifold. Rotate the V-band clamp out of
the way to access the V-band clamp that holds the
EGR cooler connection to the EGR valve. Refer to
Procedure 011-022.
Remove
Loosen the V-band clamps on each end of the exhaust gas
recirculation (EGR) cooler connection.
Remove the EGR cooler connection and V-bands.
Remove the gaskets and discard.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the EGR cooler connection with safety solvent.
Dry with compressed air.
Inspect the EGR cooler connection for cracks or other
damage.
Signature, ISX, and QSX15 Engi [...] EGR Cooler Connection
Section 11 - Exhaust System - Group 11 Page 11-41
Install
Before installing the V-band clamp, coat the clamping
surface with high temperature anti-seize compound.
Finishing Steps
Install or connect the following:
• EGR cooler coolant line. Refer to Procedure
011-031.
• Heat Shield. Refer to Procedure 011-032.
• Air intake pipe to the turbocharger. Refer to the OEM
service manual.
Fill the engine cooling system. Refer to Procedure
008-018.
Start engine and verify proper operation.
Signature, ISX, and QSX15 Engi [...] EGR Connection Tubes
Section 11 - Exhaust System - Group 11 Page 11-43
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
The differential pressure sensor tube can be hot. To
reduce the possibility of personal injury, allow the
engine to cool before removing.
• Use steam or high-pressure water to clean the rear
of the engine, specifically around the rear EGR
connection tube area.
• Remove the fuel filter. Refer to Procedure 006-015
(Fuel Filter, Spin-On Type) in Section 6.
• Remove the engine wiring harness from the exhaust
temperature sensor. Refer to Procedure 019-043
(Engine Wiring Harness) in Section 19 in the
Troubleshooting and Repair Manual, CM870
Electronic Control System, Signature and ISX
Engines, Bulletin 4021334.
• Remove the dipstick tube. Refer to Procedure
007-011 (Lubricating Oil Dipstick Tube) in Section 7.
• Remove the differential pressure sensor tubes from
the connection tube and the sensor adapter. Refer
to Procedure 011-026 (EGR Differential Pressure
Sensor Tubes) in Section 11.
• Remove the oil pressure sensor. Refer to the
Procedure 019-066 (Engine Oil Pressure Sensor) in
Section 19 in the Troubleshooting and Repair
Manual, CM870 Electronic Control System,
Signature and ISX Engines, Bulletin 4021334.
EGR Connection Tubes Signature, ISX, and QSX15 Engi [...]
Page 11-44 Section 11 - Exhaust System - Group 11
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
The differential pressure sensor tube can be hot. To
reduce the possibility of personal injury, allow the
engine to cool before removing.
Use steam or high-pressure water to clean the engine,
specifically around the EGR connection tube joints.
• Remove the engine wiring harness from the exhaust
temperature sensor. Refer to Procedure 019-013
(Exhaust Gas Temperature Sensor) in Section 19 in
the Troubleshooting and Repair Manual, CM871 and
CM876 Electronic Control System, ISX and ISM
Engines, Bulletin 4021560.
• Remove the EGR differential pressure sensing tubes
from the EGR venturi. Refer to Procedure 011-026
(EGR Differential Pressure Sensor Tubes) in Section
11.
Remove
Automotive with CM870
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.
Signature, ISX, and QSX15 Engi [...] EGR Connection Tubes
Section 11 - Exhaust System - Group 11 Page 11-45
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.
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.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the connection tubes with solvent.
Dry with compressed air.
Inspect the ends and mating joints of the connection tubes
for cracks or other damage. Replace the tube if cracks or
other damage is found.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the connection tubes with solvent.
Make sure that gasket sealing surfaces at the EGR valve
outlet and EGR cooler outlet are free of packed soot and
other debris. Avoid wiping dirt or debris down into the
tubes or valve.
Dry with compressed air.
Signature, ISX, and QSX15 Engi [...] EGR Connection Tubes
Section 11 - Exhaust System - Group 11 Page 11-47
Install
Automotive with CM870
Mask 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.
Finger tighten the capscrew and nuts.
EGR Connection Tubes Signature, ISX, and QSX15 Engi [...]
Page 11-48 Section 11 - Exhaust System - Group 11
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.
Finishing Steps
Automotive with CM870
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
The differential pressure sensor tube can be hot. To
reduce the possibility of personal injury, allow the
engine to cool before removing.
• Install the oil pressure sensor. Refer to Procedure
019-066 (Engine Oil Pressure Sensor) in Section 19
in the Troubleshooting and Repair Manual, CM870
Electronic Control System, Signature and ISX
Engines, Bulletin 4021334.
• Install the differential pressure sensor tubes to the
front connection tube and the sensor adapter. Refer
to Procedure 011-026 (EGR Differential Pressure
Sensor Tubes) in Section 11.
• Install the dipstick tube. Refer to Procedure 007-011
(Lubricating Oil Dipstick Tube) in Section 7.
• Install the engine wiring harness to the exhaust
temperature sensor. Refer to Procedure 019-043
(Engine Wiring Harness) in Section 19 in the
Troubleshooting and Repair Manual, CM870
Electronic System, Signature and ISX Engines,
Bulletin 4021334.
• Install the fuel filter. Refer to Procedure 006-015
(Fuel Filter Spin-On Type) in Section 6.
• Operate the engine and check for leaks.
Signature, ISX, and QSX15 Engi [...] EGR Differential Pressure Sensor Tubes
Section 11 - Exhaust System - Group 11 Page 11-51
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
The differential pressure sensor tube can be hot. To
reduce the possibility of personal injury, allow the
engine to cool before removing.
• Install the EGR differential pressure sensing tubes to
the EGR venturi. Refer to Procedure 011-026 (EGR
Differential Pressure Sensor Tubes) in Section 11.
• Install the engine wiring harness to the exhaust
temperature sensor. Refer to Procedure 019-013
(Exhaust Gas Temperature Sensor) in Section 19 in
the Troubleshooting and Repair Manual CM871 and
CM876 Electronic Control System ISX and ISM
Engines, Bulletin 4021560.
• Operate the engine and check for leaks.
Remove
Automotive with CM870
For engines with an ESN beginning with 14040552, the
pressure sensor does not have to be removed to allow the
removal of the EGR differential pressure sensor tube.
Pressure sensor removal is necessary only if the sensor
adapter is being replaced. Refer to Procedure 011-028.
Tag the ends of the tubes before removing the sensor
tubes. Incorrectly installing the tubes to the sensor
adapter will result in a fault code.
Loosen the tube nuts at the front EGR connection tube
and the sensor adapter.
Remove the tubes.
EGR Differential Pressure Sensor Tubes Signature, ISX, and QSX15 Engi [...]
Page 11-52 Section 11 - Exhaust System - Group 11
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Check the inside of the tubes.
If a tube is partially clogged, saturate the inside of the tube
with a mineral based solvent, or equivalent.
Carefully clean debris from the mouth of the tube, making
sure not to damage the tube.
If the tube is fully clogged or otherwise unable to be
cleaned, the tube must be replaced.
Clean the tube with safety solvent.
Dry the tube with compressed air.
Signature, ISX, and QSX15 Engi [...] EGR Differential Pressure Sensor Tubes
Section 11 - Exhaust System - Group 11 Page 11-53
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Inspect the mating orifices of the EGR crossover tubes.
If clogged, saturate the carbon deposit with a mineral
based solvent, or equivalent.
Carefully clean debris from the mouth of the orifice,
making sure not to damage the orifice.
Dry with compressed air.
EGR Differential Pressure Sensor Tubes Signature, ISX, and QSX15 Engi [...]
Page 11-54 Section 11 - Exhaust System - Group 11
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Carbon deposits inside the tubes can cause an amber
CHECK ENGINE light, in addition to any combination of
the following:
• Low power
• Black smoke
• Engine surge
• Engine runs rough
• Exhaust gas recirculation valve differential pressure
fault code.
• Progressive damage to the Cummins® particulate
filter.
Check the inside of the tubes.
If a tube is partially clogged, saturate the inside of the tube
with mineral based solvent, or equivalent.
Carefully clean the debris from the mouth of the tube.
Making sure not to damage the tube.
If the tube is fully clogged or otherwise unable to be
cleaned, the tube must be replaced.
Clean the tube with safety solvent.
Dry with compressed air.
Check the tubes for cracks or thread damage.
Inspect the mating orifices for the EGR crossover tubes.
If clogged, remove the EGR venturi tube. Refer to
Procedure 011-025.
Saturate the carbon deposit with a safety solvent or
equivalent.
Carefully clean the debris from the mouth of the orifice,
making sure not to damage the orifice.
Dry with compressed air.
Install
Automotive with CM870
For engines with an ESN beginning with 14040552, the
tubes must be installed so that they do not cross over
each other.
Apply anti-seize compound to the tube threads and install
the tubes.
Torque Value: 17 N•m [ 150 in-lb ]
This insulation is designed to only cover the bottom
portion of the tube which threads to the EGR tube. This
location proves to be most effective and prevents heat
soaking of the EGR differential pressure sensor.
Signature, ISX, and QSX15 Engi [...] Exhaust Gas Pressure Sensor Tube
Section 11 - Exhaust System - Group 11 Page 11-55
Finishing Steps
Automotive with CM870
If removed, install the EGR differential pressure sensor.
Refer to Procedure 019-370 in the Troubleshooting and
Repair Manual CM870 Electronic Control System
Signature and ISX Engines, Bulletin 4021334.
Start the engine and verify proper operation.
Check for fault codes.
Remove
Loosen the tube nuts at the exhaust manifold and at the
sensor adapter.
Remove the tube.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Inspect the inside of the tube. If clogged, use compressed
air to remove debris or soot buildup.
Clean the outside of the tube with solvent.
Dry with compressed air.
Check the tube for cracks and thread damage. Replace
the tube, if cracks or damage are found.
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.
Torque Value: 16 N•m [ 146 in-lb ]
Signature, ISX, and QSX15 Engi [...] EGR Differential Pressure Sensor Adapter
Section 11 - Exhaust System - Group 11 Page 11-57
Finishing Steps
• Connect the electrical connectors to the exhaust gas
pressure sensor. Refer to Procedure 019-376 in the
Troubleshooting and Repair Manual CM870
Electronic Control System Signature and ISX
Engines, Bulletin 4021334.
• Start the engine and verify proper operation.
• Check for fault codes.
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.
Remove
Remove the mounting capscrews.
Remove the EGR pressure sensor adapter.
EGR Differential Pressure Sensor Adapter Signature, ISX, and QSX15 Engi [...]
Page 11-58 Section 11 - Exhaust System - Group 11
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
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.
Inspect the EGR pressure sensor adapter tube holes for
clogging.
If clogged, use compressed air to remove debris or soot
buildup. Clean the outside of the adapter with solvent.
Dry with compressed air.
Inspect the EGR pressure sensor adapter for cracks or
fretting. Replace the EGR pressure sensor adapter if
cracks are found.
Install
Install the EGR pressure sensor adapter and capscrews.
Torque Value: 18 N•m [ 13 ft-lb ]
Finishing Steps
Install or connect the following:
• EGR differential pressure sensor tubes. Refer to
Procedure 011-026.
• EGR differential pressure sensor connector to the
engine wiring harness.
Operate the engine and check for leaks.
Signature, ISX, and QSX15 Engi [...] EGR Valve Coolant Lines
Section 11 - Exhaust System - Group 11 Page 11-59
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the air intake piping. Refer to the OEM
service manual.
• Remove the heat shield. Refer to Procedure
011-032.
Remove
Disconnect the EGR valve coolant supply (bottom) and
return (top) lines.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the EGR valve coolant lines with solvent.
Dry with compressed air.
Inspect the EGR valve coolant lines and rubber grommets
for cracks or damage.
Replace the lines, if cracks or damage is found.
EGR Cooler Coolant Lines Signature, ISX, and QSX15 Engi [...]
Page 11-60 Section 11 - Exhaust System - Group 11
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.
Torque Value: 10 N•m [ 88 in-lb ]
Finishing Steps
• Install the heat shield. Refer to Procedure 011-032.
• Install the air intake piping. Refer to the OEM service
manual.
• Fill the engine cooling system. Refer to Procedure
008-018.
• Start and operate the engine. Check for leaks.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the air intake piping. Refer to the OEM
service manual.
• Remove the exhaust gas pressure sensor tube.
Refer to Procedure 011-027.
Signature, ISX, and QSX15 Engi [...] EGR Cooler Coolant Lines
Section 11 - Exhaust System - Group 11 Page 11-61
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the air intake piping. Refer to the OEM
troubleshooting and repair manual.
Remove
Automotive with CM870
Disconnect the EGR cooler coolant vent line from the EGR
cooler coolant return line and the EGR cooler.
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.
EGR Cooler Coolant Lines Signature, ISX, and QSX15 Engi [...]
Page 11-62 Section 11 - Exhaust System - Group 11
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.
Signature, ISX, and QSX15 Engi [...] EGR Cooler Coolant Lines
Section 11 - Exhaust System - Group 11 Page 11-63
Remove the nuts from the EGR cooler coolant supply tube
mounting bracket.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the EGR cooler coolant vent and the EGR cooler
coolant return line with solvent.
Dry with compressed air.
Inspect the EGR cooler coolant vent and the EGR cooler
coolant return line for cracks or damage. Replace the lines
if cracked or damaged.
EGR Cooler Coolant Lines Signature, ISX, and QSX15 Engi [...]
Page 11-64 Section 11 - Exhaust System - Group 11
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the EGR cooler coolant vent line and the EGR
cooler coolant supply and return tubes with solvent.
Dry with compressed air.
Install
Automotive with CM870
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.
Torque Value: 25 N•m [ 18 ft-lb ]
Signature, ISX, and QSX15 Engi [...] EGR Cooler Coolant Lines
Section 11 - Exhaust System - Group 11 Page 11-65
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
coolant line o-rings. The o-rings will swell and cause
the connection to leak.
Install the new o-rings on the EGR cooler coolant supply
tubes and jumper connection.
Lubricate the o-rings with clean engine coolant, soapy
water, or vegetable oil to aid in installation.
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 torque at this time.
EGR Cooler Coolant Lines Signature, ISX, and QSX15 Engi [...]
Page 11-66 Section 11 - Exhaust System - Group 11
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 torque at this time.
Install the press in place seal and the coolant return tube.
Install and tighten the capscrews.
Torque Value: 47 N•m [ 35 ft-lb ]
Finishing Steps
Automotive with CM870
• Install the exhaust gas pressure sensor tube. Refer
to Procedure 011-027.
• Install the air intake piping. Refer to the OEM
troubleshooting and repair manual.
• Fill the cooling system. Refer to Procedure 008-018.
• Start and operate the engine. Check for leaks.
Remove
Automotive with CM870
Remove the three mounting capscrews from the EGR
valve.
Remove the heat shield.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the heat shield with solvent.
Dry with compressed air.
Inspect the heat shield for cracks or any other damage.
Replace the heat shield, if cracks or any other damage is
found.
Signature, ISX, and QSX15 Engi [...] Exhaust Gas Pressure Sensor Adapter
Section 11 - Exhaust System - Group 11 Page 11-69
Install
Automotive with CM870
Apply high temperature anti-seize compound onto the
mounting capscrews.
Install the three mounting capscrews and the heat shield.
Torque Value: 23 N•m [ 17 ft-lb ]
Finishing Steps
Automotive with CM870
Install the air intake piping to the turbocharger. Refer to
the OEM troubleshooting and repair manual.
Remove
All Applications
Remove the p-clamp mounting capscrew and remove the
adapter.
Install
All Applications
Install the sensor adapter and the p-clamp mounting
capscrew.
Tighten the capscrew.
Torque Value: 23 N•m [ 17 ft-lb ]
Finishing Steps
Automotive with CM870
• Install the exhaust pressure sensor tube. Refer to
Procedure 011-027.
• Install the exhaust gas pressure sensor. Refer to
Procedure 019-376 in the Troubleshooting and
Repair Manual CM870 Electronic Control System
Signature and ISX Engines, Bulletin 4021334.
Signature, ISX, and QSX15 Engi [...] Aftertreatment Diesel Particulate Filter
Section 11 - Exhaust System - Group 11 Page 11-71
WARNING
During regeneration, exhaust gas temperature could
reach 800°C [1500°F], and exhaust system surface
temperature could exceed 700°C [1300°F], which is
hot enough to ignite or melt common materials, and
to burn people. The exhaust and exhaust components
can remain hot after the vehicle has stopped moving.
To avoid the risk of fire, property damage, burns or
other serious personal injury, allow the exhaust
system to cool before beginning this procedure or
repair and make sure that no combustible materials
are located where they are likely to come in contact
with hot exhaust or exhaust components.
CAUTION
The aftertreatment diesel oxidation catalyst elements
contained in the aftertreatment system are made of
brittle material. Do not drop or strike the side of the
aftertreatment system as damage to the
aftertreatment diesel oxidation catalyst element can
result.
Due to the number of various exhaust aftertreatment
applications, this procedure contains generic information.
Not all illustrations within this procedure will represent the
applications.
The aftertreatment system is composed of four sections.
These sections are:
1. Inlet
2. Aftertreatment Diesel Oxidation Catalyst
3. Aftertreatment Diesel Particulate Filter
4. Outlet.
NOTE: In some applications, the aftertreatment diesel
oxidation catalyst can be integrated into the inlet of the
exhaust aftertreatment.
Preparatory Steps
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.
Disconnect the vehicle batteries. Refer to Procedure
013-009 (Battery Cables and Connections) in Section 13.
Disconnect the aftertreatment particulate filter differential
pressure sensor tubes, if necessary. Refer to Procedure
011-047 (Aftertreatment Diesel Particulate Filter
Differential Pressure Sensor Tubes) in Section 11.
Aftertreatment Diesel Particulate Filter Signature, ISX, and QSX15 Engi [...]
Page 11-72 Section 11 - Exhaust System - Group 11
Remove
Mark the direction of exhaust flow on the outside of the
aftertreatment to aid in installation.
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.
CAUTION
The aftertreatment diesel oxidation catalyst elements
contained in the aftertreatment system are made of
brittle material. Do not drop or strike the side of the
aftertreatment system as damage to the
aftertreatment diesel oxidation catalyst element can
result.
NOTE: If necessary, remove additional mounting
hardware to remove the aftertreatment diesel particulate
filter from the vehicle.
Remove the v-band clamps from the inlet and outlet
flanges of the aftertreatment diesel particulate filter.
Separate the flanges by approximately 25 mm [1 in] to
allow removal over the gasket retainer rings.
Remove and discard the gaskets.
Signature, ISX, and QSX15 Engi [...] Aftertreatment Diesel Particulate Filter
Section 11 - Exhaust System - Group 11 Page 11-73
CAUTION
Do not use an open flame to burn off soot
accumulation from the face of the aftertreatment
diesel particulate filter.
CAUTION
Do not scrape off soot accumulation from the face of
the aftertreatment diesel particulate filter.
NOTE: The aftertreatment diesel particulate filter relies on
gas flow through the walls to collect soot. To accomplish
gas flow through the walls of the filter, every other cell on
the face of the filter is plugged with a ceramic material.
Therefore it is not possible to see light straight through
the holes in the aftertreatment diesel particulate filter.
Remove any residual gasket material from the flanges on
the aftertreatment diesel particulate filter with a scraping
tool.
Avoid dropping fragments of gasket material into the
aftertreatment diesel particulate filter.
NOTE: It is not possible to inspect the outlet of the
aftertreatment diesel oxidation catalyst and inlet of the
aftertreatment diesel particulate filter on aftertreatment
systems with a joined aftertreatment diesel oxidation
catalyst - aftertreatment diesel particulate filter.
Install
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.
Install new gaskets on the inlet and outlet of the
aftertreatment diesel particulate filter canister.
NOTE: In some applications, a locating tab was integrated
into the gasket retaining ring. The locating tab will prevent
the jointed aftertreatment diesel oxidation catalyst -
aftertreatment diesel particulate filter from being installed
backwards, and will restrict the rotational orientation that
the filter can be installed.
NOTE: On vertical aftertreatment orientations, a
aftertreatment diesel particulate filter differential pressure
sensor tube support can be present. Be sure that the
support is aligned with the tube prior to installing the filter.
Loosely tighten the v-band clamps to allow rotation for
final alignment of the differential pressure sensor tubes.
Signature, ISX, and QSX15 Engi [...] Aftertreatment Diesel Particulate Filter
Section 11 - Exhaust System - Group 11 Page 11-75
Finishing Steps
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.
Connect the exhaust gas temperature sensor electrical
connector(s) to the wiring harness, if necessary. Refer to
Procedure 019-376 (Exhaust Gas Pressure Sensor) in
Sectrion 19 in the CM871 and CM876 Electronic Control
System, ISX and ISM Engines Troubleshooting and
Repair Manual, Bulletin 4021560.
Connect the exhaust gas pressure sensor tubes, if
necessary. For Signature, ISX, or QSX15, refer to
Procedure 011-027 (Exhaust Gas Pressure Sensor Tube)
in Section 11 in the Signature, ISX, and QSX15 Service
Manual, Bulletin 3666239. For ISM, ISMe, or QSM11,
refer to Procedure 011-027 (Exhaust Gas Pressure Sensor
Tube) in Section 11 in the ISM, ISMe, and QSM11 Engines
Service Manual, Bulletin 3666322.
Tighten the v-band clamps.
Torque Value: 20 N•m [ 180 in-lb ]
Connect the vehicle batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
Operate the vehicle on an engine dynamometer or
perform a road test with the engine at rated load for a
minimum of 5 minutes to make sure the aftertreatment
system is performing properly. Refer to Procedure
014-005 (Engine Testing (Engine Dynamometer)) in
Section 14.
Check for exhaust leaks.
Check for fault codes.
Aftertreatment Fuel Injector Signature, ISX, and QSX15 Engi [...]
Page 11-76 Section 11 - Exhaust System - Group 11
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of inaccordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
• Drain the coolant. Refer to Procedure 008-018 in the
Signature, ISX, QSX15 Service Manual, Bulletin
3666239 or in the ISM, ISMe, and QSM11 Service
Manual, Bulletin 3666322.
• Disconnect the fuel lines and coolant lines. Refer to
Procedure 011-051.
• Disconnect the wiring harness from the
aftertreatment injector.
• Remove the adapter tube and injector as an
assembly. Refer to Procedure 011-043.
Remove
Remove the gasket.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the injector using safety solvent.
Inspect the injector tip.
Some carboning can occur on the tip of the injector.
Saturate the tip of the injector with safety solvent. Mineral
based solvents can be used if results with safety solvent
are not acceptable.
Clean the injector tip with a non-abrasive brush.
Dry the injector tip with compressed air.
Inspect for cracks or other damage to the injector tip.
Replace if necessary.
Clean the adapter tube injector mounting surface. Refer
to Procedure 011-043.
Install
Attach the heat shield to the injector.
Install a new high temperature EZ tie to hold 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.
Torque Value: 14 N•m [ 124 in-lb ]
Signature, ISX, and QSX15 Engi [...] Aftertreatment Adapter Pipe
Section 11 - Exhaust System - Group 11 Page 11-79
Finishing Steps
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
• Connect the fuel line and coolant lines. Refer to
Procedure 011-051.
• Connect the adapter pipe to the turbocharger. Refer
to Procedure 011-043
• Connect the wiring harness to the aftertreatment
injector.
Fill the cooling system. Refer to Procedure 008-018 in the
Signature, ISX, QSX15 Service Manual, Bulletin 3666239
or Procedure 008-018 in the ISM, ISMe, and QSM11
Service Manual, Bulletin 3666322.
Start the engine and check for leaks.
If damage 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.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environment regulations.
• Drain the coolant. Refer to Procedure 008-018 in the
Signature, ISX, and QSM11 Service Manual, Bulletin
3666239 or Procedure 008-018 in the ISM, ISMe, and
QSM11 Service Manual, Bulletin 3666322.
• Disconnect the aftertreatment injector and coolant
lines. Refer to Procedure 011-051.
• Disconnect the electrical connection.
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.
Refer to Procedure 011-042.
Aftertreatment Adapter Pipe Signature, ISX, and QSX15 Engi [...]
Page 11-80 Section 11 - Exhaust System - Group 11
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Saturate the inside of the adapter pipe with safety solvent.
Mineral based solvents can be used if results from safety
solvent are not acceptable.
Clean the inside of the adapter pipe with a non-abrasive
brush.
Saturate the injector mounting pad with safety solvent.
Clean the mounting surface with a non-abrasive brush.
Dry with compressed air.
Install
Install the aftertreatment injector assembly onto the
adapter pipe. Refer to Procedure 011-042.
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.
Torque Value: 11 N•m [ 97 in-lb ]
Finishing Steps
• Connect the electrical connection.
• Connect the aftertreatment injector coolant lines.
Refer to Procedure 011-051.
Fill the cooling system. Refer to Procedure 008-018 in the
Signature, ISX, and QSM11 Service Manual, Bulletin
3666239 or Procedure 008-018 in the ISM, ISMe, QSM11
Service Manual, Bulletin 3666322.
Start the engine and check for leaks.
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).
EGR Valve Mounting Bracket Signature, ISX, and QSX15 Engi [...]
Page 11-82 Section 11 - Exhaust System - Group 11
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).
Torque Value: 40 N•m [ 30 ft-lb ]
Tighten the rear support bracket capscrew into the back
of the engine block (2).
Torque Value: 40 N•m [ 30 ft-lb ]
Finishing Steps
• Connect the aftertreatment fuel injector lines and
bulkhead support bracket to the EGR valve mounting
bracket. Refer to Procedure 011-051.
• Install the EGR valve and a new EGR seal. Refer to
Procedure 011-022.
• Install the front and rear EGR connection tubes.
Refer to Procedure 011-025.
• Install the EGR valve heat shield. Refer to Procedure
011-032.
• Operate the engine and check for leaks.
Signature, ISX, and QSX15 Engi [...] Aftertreatment Diesel Particulate Filter Differential P [...]
Section 11 - Exhaust System - Group 11 Page 11-83
Preparatory Steps
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.
CAUTION
The aftertreatment diesel particulate filter and
catalyst can remain hot for long periods of time after
the engine has stopped.
Disconnect the vehicle batteries. Refer to Procedure
013-009.
Disconnect the aftertreatment wiring harness from the
aftertreatment diesel particulate filter differential pressure
sensor. Refer to Procedure 019-443 in the
Troubleshooting and Repair CM871 and CM876
Electronic Control System ISX and ISM Engines, Bulletin
4021560.
Remove the aftertreatment diesel particulate filter
differential pressure sensor tubes. Refer to Procedure
011-047.
Remove the aftertreatment diesel particulate filter
differential pressure sensor. Refer to Procedure 019-376
in the Troubleshooting and Repair CM871 and CM876
Electronic Control System ISX and ISM Engines, Bulletin
4021560.
Remove
Remove the nut on the aftertreatment diesel particulate
filter differential pressure sensor mounting bracket strap.
NOTE: A cylindrical locating tab may be welded to the
outside of the catalyst canister to position the differential
pressure sensor mounting bracket. Note the orientation of
the mounting bracket prior to removal.
NOTE: Remove the differential pressure sensor mounting
bracket and strap.
Install
CAUTION
The aftertreatment system must be installed so the
aftertreatment diesel particulate filter differential
pressure sensor tubes slope downward to drain
condensation away from the differential pressure
sensor.
NOTE: A cylindrical locating tab may be welded to the
outside of the catalyst canister to position the differential
pressure sensor mounting bracket.
NOTE: Make sure the aftertreatment system is oriented
so the aftertreatment diesel particulate filter differential
pressure sensor is installed in the same orientation noted
during disassembly.
Install the differential pressure sensor mounting bracket
and strap. Be sure to align the cylindrical locating tab, if
present, with the mounting bracket as noted during
removal.
Apply a coating of anti-seize compound to the threads of
the aftertreatment diesel particulate filter differential
pressure sensor mounting bracket strap.
Install the nut on the aftertreatment diesel particulate filter
differential pressure sensor mounting bracket strap.
Tighten the differential pressure sensor mounting bracket
strap.
Torque Value: 7 N•m [ 62 in-lb ]
Aftertreatment Diesel Particulate Filter Differential P [...] Signature, ISX, and QSX15 Engi [...]
Page 11-86 Section 11 - Exhaust System - Group 11
Finishing Steps
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.
Install the aftertreatment diesel particulate filter
differential pressure sensor. Refer to Procedure 019-443
in the Troubleshooting and Repair CM871 and CM876
Electronic Control System ISX and ISM Engines, Bulletin
4021560.
Install the aftertreatment diesel particulate filter
differential pressure sensor tubes. Refer to Procedure
011-047.
Connect the vehicle batteries. Refer to Procedure
013-009.
Remove
CAUTION
The aftertreatment diesel particulate filter differential
pressure sensor will not operate properly if the
differential pressure sensor tubes are not connected
to the correct port. Mark the differential pressure
sensor tube connection port locations before
disconnecting.
NOTE: The mounting location of the aftertreatment diesel
particulate filter differential pressure sensor varies with
exhaust aftertreatment orientation and OEM mounting
location.
Remove the spring clamps from the stainless steel tube
end of the flexible hose sections attached to the exhaust
gas filter pressure sensor.
Loosen the aftertreatment diesel particulate filter
differential pressure sensor tube nuts.
If p-clips or tube clamps are used to hold the exhaust gas
filter pressure sensor tubes on the exhaust aftertreatment
system, mark their location prior to removal.
CAUTION
If the flexible hose section between the differential
pressure sensor tube and the differential pressure
sensor are difficult to remove, cut and replace the
hose. Twisting or bending the hose can damage the
pressure sensor.
Remove the p-clips or tube clamp mounting capscrews, if
necessary.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Inspect the inside of the tube.
If the tube is partially clogged, saturate the inside of the
tube with a mineral based solvent, or equivalent.
Carefully clean debris from the mouth of the tubes, make
sure not to damage the tube.
If the tube is fully clogged or otherwise unable to be
cleaned, the tube must be replaced.
Clean the tube with safety solvent.
Dry the tube with compressed air.
Check the tube for cracks and thread damage. Replace
the tube, if damage is found.
Aftertreatment Diesel Particulate Filter Differential P [...] Signature, ISX, and QSX15 Engi [...]
Page 11-88 Section 11 - Exhaust System - Group 11
Install
CAUTION
The aftertreatment diesel particulate filter differential
pressure sensor will not operate properly if the
differential pressure sensor tubes are not connected
to the correct port. Install the differential pressure
sensor tubes as noted during disassembly.
CAUTION
The aftertreatment system must be installed so the
aftertreatment diesel particulate filter differential
pressure sensor tubes slope downward to drain
condensation away from the differential pressure
sensor.
The aftertreatment diesel particulate filter differential
pressure sensor port closest to the sensor mounting
bracket connects upstream of the aftertreatment diesel
particulate filter.
NOTE: In vertical aftertreatment orientations, an
aftertreatment diesel particulate filter differential pressure
sensor tube support can be present. Be sure the
differential pressure tubes are seated in the support clip.
Apply a coating of Locite™ 80209, 51002, 76732, copper
or silver grade, or equivalent to the threads on the
differential pressure sensor tubes prior to assembly. Do
not allow Loctite™ to enter inside of the differential
pressure sensor tubes. This can cause a blockage.
Minimum Loctite Anti-seize temperature range
specifications: 1600°F [870°C].
Install the differential pressure sensor tubes on the
aftertreatment system.
Attach the flexible hose sections of the differential
pressure sensor tubes to the differential pressure sensor
using two spring clamps.
NOTE: Make sure the differential pressure sensor tubes
are not making contact with each other or any other
vehicle components prior to tightening the differential
pressure sensor tube nuts.
NOTE: Tighten the aftertreatment diesel particulate filter
differential pressure sensor tube nuts.
Torque Value: 17 N•m [ 150 in-lb ]
Install the p-clips or the tube clamps that hold the exhaust
gas filter pressure sensor tubes on the exhaust
aftertreatment system.
Tighten the p-clips or the tube clamp bolts, if necessary.
Torque Value: 14 N•m [ 124 in-lb ]
Operate the vehicle on a dynamometer or perform a road
test with the engine at rated load for a minimum of 5
minutes to make sure the aftertreatment system is
performing properly.
Check for fault codes and exhaust leaks.
Aftertreatment Inlet and Outlet Signature, ISX, and QSX15 Engi [...]
Page 11-90 Section 11 - Exhaust System - Group 11
WARNING
During regeneration, exhaust gas temperature could
reach 800°C [1500°F], and exhaust system surface
temperature could exceed 700°C [1300°F], which is
hot enough to ignite or melt common materials, and
to burn people. The exhaust and exhaust components
can remain hot after the vehicle has stopped moving.
To avoid the risk of fire, property damage, burns or
other serious personal injury, allow the exhaust
system to cool before beginning this procedure or
repair and make sure that no combustible materials
are located where they are likely to come in contact
with hot exhaust or exhaust components.
CAUTION
The catalyst elements contained in the aftertreatment
system are made of brittle material. Do not drop or
strike the side of the aftertreatment system as damage
to the catalyst element can result.
Due to the number of various exhaust aftertreatment
applications, this procedure has been written to be
generic. Illustrations within this procedure will not
represent all applications.
The aftertreatment system is composed of four sections.
These sections are:
1. Inlet
2. Aftertreatment diesel oxidation catalyst
3. Aftertreatment diesel particulate filter
4. Outlet.
NOTE: In some applications, the catalyst can be
integrated into the inlet of the exhaust aftertreatment
system.
Signature, ISX, and QSX15 Engi [...] Aftertreatment Inlet and Outlet
Section 11 - Exhaust System - Group 11 Page 11-91
Preparatory Steps
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.
CAUTION
The aftertreatment diesel particulate filter differential
pressure sensor will not operate properly if the
differential pressure sensor tubes are not connected
to the correct port. Mark the differential pressure
sensor tube connection locations before
disconnecting.
Disconnect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
Mark the direction of exhaust flow to aid in assembly.
Draw an orientation reference line across each of the v-
band clamps, aftertreatment canister sections, and
connection points to the tailpipe. This will aid in lining up
the sections and the v-band clamps to their original
orientation during installation.
Mark the number of each exhaust gas temperature sensor
connector prior to disconnecting the exhaust temperature
sensor from the wiring harness.
Disconnect the exhaust gas temperature sensor wiring
harness connectors. Refer to Procedure 019-376 (Exhaust
Gas Pressure Sensor) in Section 19 in the CM871 and
CM876 Electronic Control Systems, ISX and ISM Engines
Troubleshooting and Repair Manual, Bulletin 4021560.
Remove the mounting straps or bolts from the inlet, if
necessary. Refer to the OEM troubleshooting and repair
manual.
Remove the mounting straps or bolts from the outlet, if
necessary. Refer to the OEM troubleshooting and repair
manual.
Disconnect the aftertreatment diesel particulate filter
differential pressure sensor tube from the outlet, if
necessary. Refer to Procedure 011-047 (Aftertreatment
Diesel Particulate Filter Differential Pressure Sensor
Tubes) in Section 11.
Aftertreatment Inlet and Outlet Signature, ISX, and QSX15 Engi [...]
Page 11-92 Section 11 - Exhaust System - Group 11
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.
CAUTION
The catalyst elements contained in the aftertreatment
system are made of brittle material. Do not drop or
strike the side of the aftertreatment system as damage
to the catalyst element can result.
In some applications, the catalyst is integrated into the
aftertreatment inlet. Refer to Procedure 011-046
(Aftertreatment Diesel Particulate Filter Differential
Pressure Sensor Mounting Bracket) in Section 11 for
removal of the differential pressure sensor mounting
bracket.
Support the catalyst and aftertreatment diesel particulate
filter to avoid applying a cantilevered load on the v-band
joints.
Remove the Torca® or v-band clamp used to connect the
aftertreatment system to the exhaust pipe, if necessary.
Remove the v-band clamp connecting the inlet to the
catalyst, if necessary.
Remove the v-band clamp connecting the outlet to the
aftertreatment diesel particulate filter, if necessary.
Remove and discard the gaskets.
Disassemble
Remove the exhaust gas temperature sensor from the
boss in the inlet and/or outlet, if necessary. Refer to
Procedure 019-378 (EGR Temperature Sensor) in Section
19 in the CM871 and CM876 Electronic Control Systems,
ISX and ISM Engines Troubleshooting and Repair
Manual, Bulletin 4021560.
Assemble
Install the exhaust gas temperature sensor in the boss on
the inlet and/or outlet. Refer to Procedure 019-378 (EGR
Temperature Sensor) in the CM871 and CM876 Electronic
Control Systems, ISX and ISM Engines Troubleshooting
and Repair Manual, Bulletin 4021560.
Install
Apply a coat of anti-seize compound on the treads of the
v-band clamps and Torca® clamps.
The aftertreatment outlet section contains a differential
pressure sensor tube boss. Align the differential pressure
sensor tube boss with the differential pressure sensor tube
nut prior to tightening the v-band clamp or the Torca®
clamp.
NOTE: If the Torca® clamp is replaced during service, be
sure to replace it with another Torca® clamp. Do not use
a u-bolt as a replacement clamp. U-bolt clamps can crush
the tailpipe and make it difficult to remove the
aftertreatment system for future service.
Aftertreatment Inlet and Outlet Signature, ISX, and QSX15 Engi [...]
Page 11-94 Section 11 - Exhaust System - Group 11
Finishing Steps
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.
CAUTION
If the temperature sensor wire connectors are not
connected to the proper locations after installation,
aftertreatment system damage can result.
CAUTION
The aftertreatment diesel particulate filter differential
pressure sensor will not operate properly if the
differential pressure sensor tubes are not connected
to the correct port. Install the differential pressure
sensor tubes as noted during disassembly.
Install the mounting straps or bolts to the inlet, if
necessary. Refer to the OEM troubleshooting and repair
manual.
Install the mounting straps or bolts from the outlet, if
necessary. Refer to the OEM troubleshooting and repair
manual.
Connect the exhaust gas temperature sensor wiring
harness connectors, if necessary. Refer to Procedure
019-378 (EGR Temperature Sensor) in Section 19 in the
CM871 and CM876 Electronic Control Systems, ISX and
ISM Engines Troubleshooting and Repair Manual, Bulletin
4021560.
Connect the aftertreatment diesel particulate filter
differential pressure sensor tube to the outlet, if
necessary. Refer to Procedure 011-047 (Aftertreatment
Diesel Particulate Filter Differential Pressure Sensor
Tubes) in Section 11.
Connect the vehicle batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
Operate the vehicle on a dynamometer or perform a road
test with the engine at rated load for a minimum of 5
minutes to make sure the aftertreatment system is
performing properly. For Signature, ISX, or QSX15, refer
to Procedure 010-024 (Air Leaks, Air Intake and Exhaust
Systems) in Section 10 in the Signature, ISX, and QSX15
Service Manual, Bulletin 3666239. For ISM, ISMe, or
QSM11, refer to Procedure 010-024 (Air Leaks, Air Intake
and Exhaust Systems) in Section 10 in the ISM, ISMe, and
QSM11 Engines Service Manual, Bulletin 3666322.
Aftertreatment Diesel Oxidation Catalyst Signature, ISX, and QSX15 Engi [...]
Page 11-96 Section 11 - Exhaust System - Group 11
Preparatory Steps
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 arching, remove the negative
(-) battery cable first and attach the negative (-) batter
cable last.
CAUTION
Catalyst can remain hot for a long time after the
engine has stopped.
• Disconnect the batteries. Refer to Procedure
013-009 (Battery Cables and Connections) in Section
13.
• Disconnect the aftertreatment exhaust gas
temperature sensor electrical connector(s) from the
wiring harness, if necessary. Refer to Procedure
019-449 (Exhaust Gas Temperature Sensor) in
Section 19 of the Troubleshooting and Repair
CM871 and CM876 Electronic Control System ISX
and ISM Engines, Bulletin 4021560.
• Disconnect the aftertreatment diesel particulate filter
differential pressure sensor tubes, if necessary.
Refer to Procedure 011-047 (Aftertreatment Diesel
Particulate Filter Differential Pressure Sensor
Tubes) in Section 11.
• Disconnect the aftertreatment diesel particulate filter
differential pressure sensor mounting bracket, and
strap if applicable. Refer to Procedure 011-046
(Aftertreatment Diesel Particulate Filter Differential
Pressure Sensor Mounting Bracket) in Section 11.
Signature, ISX, and QSX15 Engi [...] Aftertreatment Diesel Oxidation Catalyst
Section 11 - Exhaust System - Group 11 Page 11-97
Remove
Draw an orientation reference line across each of the v-
band clamps, aftertreatment canister sections, and
connection points to the tailpipe. This will aid in linking up
sections and v-band clamps to their original orientation
during installation.
Mark the direction of exhaust flow on both the catalyst
section and the aftertreatment diesel particulate filter
section to aid in assembly.
WARNING
The component weighs 23 kg [50 lbs] or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift the component.
CAUTION
The catalyst elements contained in the aftertreatment
system are made of brittle material. Do not drop or
strike the side of the aftertreatment system as damage
to the catalyst element can result.
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 camp to
not be reusable.
NOTE: If necessary, remove additional mounting
hardware to remove the catalyst from the vehicle.
Remove the v-band clamps from the inlet and outlet of the
catalyst.
Separate the component sections by approximately one-
half inch to allow removal over the gasket retainer rings.
Remove and discard the gaskets.
Aftertreatment Diesel Oxidation Catalyst Signature, ISX, and QSX15 Engi [...]
Page 11-98 Section 11 - Exhaust System - Group 11
CAUTION
Do not use an open flame to burn off soot
accumulation from the face of the aftertreatment
diesel particulate filter.
CAUTION
Do not scrape off soot accumulation from the face of
the aftertreatment diesel particulate filter.
Remove any residual gasket material from the flanges on
the aftertreatment diesel particulate filter with a putty
knife.
Avoid dropping fragments of gasket material into the
aftertreatment diesel particulate filter.
NOTE: If the aftertreatment diesel particulate filter is being
inspected due to progressive damage that introduced
coolant or engine oil, or excessive fuel into the exhaust,
inspect the tailpipe from the turbocharger outlet to the
aftertreatment diesel oxidation catalyst.
If a trail of liquid coolant, engine oil, or fuel can be seen
from the turbocharger outlet to the aftertreatment diesel
oxidation catalyst, the aftertreatment diesel oxidation
catalyst must be replaced.
If a trail of coolant, engine oil, or fuel can be seen exiting
the turbocharger outlet, the tailpipe between the
turbocharger outlet and aftertreatment diesel oxidation
catalyst must be cleaned. Refer to Procedure 011-048
(Aftertreatment Inlet and Outlet) in Section 11.
Signature, ISX, and QSX15 Engi [...] Aftertreatment Diesel Oxidation Catalyst
Section 11 - Exhaust System - Group 11 Page 11-99
WARNING
The material captured in a diesel particulate filter may
contain elevated concentrations of metals, primarily
zinc and molybdenum, and possibly polynuclear
aromatic hydrocarbons that may be regulated. These
materials must be characterized, handled, and
disposed of according to applicable local regulations.
In addition, due to the presence of the above-listed
chemicals and other potentially toxic components
such as oxides of calcium, zinc, phosphorous,
silicone, sulfur, and iron, exhaust filter maintenance
must be completed only by appropriately trained
personnel.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Inspect the outlet of the aftertreatment diesel oxidation
catalyst for loose debris and soot. Use a rag to wipe off
any soot. Use a HEPA vacuum to remove any remaining
loose debris.
NOTE: Use a vacuum bag, such as a drywall dust bag to
capture the soot that is removed.
CAUTION
Use only a rubber-tipped air gun near the catalyst
material. Damage will result if a metal air gun strikes
the catalyst material.
Adjust the air supply for a rubber-tipped air gun to 207 kPa
[30 psi].
Switch on the vacuum. The vacuum and service tool kit is
properly installed if the air flow through the aftertreatment
diesel oxidation catalyst is opposite to exhaust flow.
Exhaust flow is indicated by an arrow on the canister of
the diesel oxidation catalyst.
Blow compressed air across the outlet face of the
aftertreatment diesel oxidation catalyst for approximately
5 minutes.
Assemble
Install the exhaust gas temperature sensor into the
catalyst section, if necessary. Refer to Procedure 019-378
(Exhaust Gas Temperature Sensor) in Section 19 of the
Troubleshooting and Repair CM871 and CM876
Electronic Control System ISX and ISM Engines, Bulletin
4021560.
Aftertreatment Diesel Oxidation Catalyst Signature, ISX, and QSX15 Engi [...]
Page 11-102 Section 11 - Exhaust System - Group 11
Install
WARNING
The component weighs 23 kg [50 lbs] or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift the component.
Install new gaskets on the inlet and outlet of the exhaust
gas catalyst.
Install the catalyst.
NOTE: In some applications, a locating tab was integrated
into the gasket retaining ring. The locating tab will prevent
the catalyst from being installed backwards, and will
restrict the orientation in which the aftertreatment catalyst
can be installed.
Tighten the v-band clamps
Torque Value: 20 N•m [ 177 in-lb ]
Install the aftertreatment diesel particulate filter
differential pressure sensor tubes into the catalyst section.
Torque Value: 17 N•m [ 150 in-lb ]
Finishing Steps
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 arching, remove the negative
(-) battery cable first and attach the negative (-) batter
cable last.
• Connect the aftertreatment exhaust gas temperature
sensor electrical connector(s) to the wiring harness,
if necessary. Refer to Procedure 019-449 (Exhaust
Gas Temperature Sensor) in Section 19 of the
Troubleshooting and Repair CM871 and CM876
Electronic Control System ISX and ISM Engines,
Bulletin 4021560.
• Connect the aftertreatment diesel particulate filter
differential pressure sensor tubes, if necessary.
Refer to Procedure 011-047 (Aftertreatment Diesel
Particulate Filter Differential Pressure Sensor
Mounting Bracket) in Section 11.
• Connect the aftertreatment diesel particulate filter
differential pressure sensor mounting bracket, and
strap if necessary. Refer to Procedure 011-046
(Aftertreatment Diesel Particulate Filter Differential
Pressure Sensor Mounting Bracket) in Section 11.
• Connect the batteries. Refer to Procedure 013-009
(Battery Cables and Connections) in Section 13.
• Operate the engine, check for fault codes and
exhaust leaks.
Signature, ISX, and QSX15 Engi [...] Aftertreatment System
Section 11 - Exhaust System - Group 11 Page 11-103
Preparatory Steps
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 first.
Refer to the OEM troubleshooting and repair manual for
aftertreatment system removal instructions. The OEM will
designate whether aftertreatment system components are
to be removed as individual components or as a complete
system for service.
NOTE: Mark the direction of exhaust flow on the outside
of the aftertreatment system to aid in installation.
Mark the orientation of the exhaust gas particulate trap
differential pressure sensor to aid in installation.
Disconnect the vehicle batteries. Refer to Procedure
013-009.
Remove
System - Remove the straps or bolts securing the
aftertreatment system to the vehicle chassis. Refer to the
OEM troubleshooting and repair manual.
Remove the v-band from the inlet, and the Torca™ clamp
from the outlet of the aftertreatment system. Refer to
Procedure 011-048.
Disconnect the aftertreatment diesel particulate filter
differential pressure sensor wiring harness connector.
Refer to Procedure 019-370 in the Troubleshooting and
Repair Manual CM871 and CM876 Electronic Control
System ISX and ISM Engines, Bulletin 4021560.
Aftertreatment System Signature, ISX, and QSX15 Engi [...]
Page 11-104 Section 11 - Exhaust System - Group 11
Disassemble
System - To remove the aftertreatment inlet or outlet
sections. Refer to Procedure 011-048.
To remove the catalyst. Refer to Procedure 011-049.
To remove the aftertreatment diesel particulate filter.
Refer to Procedure 011-041.
For aftertreatment diesel particulate filter cleaning
instructions, refer to Procedure 011-041.
Assemble
System - To install the aftertreatment inlet or outlet
sections. Refer to procedure 011-048.
To install the aftertreatment diesel particulate filter. Refer
to Procedure 011-041.
To install the catalyst. Refer to Procedure 011-049.
Install
NOTE: Make sure that the aftertreatment system is
oriented so that the aftertreatment diesel particulate filter
differential pressure sensor is installed in the same
orientation noted during disassembly.
NOTE: The aftertreatment system must be installed so
that the aftertreatment diesel particulate filter differential
pressure sensor tubes slope downward to drain
condensation away from the differential pressure sensor.
NOTE: Make sure that the differential pressure sensor
tubes are not making contact with each other or any other
vehicle components prior to tightening the Torca® clamps
or v-band clamps.
System - Install the straps or bolts that secure the
aftertreatment system to the vehicle chassis. Refer to the
OEM troubleshooting and repair manual.
Install the inlet and outlet of the aftertreatment on to the
exhaust pipe. Refer to Procedure 011-048.
NOTE: If a Torca™ clamp is replaced during service, be
sure to replace it with another Torca™ clamp. Do not use
a u-bolt as a replacement clamp. U-bolt clamps can crush
the tailpipe and make it difficult to remove the
aftertreatment system for future service.
Tighten the Torca™ clamps used to secure the inlet and
outlet of the aftertreatment to the exhaust pipe. Refer to
Procedure 011-048.
Connect the exhaust temperature sensor to the wiring
harness connectors. Refer to Procedure 011-048.
Connect the aftertreatment diesel particulate filter
differential pressure sensor wiring harness connector.
Refer to Procedure 019-013 in the Troubleshooting and
Repair Manual CM871 and CM876 Electronic Control
System ISX and ISM Engines, Bulletin 4021560.
Aftertreatment Injector Lines Signature, ISX, and QSX15 Engi [...]
Page 11-106 Section 11 - Exhaust System - Group 11
Finishing Steps
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 first.
Connect the battery. Refer to Procedure 013-009.
If the aftertreatment system was being serviced for an
aftertreatment diesel particulate filter cleaning, use
INSITE™ electronic service tool to clear related fault
codes.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
Drain the cooling system. Refer to Procedure 008-018.
Signature, ISX, and QSX15 Engi [...] Aftertreatment Injector Lines
Section 11 - Exhaust System - Group 11 Page 11-107
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[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
environmental regulations.
Drain the cooling system. Refer to Procedure 008-018.
Remove
Automotive With CM871
Disconnect the aftertreatment injector coolant supply line
at the inlet to the aftertreatment injector.
Disconnect the aftertreatment injector coolant supply line
at the EGR cooler.
Remove the aftertreatment injector coolant supply 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.
Clean the area around the fuel filter head and filter.
Remove the fuel filter with filter wrench, Part Number
3375249.
Aftertreatment Injector Lines Signature, ISX, and QSX15 Engi [...]
Page 11-108 Section 11 - Exhaust System - Group 11
Disconnect the wiring harness from the shut off valve, fuel
drain valve, and pressure sensor.
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacture's recommendations
for use. Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the aftertreatment injector coolant lines with a
safety solvent.
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacture's recommendations
for use. Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the aftertreatment injector coolant lines with a
safety solvent.
Install
Automotive With CM871
Connect the aftertreatment injector coolant supply line to
the aftertreatment injector and the EGR cooler.
Torque Value: 24 N•m [ 18 ft-lb ]
Finishing Steps
Automotive With CM871
Connect the wiring harness to pressure sensor, shutoff
valve, and fuel drain valve.
Install the fuel filter.
Fill the cooling system. Refer to Procedure 008-018.
Operate the engine and check for leaks.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Make sure the area around the fuel shutoff manifold is
clear of debris. Use compressed air to clean area and
remove any loose dirt particles.
Disconnect the wiring harness from the aftertreatment fuel
shutoff valve, aftertreatment fuel drain valve.
Remove the aftertreatment fuel injector lines from the fuel
shutoff manifold. Refer to Procedure 011-051.
Remove
Automotive With CM871
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.
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.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Shutoff Valve, Drain Valve, and Pressure Sensor -Clean
the shutoff valve, drain valve, and pressure sensor using
safety solvent.
Inspect the o-ring for cuts or wear. Replace the o-ring if
necessary.
Inspect the threads for damage.
Replace defective components if necessary.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Shutoff Manifold - Clean the shutoff manifold with safety
solvent.
Use compressed air to clean the shutoff manifold of any
debris.
Make sure the filter screen and orifice are still in the fuel
inlet side of the shutoff valve manifold.
Inspect the threads of the shutoff manifold for damage. If
threads are damage replace shutoff manifold.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Shutoff Valve, Drain Valve, and Pressure Sensor - Clean
the shutoff valve, drain valve, and pressure sensor using
safety solvent.
Inspect the o-ring for cuts or wear. Replace the o-ring if
necessary.
Inspect the threads for damage.
Replace defective components if necessary.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Shutoff Manifold - Clean the shutoff manifold with safety
solvent.
Use compressed air to clean the shutoff manifold of any
debris.
Make sure the filter screen and orifice are still in the fuel
inlet side of the shutoff valve manifold.
Inspect the threads of the shutoff manifold for damage. If
threads are damage replace shutoff manifold.
Install
Automotive With CM871
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 fuel
drain valve.
Torque Value:
Pressure 14 N•m [ 120 in-lb ]
Sensor
Fuel Shutoff 14 N•m [ 120 in-lb ]
Valve
Fuel Drain 14 N•m [ 120 in-lb ]
Valve
Finishing Steps
Install the aftertreatment injector lines. Refer to Procedure
011-051.
Connect the wiring harness to the fuel shutoff valve, fuel
drain valve and pressure sensor. Refer to Procedure
019-444 in the ISX CM871 and ISM CM876 Electronic
Control System, Troubleshooting and Repair Manual,
Bulletin 4021560.
Signature, ISX, and QSX15 Engi [...] Aftertreatment Fuel Injector Flow
Section 11 - Exhaust System - Group 11 Page 11-123
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
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.
• Drain the engine coolant. Refer to Procedure
008-018 (Cooling System) in Section 8, in the
Signature, ISX, QSX15 Service Manual, Bulletin
3666239.
• Drain the engine coolant. Refer to Procedure
008-018 (Cooling System) in Section 8, in the ISM,
ISMe, and QSM11 Service Manual, Bulletin
3666322.
• Disconnect the fuel line to aftertreatment fuel
injector. Refer to Procedure 011-051 (Aftertreatment
Injector Lines) in Section 11.
• Disconnect coolant lines to the aftertreatment fuel
injector. Refer to Procedure 011-051 (Aftertreatment
Injector Lines) in Section 11.
• Remove the aftertreatment fuel injector from the
exhaust adapter pipe. Refer to Procedure 011-042
(Aftertreatment Fuel Injector) in Section 11.
Setup
Connect the fuel extension line, Part Number 4918519, to
the aftertreatment fuel injector fuel supply line that was
connected to the injector.
Aftertreatment Fuel Injector Flow Signature, ISX, and QSX15 Engi [...]
Page 11-124 Section 11 - Exhaust System - Group 11
CAUTION
Do not connect a 12 VDC supply to the injector as this
will cause permanent damage to the injector.
Connect the aftertreatment fuel injector electrical harness
extension, Part Number 4918518, to the engine harness
and the aftertreatment fuel injector.
Test
Start the engine.
Use INSITE™ electronic service tool to select System Test
in the test mode section of the Aftertreatment Shutoff
Valve and Injector Override Test.
Use INSITE™ electronic service tool to enter a time delay,
if needed.
Click the Start button when ready to perform the test.
Click the OK button when the warning windows pop up, if
the conditions are met.
INSITE™ electronic service tool will start the test and will
inject fuel for 2 minutes and 30 seconds. INSITE™
electronic service tool will automatically disable the
injector at the end of the test. If the test needs to be
stopped before finishing, click the Stop button.
Leak Test
To perform an Aftertreatment Shutoff Valve Leak Test,
turn off the engine.
On the ISX, the lift pump must be disconnected in order
to prevent a surge of fuel from the integrated Fuel System
Module.
Disconnect the fuel drain.
On both the ISX and the ISM, a plug will need to be
installed on the aftertreatment fuel drain line connection
point in order to prevent fuel from leaking.
Hold the fuel drain line over the empty graduated cylinder.
Start and idle the engine for 5 minutes before running the
test.
Finishing Steps
• Drain the engine coolant. Refer to Procedure
008-018 in the Signature, ISX, QSX15 Service
Manual, Bulletin 3666239.
• Drain the engine coolant. Refer to Procedure
008-018 in the ISM, ISMe, and QSM11 Service
Manual, Bulletin 3666322.
• Remove the injector spray tester service tool kit, Part
Number 4818517.
• Install the aftertreatment fuel injector assembly onto
the adapter pipe. Refer to Procedure 011-042
(Aftertreatment Fuel Injector) in Section 11.
• Connect the fuel line to the aftertreatment fuel
injector. Refer to Procedure 011-051 (Aftertreatment
Injector Lines) in Section 11.
• Connect the coolant lines to the aftertreatment fuel
injector. Refer to Procedure 011-051 (Aftertreatment
Injector Lines) in Section 11.
• Fill the engine coolant. Refer to Procedure 008-018
(Cooling System) in Section 8, in the Signature, ISX,
QSX15 Service Manual, Bulletin 3666239.
• Fill the engine coolant. Refer to Procedure 008-018
(Cooling System) in Section 8, in the ISM, ISMe, and
QSM11 Service Manual, Bulletin 3666322.
• Start the engine, check for leaks, and verify that all
fault codes are inactive.
Aftertreatment Fuel Injector Flow Signature, ISX, and QSX15 Engi [...]
Page 11-130 Section 11 - Exhaust System - Group 11
Notes
Signature, ISX, and QSX15 Engi [...]
Section 12 - Compressed Air System - Group 12 Page 12-a
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
bodily injury.
Shut off the engine.
Open the drain cock on the wet tank to release
compressed air from the system.
WARNING
Air discharge lines can be very hot. Be sure the lines
are cool before handling to prevent personal injury.
Remove the air inlet and outlet connections from the air
compressor.
WARNING
The air discharge line must be capable of
withstanding extreme heat and pressure to prevent
personal injury and property damage. Refer to the
OEM specifications.
NOTE: If the total carbon deposit thickness exceeds
specification, remove and clean, or replace the air
discharge line.
Continue to check for carbon buildup in the air discharge
line connections up to the first connection or wet tank.
Clean or replace any lines and fittings with carbon
deposits thicker than 1.6 mm [0.06 in]. Refer to the OEM
specifications for cleaning or replacement instructions.
Air Compressor Carbon Buildup Signature, ISX, and QSX15 Engi [...]
Page 12-2 Section 12 - Compressed Air System - Group 12
Clean
WARNING
Use skin and eye protection when handling caustic
solutions to reduce the possibility of personal injury.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
CAUTION
Do not use a sharp object to remove carbon. The
sealing surfaces can be damaged.
CAUTION
Avoid getting debris and solvents into the clearance
between the piston and bore.
CAUTION
Avoid the use of abrasive products similar to “Scotch
Brite™” because any abrasive grit left after cleaning
will shorten the life of the air compressor.
Remove the compressor head and valve assembly. Refer
to Procedure 012-007.
Remove
Remove the coolant lines.
Remove the air governor or air governor signal line (if
equipped).
Remove the air inlet and outlet connections from the air
compressor.
Remove the four 8-mm capscrews.
Remove the air compressor head and gasket.
Install
Assemble the air compressor using a new gasket.
Install the head and gasket.
Install the four 8-mm capscrews.
Tighten the capscrews in the sequence shown. Use the
torque plus angle method.
Torque Value: Step1 25 N•m [ 18 ft-lb ]
Step2 Rotate 90 degrees.
Air Compressor Unloader and Valve Assembly Signature, ISX, and QSX15 Engi [...]
Page 12-4 Section 12 - Compressed Air System - Group 12
Finishing Steps
Fill the cooling system. Refer to Procedure 008-018 in the
Signature, ISX, and QSX15 Service Manual or Procedure
008-018 in the ISM, ISMe and QSM11 Service Manual .
Operate the engine and check for leaks and proper
operation.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
WARNING
Wear safety glasses or a face shield, as well as
protective clothing, to prevent personal injury when
using a steam cleaner or high-pressure water.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Drain the engine coolant. Refer to Procedure 008-018.
Use steam to clean the air compressor. Dry with
compressed air.
Remove
Remove the coolant lines from the air compressor.
Remove the air connections from the air compressor.
Remove or disconnect the air governor.
Install
Pin the engine crankshaft. Refer to Procedure 001-088.
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 which 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.
Use two elbows and run the locking nuts all the way up
prior to installation
Start threading the elbows in the cylinder head.
Use a 24 mm open-ended wrench to position the elbows.
Install the U-shaped water inlet tube in the left elbow, start
threading the compression nut.
Install the other end of the water inlet tube into the
grommet in the cylinder block.
Air Compressor Signature, ISX, and QSX15 Engi [...]
Page 12-8 Section 12 - Compressed Air System - Group 12
Insert the water outlet tube into the other elbow and start
threading the compression nut.
Install the other end of the water inlet tube into the
grommet in the cylinder block.
Finishing Steps
Fill the engine cooling system. Refer to Procedure
008-018.
Operate the engine and check for leaks.
Signature, ISX, and QSX15 Engi [...] Air Governor (Air Compressor Pumps Continuously)
Section 12 - Compressed Air System - Group 12 Page 12-9
Apply 690 kPa [100 psi] air pressure to the unloader port.
If the air compressor stops pumping (air pressure stops
rising), the air governor is malfunctioning and must be
repaired or replaced, or the air governor mounting gasket
is leaking. Refer to the manufacturer's instructions.
Remove the pipe plugs from the unloader ports used for
accessory air lines.
Install and tighten the accessory air lines.
Connect the line to the unloader valve.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
bodily injury.
Shut off the engine.
Open the drain cock on the wet tank to release air from
the system. Close the drain cock after the pressure is
released.
CAUTION
Do not hold hand too close to the intake port of the
air compressor. Personal injury can result.
Operate the engine to activate the air compressor.
Hold your hand 5 cm [2 in] from the air compressor intake
port. If air is coming out of the intake port, the pressure
relief valve is malfunctioning and the air compressor
cylinder head must be replaced. Refer to Procedure
012-007.
Install the air intake line to the cylinder head. Install the
air governor or air governor line to the air compressor.
Signature, ISX, and QSX15 Engi [...]
Section 13 - Electrical Equipment - Group 13 Page 13-a
Service Tools
Electrical Equipment
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.
Digital Multimeter
Used to test various electrical circuits.
3377161
Alternator (013-001)
Initial Check
Alternator Wiring Test
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
Acid is extremely dangerous and can damage the
machinery and can also cause serious burns. Always
provide a tank of strong soda water as a neutralizing
agent when servicing batteries. Wear goggles and
protective clothing to avoid serious personal injury.
Systems that are 24 VDC must be connected into a
temporary 12 VDC configuration.
Attach the carbon-pile and clip-on ammeter as shown.
Adjust the load from the carbon-pile tester to the rated
performance of the alternator.
Measure the voltage drop in both the positive and negative
circuits.
Add these together and compare the sum to the table
below.
Preparatory Steps
Driven by Cooling Fan Drive Belt
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 arching, remove the negative
(-) battery cable first and attach the negative (-) battery
cable last.
• Remove the battery cables.
• Remove the electrical connection from alternator.
• Remove the cooling fan drive belt. Refer to
Procedure 008-002.
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.
• Disconnect the battery cables.
• Disconnect the electrical connections from the
alternator.
• Remove the alternator drive belt. Refer to Procedure
013-005.
Signature, ISX, and QSX15 Engi [...] Alternator
Section 13 - Electrical Equipment - Group 13 Page 13-5
Remove
Driven by Cooling Fan Drive Belt
Remove the four alternator mounting capscrews.
Remove the alternator from the alternator spacers.
Install
Driven by Cooling Fan Drive Belt
Install the alternator and the four mounting capscrews.
Torque Value: 36 N•m [ 27 ft-lb ]
No alignment is required for the alternator to the alternator
bracket.
Finishing Steps
Driven by Cooling Fan Drive Belt
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.
• Install the cooling fan drive belt. Refer to Procedure
008-002.
• Install the electrical connection to alternator.
• Install the battery cables.
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.
• Install the alternator drive belt. Refer to Procedure
013-005.
• Install the electrical connections to the alternator.
• Connect the battery cables.
Signature, ISX, and QSX15 Engi [...] Drive Belt, Alternator
Section 13 - Electrical Equipment - Group 13 Page 13-7
Install
Using a 1/2-inch drive ratchet and extension, force the belt
tensioner down, install belt, and release tensioner.
Check belt for proper fit into pulley grooves.
Alternator Pulley Signature, ISX, and QSX15 Engi [...]
Page 13-8 Section 13 - Electrical Equipment - Group 13
Adjust
Belt drive systems equipped with an automatic belt
tensioner can not be adjusted. A belt tension gauge will
not give an accurate measure of the belt tension. The
automatic belt tensioner is designed to maintain proper
belt tension over the life of the belt. Only inspection of the
tensioner is required.
The belt tensioner is designed to operate within the limit
of arm movement provided by the cast stops when the belt
length and geometry are correct.
If the tensioner is hitting either of the limits during
operation, check the mounting brackets and the belt
length. Loose brackets, bracket failure, alternator
movement, incorrect belt length, or belt failure can cause
the tensioner to hit the limits.
Clean
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.
Clean the pulley with solvent.
Install
Install key into shaft keyway (if equipped).
Install the alternator pulley with the shoulder of the pulley
towards the alternator.
Lubricate the threads with engine oil and install the nut.
Torque locking nut, hold the shaft with an allen wrench, if
necessary.
Torque Value: 100 N•m [ 74 ft-lb ]
Batteries (013-007)
Initial Check
If conventional batteries (not maintenance-free batteries)
are used, check the electrolyte level in each cell. If it is
low, add distilled water to bring the level up to the top of
all plates. Refer to the battery manufacturer's
specifications.
NOTE: If water is added to the battery, the battery must
be charged before any testing can be accomplished.
With conventional batteries, check the electrolyte specific
gravity with a hydrometer. To check the specific gravity,
the battery temperature will be 26.67°C [80°F]. All cells
will not be less than 1.230. The difference between high
and low readings will not exceed 0.050. If the readings
indicate a difference of more than 0.050, replace the
battery. If the readings indicate less than 0.050 difference
but one or more cells indicate less than 1.230, recharge
the battery.
WARNING
Batteries can emit explosive gases. To avoid personal
injury, always ventilate the compartment before
servicing the batteries. To avoid arcing, remove the
negative (-) battery cable first and attach the negative
(-) battery cable last.
Remove and inspect the battery cables and connections
for cracks or corrosion.
Replace broken terminals, connectors, or cables.
WARNING
Batteries can emit explosive gases. To avoid personal
injury, always ventilate the compartment before
servicing the batteries. To avoid arcing, remove the
negative (-) battery cable first and attach the negative
(-) battery cable last.
Install the cables and tighten the battery connections.
Coat the terminals with grease to prevent corrosion.
WARNING
Make sure the starter switch is in the OFF position to
prevent electrical shock.
Remove the cable connecting the magnetic switch to the
starter solenoid from the magnetic switch terminal.
Connect the leads of the digital multimeter, Part Number
3377161, to the two large switch terminals.
Signature, ISX, and QSX15 Engi [...] Starter Magnetic Switch
Section 13 - Electrical Equipment - Group 13 Page 13-13
WARNING
Make sure the starter switch is in the OFF position to
prevent electrical shock.
Remove the wire connecting the starter switch to the
magnetic switch from the starter switch terminal.
Connect the positive lead of digital multimeter, Part
Number 3377161, to the starter switch terminal and the
negative lead to the chassis or an engine ground location.
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.
• Remove the electrical connections from the
batteries.
• Remove the electrical connections from the starting
motor.
Starting Motor Signature, ISX, and QSX15 Engi [...]
Page 13-18 Section 13 - Electrical Equipment - Group 13
Remove
All Except 50MT With Aluminum Flywheel Housing
Remove the three capscrews, starting motor, and starting
motor spacer (if used).
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.
Tighten the mounting capscrews.
Torque Value:
5/8-11 x 1.75 in 140 N•m [ 103 ft-lb ]
capscrew
5/8-11 x 2.00 in 201 N•m [ 148 ft-lb ]
capscrew
39 MT Starters 129 N•m [ 95 ft-lb ]
(Aluminum
Flywheel
Housing)
39 MT Starters 163 N•m [ 120 ft-lb ]
(Cast Iron
Flywheel
Housing)
Signature, ISX, and QSX15 Engi [...] Starting Motor
Section 13 - Electrical Equipment - Group 13 Page 13-19
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.
Tighten the mounting capscrews.
Torque Value:
5/8-11 x 1.75 in 140 N•m [ 103 ft-lb ]
capscrew
5/8-11 x 2.00 in 201 N•m [ 148 ft-lb ]
capscrew
Finishing Steps
All Applications
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.
• Install the electrical connections to the starting
motor.
• Install the electrical connections to the batteries.
Belt Tensioner, Automatic (Alternator) Signature, ISX, and QSX15 Engi [...]
Page 13-20 Section 13 - Electrical Equipment - Group 13
Clean
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.
Check the tensioner for dirt buildup. If this condition
exists, the tensioner must be removed and steam-
cleaned.
Install
Automotive Applications
Install the tensioner and capscrew.
Torque Value: 56 N•m [ 41 ft-lb ]
Alternator Spacer Signature, ISX, and QSX15 Engi [...]
Page 13-22 Section 13 - Electrical Equipment - Group 13
Remove
Remove the two alternator spacer mounting capscrews.
Remove the alternator spacers.
Signature, ISX, and QSX15 Engi [...] Alternator Spacer
Section 13 - Electrical Equipment - Group 13 Page 13-23
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.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the alternator spacers with solvents.
Dry with compressed air.
Install
NOTE: No special alignment process is required for
alternator spacers to the alternator/refrigerant
compressor mounting bracket.
Install the alternator spacers with roll pins and two
capscrews.
Torque Value: 36 N•m [ 27 ft-lb ]
Alternator Idler Pulley Signature, ISX, and QSX15 Engi [...]
Page 13-24 Section 13 - Electrical Equipment - Group 13
Finishing Steps
Install the following:
• Alternator. Refer to Procedure 013-001.
• Cooling fan drive belt. Refer to Procedure 008-002.
Clean
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the pulley with solvent and dry with compressed air.
Signature, ISX, and QSX15 Engi [...] Bracket, Idler Pulley and Alternator Belt Tensioner
Section 13 - Electrical Equipment - Group 13 Page 13-25
Install
Install the idler pulley and mounting capscrew.
Torque Value: 60 N•m [ 44 ft-lb ]
Remove
Automotive Applications
Remove the tensioner and idler mounting bracket.
Clean
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the parts with solvent.
Dry with compressed air.
Signature, ISX, and QSX15 Engi [...] Bracket, Idler Pulley and Alternator Belt Tensioner
Section 13 - Electrical Equipment - Group 13 Page 13-27
Install
Automotive Applications
Install the mounting bracket.
Torque Value: 56 N•m [ 41 ft-lb ]
Finishing Steps
Automotive Applications
Install the alternator belt pulley. Refer to Procedure
013-039.
Install the alternator belt tensioner. Refer to Procedure
013-021.
Install the alternator belt. Refer to Procedure 013-005.
Service Tools
Engine Testing
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.
Engine Controller
Use to test engine separate from the chassis system.
3163890
Harness Extension
Extends engine controller harness, Part Number 3164242, 20 ft.
3163895
Digital Multimeter
Use to measure pressures, vacuums, and temperatures.
3377161
Thermocouple Module
This module converts the digital multimeter into a thermometer via
3824963 standard banana plugs.
3824965
Signature, ISX, and QSX15 Engi [...] Service Tools
Section 14 - Engine Testing - Group 14 Page 14-3
Engine Set up for Dyno with INSITE™ Electronic Service Tool? (Circle one) Yes / No
Oil Level (Circle one) Low / High / OK Fuel Quality (Circle one) OK / Not OK
Road Speed Limit
Engine Speed
Horsepower or Torque
EGR Valve Position
Turbocharger Control Valve Command
Fuel Rate (lb/hr)3
Rail Fuel Pressure (psi)
Fuel Temperature
Intake Manifold Air Temperature
Intake Manifold Pressure (in Hg)
Coolant Temperature
Coolant Pressure (psi)
Engine Oil Pressure (psi)
Pressure Conversions
1 in H20 = 0.074 in Hg = 0.036 psi
1 in Hg = 13.600 in H20 = 0.491 psi
1 psi = 2.036 in Hg = 27.680 in H20
Pressure Conversions
1 in H2O = 0.074 in Hg = 0.036 psi
1 in Hg = 13.600 in H2O = 0.491 psi
1 psi = 2.036 in Hg = 27.680 in H2O
Engine Testing (Chassis Dynamometer) Signature, ISX, and QSX15 Engi [...]
Page 14-6 Section 14 - Engine Testing - Group 14
WARNING
Before installing or operating a vehicle on a chassis
dynamometer, follow all the vehicle manufacturer's
safety precautions.
CAUTION
Low-profile radial tires are more sensitive to heat than
bias ply tires. Excessive operating time at full load can
damage tires due to overheating. Check the tire
manufacturers's recommendations for the maximum
allowable chassis dynamometer operating time.
Signature, ISX, and QSX15 Engi [...] Engine Testing (Chassis Dynamometer)
Section 14 - Engine Testing - Group 14 Page 14-7
CAUTION
The “tie-down” chains must have slack to prevent
damage to the chassis dynamometer.
• Carefully position the vehicle on the rollers.
• Attach the “tie-down” chains to the rear of the
vehicle, and put wheel chocks in front of the front
wheels.
Engine Testing (Chassis Dynamometer) Signature, ISX, and QSX15 Engi [...]
Page 14-8 Section 14 - Engine Testing - Group 14
WARNING
Check the coolant level only when the engine is
stopped. Wait until the coolant temperature is below
50°C [120°F] before removing the pressure cap.
Failure to do so can cause personal injury from heated
coolant spray.
CAUTION
Do not add cold coolant to a hot engine. This can
cause engine casting damage. Allow the engine to
cool to below 50°C [120°F] before adding coolant.
Test
To monitor engine performance correctly, record the
following parameters. To limit dynamometer operating
time, instrument the engine or use INSITE™ to make as
many checks as possible.
• Engine speed (rpm)
• Fuel rate
• Intake manifold air temperature
• Engine blowby
• Engine coolant pressure
• Engine coolant temperature
• Rail fuel pressure. Refer to Procedure 005-016.
• Engine fuel temperature (if needed to correct fuel
rate).
• Fuel inlet restriction. Refer to Procedure 006-020.
• Fuel drain line restriction. Refer to Procedure
006-012.
• Intake manifold pressure. Refer to Procedure
010-024.
• Intake air restriction. Refer to Procedure 010-027.
• Exhaust restriction. Refer to Procedure 011-009.
• Engine oil pressure. Refer to Procedure 007-021.
Fuel Rate
Reference the Fuel Flow Measurement on Engine or
Chassis Dynamometer in this section.
NOTE: Adjust the fuel rate reading to compensate for
temperature variation if required.
Engine Blowby
Use blowby checking tool, Part Number 3822567, and
water manometer, Part Number ST-1111-3, to measure
the engine crankcase pressure.
Signature, ISX, and QSX15 Engi [...] Engine Testing (Chassis Dynamometer)
Section 14 - Engine Testing - Group 14 Page 14-11
Do not idle the engine for more than five minutes at any
one time during the first 160 Km [100 mi] of operation.
CAUTION
Do not shut off the engine immediately after the run-
in is completed. Allow the engine to cool by operating
it at 700 to 900 rpm for a minimum of 3 to 5 minutes
to avoid internal damage. This allows the
turbocharger and other components to cool.
WARNING
Refer to Engine Testing - General Information and
Specifications - Engine Testing at the front of this
section before operating the engine to avoid internal
component damage.
Operate the vehicle pulling the heaviest available trailer
allowed for the first 80 to 160 Km [50 to 100 mi] after
rebuild. Operate the vehicle in the highest gear possible
within the normal operating rpm range of the engine. It will
be necessary to operate the engine at or near full throttle
at 75 to 85 percent of maximum horsepower rpm indicated
on the dataplate.
Do not idle the engine for more than 5 minutes at any one
time during the first 160 Km [100 mi] of operation.
Off-Highway Applications
WARNING
Refer to Engine Testing - General Information and
Specifications - Engine Testing at the front of this
section before operating the engine to avoid internal
component damage.
Operate the engine under the highest load possible at full
throttle within the normal operating rpm range of the
engine for the first 3 hours of operation after rebuild.
Signature, ISX, and QSX15 Engi [...] Engine Testing (Engine Dynamometer)
Section 14 - Engine Testing - Group 14 Page 14-17
Do not idle the engine for more than 5 minutes at any one
time during the first 3 hours of operation after a rebuild.
Coolant Plumbing
Connect the coolant supply to the water inlet connection.
Connect the coolant return to the water outlet connection.
Install the drain plugs and close all of the water drain
cocks.
Water from a city tap line flows to the aftercooler via a 25.4
mm [1-inch] inner diameter neoprene hose. Testing has
shown that 45.4 liter [12 gal] per minute city water flow is
required (22.7 liter [6 gal] per minute per aftercooler core)
to adequately cool the intake air for the 435 through 500
horsepower-rated engine. A typical garden hose is not
suitable for this flow due to the excessive restriction. A
low-restriction ball-type or gate valve is suitable for the
operation, provided that the required flow rates are
achieved.
Water returns to the drain or reservoir from the
aftercoolers via a 25.4 mm [1-inch] inner diameter hose.
A low-restriction gate valve or ball valve must be placed
on the drain line(s) to regulate water flow through the
aftercoolers. This provides the ability to maintain optimum
intake air temperature during the test or run-in procedure.
The condensate that will develop as the intake air is
cooled in the remote aftercooler is allowed to drain at all
times through a hole at the bottom of the tubular steel
manifold between the aftercoolers. This fitting must
remain unobstructed throughout each use of the
aftercoolers.
NOTE: Some airflow will escape through the condensate
drain opening, but it is insignificant compared to the total
airflow.
1. Air in from turbocharger compressor outlet
2. Lifting eye
3. Air out to engine intake manifold
4. Water in to aftercooler
5. Water out to drain
6. Condensate drain.
Signature, ISX, and QSX15 Engi [...] Engine Testing (Engine Dynamometer)
Section 14 - Engine Testing - Group 14 Page 14-19
Air Compressor
NOTE: All air compressors manufactured by Cummins
Inc. must operate during the engine run-in. During the
performance check, all air compressors must be in the
unloaded or non-operating mode.
Connect a source of compressed air capable of producing
665 kPa [96 psi] to the air compressor unloader (1). This
air line must contain a valve between the air source and
the unloader.
NOTE: The compressed air load in the accompanying
illustration must be attached to the air compressor outlet
(2).
Hose Temperature
°C °F
235 MIN 500
Connect the tube or hose (1) to the air compressor outlet.
Engine Testing (Engine Dynamometer) Signature, ISX, and QSX15 Engi [...]
Page 14-20 Section 14 - Engine Testing - Group 14
Starting Motor
Inspect the voltage rating on the starting motor before
installing the electrical wiring.
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.
Install the electrical wiring to the starting motor and
batteries, if used.
If another method of starting the engine is used, follow the
manufacturer's instructions to make the necessary
connections.
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.
Connect the dynamometer test OEM wiring harness
starter solenoid lead (yellow) to the starter solenoid.
Connect the ground lead (black) to the starter or battery
negative (-) or ground side. Connect the +12 VDC power
lead (red) to either the starter or battery positive (+12-
VDC) side.
Test
To monitor engine performance correctly, record the
following parameters. To limit dynamometer operating
time, instrument the engine or use INSITE™ electronic
service tool to make as many checks as possible.
• Engine speed (RPM)
• Fuel rate
• Intake manifold air temperature
• Engine blowby
• Engine coolant pressure
• Engine coolant temperature
• Rail fuel pressure. Refer to Procedure 005-016 in the
ISM, ISM e, and QSM11 Service Manual, Bulletin
3666322 or Procedure 005-016 in the Signature, ISX,
and QSX15 Service Manual, Bulletin 3666239
• Engine fuel temperature (if needed to correct fuel
rate)
• Fuel inlet restriction. Refer to Procedure 006-020 in
the ISM, ISM e, and QSM11 Service Manual, Bulletin
3666322 or Procedure 006-020 in the Signature, ISX,
and QSX15 Service Manual, Bulletin 3666239
• Fuel drain line restriction. Refer to Procedure
006-012 in the ISM, ISM e, and QSM11 Service
Manual, Bulletin 3666322 or Procedure 006-012 in
the Signature, ISX, and QSX15 Service Manual,
Bulletin 3666239
• Intake manifold pressure. Refer to Procedure
010-024 in the ISM, ISM e, and QSM11 Service
Manual, Bulletin 3666322 or Procedure 010-024 in
the Signature, ISX, and QSX15 Service Manual,
Bulletin 3666239
• Intake air restriction. Refer to Procedure 010-027 in
the ISM, ISM e, and QSM11 Service Manual, Bulletin
3666322 or Procedure 010-027 in the Signature, ISX,
and QSX15 Service Manual, Bulletin 3666239
• Exhaust restriction. Refer to Procedure 011-009 in
the ISM, ISM e, and QSM11 Service Manual, Bulletin
3666322 or Procedure 011-009 in the Signature, ISX,
and QSX15 Service Manual, Bulletin 3666239
• Engine oil pressure. Refer to Procedure 007-021 in
the ISM, ISM e, and QSM11 Service Manual, Bulletin
3666322 or Procedure 007-021 in the in the
Signature, ISX, and QSX15 Service Manual, Bulletin
3666239.
Fuel Rate
See the Fuel Flow Measurement on Engine or Chassis
Dynamometer in this section.
Adjust the fuel rate reading to compensate for
temperature variation if required.
Engine Blowby
Use blowby checking tool, Part Number 3822566 (ISM) or
Part Number 3822567 (ISX), and water manometer, Part
Number ST-1111-3, to measure the engine crankcase
pressure.
Do not idle the engine for more than five minutes at any
one time during the first three hours or 160 km [100 mi] of
operation.
CAUTION
Do not shut off the engine immediately after the run-
in is completed. Allow the engine to cool by operating
it at 700 to 900 rpm for a minimum of three to five
minutes to avoid internal damage. This allows the
turbocharger and other components to cool.
Preparatory Steps
To perform a Stationary Regeneration, connect INSITE™ electronic
service tool and check for active fault codes. If any fault codes are
present other than Fault Codes 2639 or 1921, go to Section TF for any
fault code troubleshooting before proceeding. Do not perform a
stationary regeneration with active fault codes other than Fault Codes
2639 or 1921 unless guided to do so by the fault code troubleshooting.
WARNING
During regeneration, exhaust gas temperature could reach 800°C
[1500°F] and exhaust system surface temperature can exceed
700°C [1300°F], which is hot enough to ignite or melt common
materials, and to burn people. The exhaust and exhaust
components can remain hot after the vehicle stopped moving. To
avoid the risk of fire, property damage, burns or other serious
personal injury, allow the exhaust system to cool before beginning
this procedure or repair and make sure that no combustible
materials are located where they are likely to come in contact with
hot exhaust or exhaust components.
Before performing a stationary regeneration, follow the steps listed
below:
1. Select on appropriate location to park the vehicle.
a. On a surface that will not burn or melt under high temperatures
(such as clean concrete or gravel, not grass or asphalt)
b. Away from anything that can burn, melt, or explode
- Nothing within 0.6 m [2 ft] of the exhaust outlet
- Nothing that can burn, melt, or explode within 1.5 m [5 ft] (such
as gasoline, wood, paper, plastics, fabric, compressed gas
containers, hydraulic lines)
a. No gas or vapors nearby that could burn, explode, or contribute
to a fire (such as LP gas, gasoline vapors, oxygen, nitrous oxide).
1. Park the truck securely.
a. Set the parking brake.
b. Place transmission in Park, if provided, otherwise in Neutral.
c. Set wheel chocks at front and rear of at least one tire.
1. Set up a safe exhaust area.
a. If bystanders might enter the area, set up barriers to keep people
at least 1.5 m [5 ft] from the exhaust outlet during regeneration.
b. When indoors, attach an exhaust discharge pipe rated for at least
800°C [1500°F]
c. Keep a fire extinguisher nearby.
1. Check exhaust system surfaces.
a. Confirm that nothing is on or near the exhaust system surfaces
(such as tools, rags, grease, or debris).
1. Prepare for engine speed changes during regeneration.
a. Do not operate any PTO-powered devices. Disconnect these
devices before starting regeneration.
b. Stay clear of the engine compartment.
1. Begin the stationary regeneration. This can be performed in two
ways:
a. Vehicles equipped with a stationary regeneration switch in the
cab must also have the stationary regeneration switch parameter
enabled in the ECM. The stationary regeneration switch can be
a stand-alone switch, or can be combined with a diagnostic
switch, at the choice of the vehicle manufacturer.
b. The INSITE™ electronic service tool can be used to perform
regeneration by starting the Aftertreatment Diesel Particulate
Filter Regeneration Test.
c. In either case, the engine will create enough heat to regenerate
the aftermarket diesel particulate filter. Engine speed will
increase and the turbocharger can whistle loudly during the
regeneration process. Once the aftermarket diesel particulate
filter is regenerated, the engine will automatically return to
normal idle speed.
1. Monitor the area.
a. Make sure that the vehicle and surrounding area is monitored
during regeneration. If any unsafe condition occurs, shut off the
engine immediately.
To stop a stationary regeneration, engage the clutch, brake, or throttle
pedal, or turn off the engine.
Once regeneration is complete, exhaust gas and exhaust surface
temperatures will remain elevated for 3 to 5 minutes.
Aftertreatment Testing Signature, ISX, and QSX15 Engi [...]
Page 14-32 Section 14 - Engine Testing - Group 14
Setup
Start and idle the engine.
Prior to the Aftertreatment Diesel Particulate Filter
Regeneration Test, inspect the exhaust piping for leaks,
cracks, and loose connections. Refer to Procedure
010-024 in the Service Manual, ISM, ISM e, and QSM11
Engines, Bulletin 3666322 or Procedure 010-024 in the
Service Manual, Signature, ISX, and QSX15 Engines,
Bulletin 3666239.
Tighten the exhaust clamps if necessary.
Consult the OEM specifications for the correct torque
value.
Any leaks in the exhaust system will cause the
Aftertreatment Diesel Particulate Filter Regeneration Test
to be less efficient in reducing the soot load of the filter.
Test
The Aftertreatment Diesel Particulate Filter Regeneration
Test can be found under the ECM Diagnostic Test menu
in the INSITE™ electronic service tool.
CAUTION
During the stationary regeneration, the exhaust gas
temperature can reach 800°C [1500°F] and the
surface temperature can exceed 700°C [1300°F].
The stationary regeneration can take up to one hour to
complete, depending on the soot loading of the filter. At
any time the stationary regeneration can be aborted by
clicking on the “Stop” button in the INSITE™ electronic
service tool.
The stationary regeneration will be aborted if:
• A fault becomes active
• The accelerator is depressed
• The clutch pedal is depressed
• The brake pedal is depressed
• The transmission is put into gear.
NOTE: If a stationary regeneration can not be initiated or
is aborted, and the engine has a low power complaint,
refer to Procedure 011-009.
Pass or Fail Criteria
• Pass: Aftertreatment Testing Procedure 014-013,
has passed if there is no visible black smoke and the
stationary regeneration completes with no
aftertreatment fault codes being generated.
• Fail: Aftertreatment Testing Procedure 014-013, has
failed if there is visible black smoke and /or
aftertreatment fault codes are generated. Repair
cause of black smoke and/or correct the fault codes.
Finishing Steps
Allow the engine and exhaust system to cool down.
Temperatures can maintain an elevated state for several
minutes.
Check to make sure the Diesel Particulate Filter lamp is
not illuminated.
NOTE: If the Diesel Particulate Filter lamp is illuminated
and Fault Code 2639 or 1921 are still active, a second
regeneration will be needed. If the fault is still active after
a second regeneration, then the filter needs to be cleaned
of ash. Refer to Procedure 011-041. If the Diesel
Particulate Filter lamp is illuminated and Fault Code 1922
is active, replace the Aftertreatment Diesel Particulate
Filter and use the troubleshooting steps.
Check for any active fault codes. If active fault codes are
present, use Section TF for fault code troubleshooting.
Use INSITE™ electronic service tool to clear all inactive
fault codes.
Signature, ISX, and QSX15 Engi [...]
Section 16 - Mounting Adaptations - Group 16 Page 16-a
Service Tools
Mounting Adaptations
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.
Barring Tool
This tool provides a way of barring over most engines when making
3163160 valve and injector adjustments or checking engine timing.
Engine Lifting Brackets Signature, ISX, and QSX15 Engi [...]
Page 16-2 Section 16 - Mounting Adaptations - Group 16
Remove
NOTE: Newer models use three mounting capscrews.
Remove the four capscrews and the rear lifting bracket.
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
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
bodily injury.
Clean with steam or solvent.
Dry with compressed air.
Install
Install the front bracket and four capscrews.
Install the rear bracket and four capscrews.
Tighten the capscrews.
Torque Value: 108 N•m [ 80 ft-lb ]
Engine Support Bracket, Front Signature, ISX, and QSX15 Engi [...]
Page 16-4 Section 16 - Mounting Adaptations - Group 16
Finishing Steps
• Install the retaining brace bracket. Refer to
Procedure 001-081.
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.
• Use a hoist or lifting fixture to support the front of the
engine.
• Remove the fan and water pump drive belt. Refer to
Procedure 008-003.
• Remove the fan and water pump belt tensioner if a
low mount tensioner is used. Refer to Procedure
008-080.
• Remove the vibration damper and the crankshaft
pulley. Refer to Procedure 001-052.
Remove
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 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.
Signature, ISX, and QSX15 Engi [...] Engine Support Bracket, Front
Section 16 - Mounting Adaptations - Group 16 Page 16-5
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.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Clean the parts with steam or solvent.
Dry the parts with compressed air.
Install
Install the engine support bracket and the six mounting
capscrews.
Tighten the capscrews.
Torque: 97 N•m + 60 deg [72 ft-lb + 60 deg]
Install the rubber engine mounts into the crossmember.
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.
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.
Finishing Steps
• Install the vibration damper and the crankshaft
pulley. Refer to Procedure 001-052.
• Install the fan and water pump drive belt tensioner.
Refer to Procedure 008-080.
• Install the fan and water pump drive belt. Refer to
Procedure 008-003.
Signature, ISX, and QSX15 Engi [...] Flywheel
Section 16 - Mounting Adaptations - Group 16 Page 16-7
Flywheel (016-005)
Initial Check
Bore Runout
Use dial indicator gauge (1), Part Number 3376050, or
equivalent, and dial gauge attachment (2), Part Number
ST-1325, to inspect the flywheel bore (3) and face (4)
runout.
Install the attachment to the flywheel housing.
Install the gauge on the attachment.
Install the contact tip of the indicator against the inside of
the flywheel bore.
Face Runout
Install the contact tip of the indicator against the flywheel
face as close to the outside as possible to inspect the face
(4) runout.
Push the flywheel forward to remove the crankshaft end
thrust.
Signature, ISX, and QSX15 Engi [...] Flywheel
Section 16 - Mounting Adaptations - Group 16 Page 16-9
Preparatory Steps
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
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.
• Disconnect the batteries or air starter to prevent
accidental engine starting.
• Remove the transmission, clutch, and all related
components. See the equipment manufacturer's
instructions.
Flywheel Signature, ISX, and QSX15 Engi [...]
Page 16-10 Section 16 - Mounting Adaptations - Group 16
Remove
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 the component.
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.
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.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use a wire brush to clean the crankshaft pilot bore.
Use a wire brush to clean the flywheel pilot bore.
Clean with steam or solvent.
Dry with compressed air.
Signature, ISX, and QSX15 Engi [...] Flywheel
Section 16 - Mounting Adaptations - Group 16 Page 16-11
WARNING
Do not use a cracked or resurfaced flywheel. These
can break, causing serious personal injury or property
damage.
Use the crack detection kit, Part Number 3375432, to
check for cracks in the flywheel. Follow the instructions
provided with the kit.
Inspect the flywheel ring gear teeth for cracks and chips.
If the ring gear teeth are cracked or broken, the ring gear
must be replaced. Refer to Procedure 016-008 (Flywheel
Ring Gear) in Section 16.
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.
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
This component weighs 23 kg [50 lb] or more. To
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.
Finishing Steps
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.
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.
• Perform the bore runout check and face runout
check located in this procedure.
• Install the clutch discs, pressure plate, transmission,
and driveline, if equipped, in reverse order of
removal. See the manufacturer's instructions.
• Align the universal joints on each end of the
driveshaft to prevent vibration.
• Connect batteries and air starter.
• Start the engine and check the operation of the
equipment.
Flywheel Housing Signature, ISX, and QSX15 Engi [...]
Page 16-14 Section 16 - Mounting Adaptations - Group 16
WARNING
Batteries can emit explosive gases. To avoid personal
injury, always ventilate the compartment before
servicing the batteries. To avoid arcing, remove the
negative (-) battery cable first and attach the negative
(-) battery cable last.
WARNING
This component weighs 23 kg [50 lb] or more. To
avoid personal injury, use a hoist or get assistance to
lift the component.
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
environmental regulations.
WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.
WARNING
Adequately support the engine to prevent damage and
personal injury.
• Disconnect the batteries and air starter to prevent
accidental engine starting.
• Remove the transmission, clutch, and all related
components. Refer to the equipment manufacturer's
instructions.
• Remove the flywheel. Refer to Procedure 016-005.
• Drain the oil. Refer to Procedure 007-037.
• Remove the oil pan. Refer to Procedure 007-025.
• Remove the rear crankshaft seal. Refer to Procedure
001-024.
• Remove the starting motor. Refer to Procedure
013-020.
• Remove the rear engine mounts from the flywheel
housing.
Remove
Remove the two top exterior capscrews from the flywheel
housing.
Install two guide studs.
Signature, ISX, and QSX15 Engi [...] Flywheel Housing
Section 16 - Mounting Adaptations - Group 16 Page 16-15
WARNING
This component weighs 23 kg [50 lb] or more. To
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.
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 Signature, ISX, and QSX15 Engi [...]
Page 16-16 Section 16 - Mounting Adaptations - Group 16
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.
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to avoid
personal injury.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
bodily injury.
Steam-clean or use solvent to clean the housing.
Dry with compressed air.
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 and inspect to make sure no debris is left in the
passage.
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.
Signature, ISX, and QSX15 Engi [...] Flywheel Housing
Section 16 - Mounting Adaptations - Group 16 Page 16-19
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.
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.
Finishing Steps
WARNING
Batteries can emit explosive gases. To avoid personal
injury, always ventilate the compartment before
servicing the batteries. To avoid arcing, remove the
negative (-) battery cable first and attach the negative
(-) battery cable last.
WARNING
This component weighs 23 kg [50 lb] or more. To
avoid personal injury, use a hoist or get assistance to
lift the component.
• Install the rear engine mounts on the flywheel
housing.
• Install the starting motor capscrews, starter, and
spacer. Refer to Procedure 013-020.
• Install the rear crankshaft seal. Refer to Procedure
001-024.
• Install the oil pan. Refer to Procedure 007-025.
• Fill the oil. Refer to Procedure 007-037.
• Install the flywheel. Refer to Procedure 016-005.
• Install the transmission, clutch, and all related
components. Refer to the equipment manufacturer's
instructions.
• Connect the batteries and air starter.
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing batteries. To reduce
the possibility of arcing, remove the negative (-)
battery cable first and attach the negative (-) battery
cable last.
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
environmental regulations.
WARNING
To reduce the possibility of personal injury, avoid
direct contact of hot oil with your skin.
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.
• Disconnect the batteries or air supply to the starter
to prevent accidental engine starting.
• Drain the oil. Refer to Procedure 007-025.
• Remove the transmission, clutch, and all related
components. Refer to the equipment manufacturer's
instructions.
Flywheel Housing, REPTO Signature, ISX, and QSX15 Engi [...]
Page 16-24 Section 16 - Mounting Adaptations - Group 16
Remove
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 the component.
Remove three flywheel capscrews equally spaced from
the flywheel. Install three guide pins, Part Number
3164765, through the flywheel, crankshaft gear, and into
the crankshaft holes.
Use a hoist, two T-handles, and a lifting sling. Install the
T-handles into the holes of the flywheel. Remove the
remaining 10 capscrews and remove the flywheel. Use a
mallet to tap the flywheel from the crankshaft gear, if
necessary.
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.
Disconnect the battery cables before beginning the
following procedure.
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 the component.
Remove the starting motor capscrews, starter, and
spacer.
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 the component.
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 four plugs (1) and o-rings (2) from the REPTO
flywheel housing.
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 N•m [ 10 ft-lb ]
Remove the idler shaft, idler gear, and bearing from the
REPTO flywheel housing.
Install the two eye bolts, Part Number 3164767, on the top
of the REPTO flywheel housing. Install the lifting slings to
the eyehooks. Adjust the hoist until there is tension in the
lifting sling.
Remove the remaining capscrews.
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 the component.
Use a mallet to tap the REPTO flywheel housing off the
two locating dowels. Remove and discard the gasket.
Signature, ISX, and QSX15 Engi [...] Flywheel Housing, REPTO
Section 16 - Mounting Adaptations - Group 16 Page 16-27
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.
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
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use steam or solvent to clean the REPTO flywheel
housing.
Dry with compressed air.
Inspect the idler shaft, bearing, and gear for nicks, burrs,
or cracks. Replace if damaged.
Inspect the four o-rings from the plugs and the one large
o-ring from the REPTO flywheel housing for cuts or tears.
Replace the o-rings if damaged.
Install
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
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.
Install the two eyehooks (4) in the top of the REPTO
flywheel housing. Install the lifting slings to the eyehooks
and push the REPTO flywheel housing onto the two
guides pins (3).
Signature, ISX, and QSX15 Engi [...] Flywheel Housing, REPTO
Section 16 - Mounting Adaptations - Group 16 Page 16-29
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.
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.
Measure the REPTO flywheel housing alignment.
Refer to Procedure 016-006.
Install the large o-ring seal (1) and the small o-ring seal (2)
onto 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 15W40 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 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.
Signature, ISX, and QSX15 Engi [...] Flywheel Housing, REPTO
Section 16 - Mounting Adaptations - Group 16 Page 16-31
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.
Torque Value: 28 N•m [ 21 ft-lb ]
Flywheel Housing, REPTO Signature, ISX, and QSX15 Engi [...]
Page 16-32 Section 16 - Mounting Adaptations - Group 16
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.
Signature, ISX, and QSX15 Engi [...] Flywheel Housing, REPTO
Section 16 - Mounting Adaptations - Group 16 Page 16-33
CAUTION
Never use a hammer or mallet to install the rear
crankshaft oil seal.
No lubricants are to be used 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
1/2 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.
Torque Value: 20 N•m [ 15 ft-lb ]
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.
Install the starting motor capscrews, starter, and spacer.
Refer to the Troubleshooting and Repair Manual
Signature, ISX and QSX15 Engines, Bulletin 3666239,
Procedure 013-020.
Finishing Steps
• Fill the engine with clean oil. Refer to Procedure
007-025.
• Install the transmission, clutch, and all related
components. Refer to the equipment manufacturer's
instructions.
Install
Heat the new ring gear in an oven heated to 316°C [600°
F] for a minimum of 1-hour.
NOTE: Do not overheat the ring gear. The metal hardness
will be changed.
WARNING
Wear protective gloves when handling parts that have
been heated to prevent personal injury.
Remove the gear from the oven and install it on the
flywheel before it cools.
NOTE: If an oven is not available, use a heating torch to
heat the inside diameter of the new ring gear to 316°C
[600°F]. Use a Tempilstik® crayon, or its equivalent, to
check the gear temperature before installing it on the
flywheel.
Voltage Check
Disconnect the engine wiring harness connector from the
cylinder head pass-through connector.
Connect one end of the engine brake breakout cable, Part
Number 3163150, to the cylinder pass-through connector
and the other end to the engine wiring harness connector.
Engine Brake Assembly Signature, ISX, and QSX15 Engi [...]
Page 20-2 Section 20 - Vehicle Braking - Group 20
Initial Check
Engine Brake Solenoid
Disconnect the engine wiring harness connector from the
cylinder head pass-through connector.
Connect one end of the engine brake breakout cable, Part
Number 3163150, to the cylinder pass-through connector
and the other end to the engine wiring harness connector.
Signature, ISX, and QSX15 Engi [...] Engine Brake Assembly
Section 20 - Vehicle Braking - Group 20 Page 20-3
Adjust
All overhead adjustments must be made when the engine
is cold (any stabilized coolant temperature at 60°C [140°
F] or below).
CAUTION
Do not use solvent to clean the rocker cover gasket.
Solvent can damage the gasket material and cause it
to swell.
Remove the rocker lever cover and gasket. Refer to
Procedure 003-011.
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.
Start A 1
Advance to B 5
Advance to C 3
Advance to A 6
Advance to B 2
Advance to C 4
Firing Order: 1-5-3-6-2-4
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
BRAKE SET 2-5: Cylinder 2 or 5 adjust
BRAKE SET 3-4: Cylinder 3 or 4 adjust
CAUTION
Engine damage can occur if running clearance is not
within specifications.
Check the running clearance:
1. Rotate the engine brake rocker lever to the detent
(neutral) position.
2. Check the clearance (1) between the engine brake
lever actuator piston and the crosshead guide pin.
Remove
Disconnect the engine brake wiring harness from the
solenoid.
Use a 3/4 inch socket to remove the solenoid from the
manifold.
Discard the three solenoid o-rings.
24-VDC
Cold Engine 32 to 40 ohms
Hot Engine 60 to 80 ohms
Install
Lubricate the seal rings with clean engine oil.
Install the upper (1) and center (2) seal ring on the
solenoid.
Coat the inside of the manifold with oil and place the lower
seal ring (3) in the bottom of the manifold.
Install the solenoid into the manifold.
Tighten the solenoid.
Torque Value: 20 N•m [ 15 ft-lb ]
Connect the engine brake wiring harness to the solenoid.
Finishing Steps
• Install the rocker lever cover. Refer to Procedure
003-011.
• Operate the engine and check for proper operation
and leaks.
NOTE: The engine brake harness can be laid over the side
of the engine to service overhead components. It is not
necessary to remove the brake pass-through connector.
Disconnect the solenoid wires.
With your hands about 18 inches apart, grasp the engine
brake wiring harness support bracket and pull it up and
out of the cylinder head.
Install
Threaded Brake Pass-Through
Install the engine brake wiring harness support bracket
into the cylinder head.
Connect the solenoid wires.
WARNING
The control valve is spring-loaded. To avoid personal
injury, apply thumb pressure to the control valve
cover, slowly remove cover until spring pressure
ceases, and then remove the valve.
Use snap ring pliers to remove the snap ring and control
valve from rocker lever assembly.
Install
Move the control valve in the bore to insure free
movement.
Lubricate the control valve assembly.
Install the control valve into rocker lever assembly and
snap ring.
Signature, ISX, and QSX15 Engi [...] Engine Brake Piston
Section 20 - Vehicle Braking - Group 20 Page 20-15
Install
Place the piston into the rocker arm.
Holding the piston in place, turn the adjusting screw
counterclockwise until the piston is seated. Install the
locknut.
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Cummins Service Publications Electronic Books on CD-ROM Information
(continued)
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Signature, ISX, and QSX15 Engi [...]
Section L - Service Literature Page L-a
Notes
Signature, ISX, and QSX15 Engi [...]
Section M - Component Manufacturers Page M-a
Notes
Signature, ISX, and QSX15 Engi [...]
Section V - Specifications Page V-a
Section V - Specifications
Section Contents
Page
Air Intake System ............................................................................................................................................V-73
Specifications.................................................................................................................................................V-73
Automotive Applications...............................................................................................................................V-73
Industrial and Generator Drive..................................................................................................................... V-73
Air Intake System - Group 10 - Specifications ...............................................................................................V-41
Charge-Air Cooler.................................................................................................................................................... V-41
Turbocharger............................................................................................................................................................V-41
Turbocharger Wastegate Actuator...........................................................................................................................V-41
Turbocharger Wastegate Valve Body...................................................................................................................... V-42
Turbocharger, Variable Geometry Actuator............................................................................................................. V-42
Air Intake System - Group 10 - Torque Values ..............................................................................................V-43
Air Intake Connection...............................................................................................................................................V-46
Air Leaks, Air Intake and Exhaust Systems............................................................................................................. V-43
Turbocharger............................................................................................................................................................V-43
Turbocharger Control Shutoff Valve Filter Head......................................................................................................V-47
Turbocharger Coolant Hoses...................................................................................................................................V-45
Turbocharger Wastegate Actuator...........................................................................................................................V-46
Turbocharger Wastegate Controller.........................................................................................................................V-46
Turbocharger, Variable Geometry Actuator............................................................................................................. V-47
Turbocharger, Variable Geometry Actuator Air Supply Line....................................................................................V-47
Turbocharger, Variable Geometry Control Valve Air Supply Line............................................................................V-47
Variable Geometry Turbocharger Actuator, Electric.................................................................................................V-48
Capscrew Markings and Torque Values .........................................................................................................V-79
Capscrew Markings and Torque Values - Metric..............................................................................................V-79
Capscrew Markings and Torque Values - U.S. Customary...............................................................................V-79
General Information........................................................................................................................................V-79
Compressed Air System .................................................................................................................................V-76
Specifications.................................................................................................................................................V-76
Cummins 18.7 CFM Model...........................................................................................................................V-76
Compressed Air System - Group 12 - Torque Values ....................................................................................V-58
Air Compressor........................................................................................................................................................ V-58
Air Compressor Cylinder Head, Single Cylinder...................................................................................................... V-58
Cooling System ...............................................................................................................................................V-71
General Information........................................................................................................................................V-71
Specifications.................................................................................................................................................V-71
Automotive Applications...............................................................................................................................V-71
Industrial and Generator Drive..................................................................................................................... V-72
Cooling System - Group 08 - Specifications ..................................................................................................V-32
Coolant Thermostat..................................................................................................................................................V-32
Fan Hub, Belt Driven................................................................................................................................................V-32
Water Pump............................................................................................................................................................. V-32
Cooling System - Group 08 - Torque Values .................................................................................................V-34
Belt Tensioner, Automatic (Water Pump).................................................................................................................V-36
Coolant Filter Valve..................................................................................................................................................V-34
Coolant Thermostat..................................................................................................................................................V-34
Coolant Thermostat Housing....................................................................................................................................V-34
Cooling System........................................................................................................................................................V-35
Fan Hub, Belt Driven................................................................................................................................................V-35
Fan Pulley................................................................................................................................................................ V-38
Fan Support..............................................................................................................................................................V-37
Water Inlet Connection.............................................................................................................................................V-37
Water Pump............................................................................................................................................................. V-36
Cylinder Block - Group 01 - Specifications ......................................................................................................V-1
Bearings, Connecting Rod.........................................................................................................................................V-1
Bearings, Main...........................................................................................................................................................V-1
Connecting Rod..........................................................................................................................................................V-1
Crankshaft..................................................................................................................................................................V-2
Signature, ISX, and QSX15 Engi [...]
Page V-b Section V - Specifications
Cylinder Liner.............................................................................................................................................................V-3
Engine Base Timing...................................................................................................................................................V-5
Piston.........................................................................................................................................................................V-4
Piston Rings...............................................................................................................................................................V-4
Vibration Damper, Viscous.........................................................................................................................................V-4
Cylinder Block - Group 01 - Torque Values .....................................................................................................V-6
Bearings, Connecting Rod.........................................................................................................................................V-6
Bearings, Main...........................................................................................................................................................V-6
Block Stiffener Plate.................................................................................................................................................V-11
Bracket, Accessory.....................................................................................................................................................V-9
Bracket, Retaining Brace............................................................................................................................................V-8
Connecting Rod..........................................................................................................................................................V-6
Crankshaft Adapter....................................................................................................................................................V-6
Crankshaft Pulley.......................................................................................................................................................V-7
Crankshaft Seal, Front...............................................................................................................................................V-7
Crankshaft Seal, Rear................................................................................................................................................V-7
Engine Base Timing.................................................................................................................................................V-10
Gear Cover, Lower.....................................................................................................................................................V-8
Gear Cover, Upper.....................................................................................................................................................V-8
Gear Housing, Front...................................................................................................................................................V-8
Piston Cooling Nozzle................................................................................................................................................V-8
Vibration Damper, Viscous.........................................................................................................................................V-8
Cylinder Head - Group 02 - Specifications .....................................................................................................V-12
Cylinder Head...........................................................................................................................................................V-12
Overhead Camshaft End Clearance, Injector...........................................................................................................V-14
Overhead Camshaft End Clearance, Valve............................................................................................................. V-14
Overhead Camshaft, Injector................................................................................................................................... V-14
Overhead Camshaft, Valve......................................................................................................................................V-13
Cylinder Head - Group 02 - Torque Values ....................................................................................................V-15
Cylinder Head...........................................................................................................................................................V-15
Overhead Camshaft, Injector................................................................................................................................... V-15
Overhead Camshaft, Valve......................................................................................................................................V-15
Drive Belt Tension ..........................................................................................................................................V-78
Tension Chart.................................................................................................................................................V-78
Drive Units - Group 09 - Torque Values .........................................................................................................V-39
Alternator/Refrigerant Compressor Mounting Bracket............................................................................................. V-40
Belt Tensioner, Refrigerant Compressor, Automatic................................................................................................V-39
Idler Pulley, Refrigerant Compressor.......................................................................................................................V-39
Refrigerant Compressor...........................................................................................................................................V-39
Refrigerant Compressor Mounting Bracket..............................................................................................................V-39
Electrical Equipment - Group 13 - Torque Values .........................................................................................V-59
Alternator..................................................................................................................................................................V-59
Alternator Idler Pulley...............................................................................................................................................V-60
Alternator Pulley.......................................................................................................................................................V-59
Alternator Spacer..................................................................................................................................................... V-60
Belt Tensioner, Automatic (Alternator).....................................................................................................................V-60
Bracket, Idler Pulley and Alternator Belt Tensioner..................................................................................................V-60
Starting Motor...........................................................................................................................................................V-59
Electrical System ............................................................................................................................................V-75
Specifications.................................................................................................................................................V-75
Engine Testing ................................................................................................................................................V-77
Specifications.................................................................................................................................................V-77
Automotive with CM870............................................................................................................................... V-77
Automotive With CM871...............................................................................................................................V-77
Engine Testing - Group 14 - Specifications ...................................................................................................V-61
Engine Testing (Chassis Dynamometer)..................................................................................................................V-61
Engine Testing (Engine Dynamometer)...................................................................................................................V-61
Exhaust System ..............................................................................................................................................V-74
Specifications.................................................................................................................................................V-74
Automotive Applications...............................................................................................................................V-74
Industrial and Generator Drive..................................................................................................................... V-74
Automotive With CM871...............................................................................................................................V-74
Exhaust System - Group 11 - Specifications ................................................................................................. V-49
Signature, ISX, and QSX15 Engi [...]
Section V - Specifications Page V-c
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Crankshaft (001-016)
Crankshaft Connecting Rod Journal Outside 93.98 mm MIN 3.700 in
Diameter
94.02 mm MAX 3.702 in
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Rear Oil Seal Flange Total Indicator Runout 0.03 mm MAX 0.0012 in
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Valve Spring Load at 61.75 mm [2.431 in] 1511 N MIN 339.5 lbf
1604 N MAX 360.5 lbf
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Valve Recess
Intake 1.02 MIN 0.040
4.82 MAX 0.190
Exhaust 0.53 MIN 0.021
0.91 MAX 0.036
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Valve and Brake Rocker Lever Bushing Bore 35.037 mm MIN 1.3794 in
Inside Diameter
35.138 mm MAX 1.3834 in
Signature, ISX, and QSX15 Engi [...] Rocker Levers - Group 03
Section V - Specifications Page V-17
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
68 N•m [ 50 ft-lb ]
1 30 N•m [ 22 ft-lb ]
2 Rotate 60 degrees
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ifsm Fuel Inlet Check Valves (Without Egr) 17 N•m [ 150 in-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
25 N•m [ 18 ft-lb ]
Injector (006-026)
Front Mounting Plate Capscrews 9 N•m [ 80 in-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
70 N•m [ 52 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
28 N•m [ 21 ft-lb ]
Cooling System - Group 08 - Specifications Signature, ISX, and QSX15 Engi [...]
Page V-32 Section V - Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
72 N•m [ 53 ft-lb ]
30 N•m [ 25 ft-lb ]
30 N•m [ 25 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
36 N•m [ 27 ft-lb ]
41 N•m [ 30 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Turbocharger (010-033)
Turbocharger Axial Clearance 0.025 mm MIN 0.001 in
0.127 mm MAX 0.005 in
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Turbocharger (010-033)
Charge Air Cooling Piping 8.5 N•m [ 75 in-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
88 N•m [ 65 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
30 N•m [ 22 ft-lb ]
30 N•m [ 22 ft-lb ]
88 N•m [ 65 ft-lb ]
9 N•m [ 80 in-lb ]
25 N•m [ 18 ft-lb ]
30 N•m [ 22 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
41 N•m [ 30 ft-lb ]
15 N•m [ 133 in-lb ]
54 N•m [ 40 ft-lb ]
46 N•m [ 34 ft-lb ]
24 N•m [ 18 ft-lb ]
16 N•m [ 142 in-lb ]
24 N•m [ 18 ft-lb ]
45 N•m [ 33 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
54 N•m [ 40 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
27 N•m [ 20 ft-lb ]
5 N•m [ 44 in-lb ]
47 N•m [ 35 ft-lb ]
47 N•m [ 35 ft-lb ]
47 N•m [ 35 ft-lb ]
27 N•m [ 20 ft-lb ]
5 N•m [ 44 in-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
34 N•m [ 25 ft-lb ]
47 N•m [ 35 ft-lb ]
47 N•m [ 35 ft-lb ]
47 N•m [ 35 ft-lb ]
47 N•m [ 35 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
23 N•m [ 17 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
24 N•m [ 18 ft-lb ]
24 N•m [ 18 ft-lb ]
24 N•m [ 18 ft-lb ]
24 N•m [ 18 ft-lb ]
24 N•m [ 18 ft-lb ]
Exhaust System - Group 11 Signature, ISX, and QSX15 Engi [...]
Page V-56 Section V - Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
24 N•m [ 18 ft-lb ]
24 N•m [ 18 ft-lb ]
24 N•m [ 18 ft-lb ]
34 N•m [ 25 ft-lb ]
24 N•m [ 18 ft-lb ]
24 N•m [ 18 ft-lb ]
Signature, ISX, and QSX15 Engi [...] Exhaust System - Group 11
Section V - Specifications Page V-57
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
25 N•m [ 18 ft-lb ]
25 N•m [ 18 ft-lb ]
24 N•m [ 18 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
3 N•m [ 26 in-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Flywheel (016-005)
Flywheel Mounting Capscrews 1 125 N•m [ 92 ft-lb ]
2 250 N•m [ 184 ft-lb ]
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
14 N•m [ 10 ft-lb ]
28 N•m [ 21 ft-lb ]
28 N•m [ 21 ft-lb ]
60 N•m [ 45 ft-lb ]
20 N•m [ 15 ft-lb ]
20 N•m [ 15 ft-lb ]
35 N•m [ 26 ft-lb ]
Signature, ISX, and QSX15 Engi [...] Mounting Adaptations - Group 16
Section V - Specifications Page V-65
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
65 N•m [ 48 ft-lb ]
20 N•m [ 15 ft-lb ]
65 N•m [ 50 ft-lb ]
32 N•m [ 25 ft-lb ]
32 N•m [ 25 ft-lb ]
Vehicle Braking - Group 20 - Specifications Signature, ISX, and QSX15 Engi [...]
Page V-66 Section V - Specifications
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
23 N•m [ 18 ft-lb ]
General Engine Signature, ISX, and QSX15 Engi [...]
Page V-68 Section V - Specifications
General Engine
Specifications
Automotive with CM870
Listed below are general specifications for this engine.
Horsepower................................................................................................................Refer to the engine dataplate.
Engine Speed:
400 to 450 hp.........................................................................................................Refer to the engine dataplate.
500 to 600 hp.........................................................................................................Refer to the engine dataplate.
Displacement.............................................................................................................................15 liters [912 C.I.D.]
Bore and Stroke................................................................................................137 mm [5.40 in] x 169 mm [6.65 in]
Dry Engine Weight:
Automotive................................................................................................................................1202 kg [2650 lb]
Industrial...................................................................................................................................1524 kg [3360 lb]
Power Generation.....................................................................................................................1370 kg [3020 lb]
Wet Engine Weight:
Automotive................................................................................................................................1266 kg [2790 lb]
Industrial...................................................................................................................................1628 kg [3590 lb]
Power Generation.....................................................................................................................1474 kg [3250 lb]
Firing Order..............................................................................................................................................1-5-3-6-2-4
Crankshaft Rotation (viewed from front of engine)......................................................................................Clockwise
Overhead Adjustment:
Intake Valve Adjustment..........................................................................................................0.36 mm [0.014 in]
Exhaust Valve Adjustment.......................................................................................................0.69 mm [0.027 in]
Injector Lash Adjustment Torque.................................................................................................8 N•m [70 in-lb]
Engine Brake Adjustment.............................................................................................................7.00 mm [0.276 in]
Automotive With CM871
Listed below are general specifications for this engine.
Horsepower................................................................................................................Refer to the engine dataplate.
Engine Speed:
400 to 450 hp.........................................................................................................Refer to the engine dataplate.
500 to 600 hp.........................................................................................................Refer to the engine dataplate.
Displacement.............................................................................................................................15 liters [912 C.I.D.]
Bore and Stroke................................................................................................137 mm [5.40 in] x 169 mm [6.65 in]
Dry Engine Weight:........................................................................................................................1403 kg [3093 lb]
Wet Engine Weight........................................................................................................................1472 kg [3246 lb]
Firing Order..............................................................................................................................................1-5-3-6-2-4
Crankshaft Rotation (viewed from front of engine)......................................................................................Clockwise
Overhead Adjustment:
Intake Valve Adjustment..........................................................................................................0.36 mm [0.014 in]
Exhaust Valve Adjustment.......................................................................................................0.69 mm [0.027 in]
Injector Lash Adjustment Torque.................................................................................................8 N•m [70 in-lb]
Engine Brake Adjustment.............................................................................................................7.00 mm [0.276 in]
Signature, ISX, and QSX15 Engi [...] Fuel System
Section V - Specifications Page V-69
Fuel System
Specifications
Automotive with CM870
Maximum Allowable Restriction to Pump with or without Fuel Cooler:
With Clean Filter..................................................................................................................203 mm Hg [8 in Hg]
With Dirty Filter..................................................................................................................305 mm Hg [12 in Hg]
Maximum Allowable Fuel Return Line Restriction......................................................................229 mm Hg [9 in Hg]
Minimum Allowable Fuel Tank Vent Capability........................................................................... 2.0 m3/hr [70 ft3/hr]
Maximum Allowable Fuel Inlet Temperature.........................................................................................71°C [160°F]
Fuel Shutoff Solenoids' Resistance.......................................................................................................6 to 10 ohms
Maximum Allowable Pressure Drop Across Pressure Fuel Filter.......................................................517 kPa [75 psi]
Automotive, Industrial with CM570 and Power Generation without CM570
Maximum Allowable Fuel Return Line Restriction......................................................................229 mm Hg [9 in Hg]
Minimum Allowable Fuel Tank Vent Capability........................................................................... 2.0 m3/hr [70 ft3/hr]
Maximum Allowable Fuel Inlet Temperature.........................................................................................71°C [160°F]
Fuel Shutoff Solenoids' Resistance.......................................................................................................6 to 10 ohms
Maximum Allowable Inlet Restriction at the IFSM - high idle, no load:
Upper Location..................................................................................................................355 mm Hg [14 in Hg]
Lower Location..................................................................................................................305 mm Hg [12 in Hg]
Maximum Allowable Inlet Restriction at OEM Fuel Inlet:
Without Remote Mount Filter.................................................................................................76 mm Hg [3 in Hg]
With Remote Mount Filter..................................................................................................254 mm Hg [10 in Hg]
Lubricating Oil System Signature, ISX, and QSX15 Engi [...]
Page V-70 Section V - Specifications
Cooling System
General Information
Cummins Inc. recommends the use of fully-formulated antifreeze or coolant containing a precharge of supplemental
coolant additive (SCA). The antifreeze or coolant must meet the specifications outlined in The Maintenance Council
(TMC) Recommended Practice (RP) 329 (ethylene glycol) or RP 330 (propylene glycol). The use of fully-formulated
antifreeze or coolant significantly simplifies cooling system maintenance.
Copies of TMC specifications can be obtained through Cummins Inc., or by contacting:
The Maintenance Council
American Trucking Association
2200 Mill Road
Alexandria, VA 33314-5388
Phone: (703) 838-1763
Fax (703) 836-6070
Fully-formulated antifreeze contains balanced amounts of antifreeze, SCA, and buffering compounds, but does not
contain 50 percent water. Fully-formulated coolant contains balanced amounts of antifreeze, SCA, and buffering
compounds already premixed 50/50 with deionized water.
The following pages explain water, antifreeze, and SCAs and how to test antifreeze and SCA levels.
This section also contains information on cooling system maintenance and a coolant treatment chart that is used to
determine the correct SCA service filter.
Alternative maintenance practices for cooling systems can be found in Cummins Coolant Requirements and
Maintenance, Bulletin 3666132.
Specifications
Automotive Applications
Coolant Capacity (engine only)
With EGR...................................................................................................................................26.5 liters [28 qt]
Without EGR.................................................................................................................................24 liters [25 qt]
Standard Modulating Thermostat
Temperature Range.....................................................................................................82 to 93°C [180 to 200°F]
Maximum Coolant Pressure (exclusive of pressure cap - closed thermostat at the maximum no-load governed
speed)
With EGR....................................................................................................................82 to 93°C [180 to 200°F]
Without EGR...............................................................................................................................227 kPa [33 psi]
Coolant Alarm Activation Temperature
With EGR - Ratings Below 565 Horsepower...................................................................................107°C [225°F]
With EGR - Ratings of 565/600 Horsepower..................................................................................110°C [230°F]
Without EGR.................................................................................................................................110°C [230°F]
Maximum Allowable Top Tank Temperature
Ratings Below 565 Horsepower with EGR and without EGR Engines.............................................107°C [225°F]
Ratings of 565/600 Horsepower with EGR only..............................................................................110°C [230°F]
Minimum Recommended Top Tank Temperature
MinimumTemperature.....................................................................................................................70°C [160°F]
Minimum Allowable Draw Down
With EGR............................................................................................................................................11 Percent
Without EGR............................................2.4 liters [2.5 qt] 10 Percent of System Capacity (whichever is greater)
Minimum Recommended Pressure Cap
With EGR....................................................................................................................................103 kPa [15 psi]
Without EGR..................................................................................................................................50 kPa [7 psi]
Preferred......................................................................................................................................69 kPa [10 psi]
Minimum Fill Rate
Without Low-Level Alarm......................................................................................................19 liters/min [5 gpm]
Maximum Deaeration Time
Maximum Time...................................................................................................................................25 minutes
Fan-on Coolant Temperature
With EGR........................................................................................................................................99°C [210°F]
Without EGR...................................................................................................................................99°C [210°F]
Fan-on Intake Air Temperature
With EGR........................................................................................................................................93°C [200°F]
Cooling System Signature, ISX, and QSX15 Engi [...]
Page V-72 Section V - Specifications
Exhaust System
Specifications
Automotive Applications
Maximum Allowable Exhaust Back Pressure Created by Piping and Silencer
Hg (mercury)..........................................................................................................................76 mm Hg [3 in Hg]
H2O (water).................................................................................................................1016 mm H2O [40 in H2O]
Exhaust Pipe Size (normally acceptable inside diameter).....................................................................127 mm [5 in]
Industrial and Generator Drive
Maximum Allowable Exhaust Back Pressure Created by Piping and Silencer:
Industrial:
Hg (mercury)....................................................................................................................76 mm Hg [3 in Hg]
H2O (water)............................................................................................................1016 mm H2O [40 in H2O]
Maximum Allowable Exhaust Back Pressure Created by Piping and Silencer:
Power Generation:
Hg (mercury)....................................................................................................................51 mm Hg [2 in Hg]
H2O (water)..............................................................................................................682 mm H2O [27 in H2O]
Exhaust Pipe Size (normally acceptable inside diameter):
Industrial........................................................................................................................................127 mm [5 in]
Power Generation...........................................................................................................................152 mm [6 in]
Automotive With CM871
Maximum Allowable Exhaust Back Pressure Created by Piping and Silencer:
Automotive and Industrial:
Hg (mercury).................................................................................................................305 mm Hg [12 in Hg]
H20 (water).............................................................................................................4145 mm H20 [163 in H20]
Exhaust Pipe Size (normally acceptable inside diameter):
Automotive and Industrial...............................................................................................................127 mm [5 in]
Signature, ISX, and QSX15 Engi [...] Electrical System
Section V - Specifications Page V-75
Electrical System
Specifications
Minimum Recommended Battery Capacity:
* The number of plates within a given battery size determines reserve capacity. Reserve capacity determines the
length of time that sustained cranking can occur.
**CCA ratings are based on two 12-VDC batteries in series.
A minimum of 6 VDC at the OEM connector is required to power up the ECM.
Minimum Battery Capacity:
12-VDC Starter......................................................400 ampere-hours to 1800 cold cranking amps @ -18°C [0°F]
24-VDC Starter........................................................200 ampere-hours to 900 cold cranking amps @ -18°C [0°F]
Maximum Starting Circuit Resistance:
12-VDC Starter................................................................................................................................0.00075 ohm
24-VDC Starter................................................................................................................................0.00200 ohm
Battery Cable Sizes - American Wire Gauge (maximum length in cranking motor circuit):
12-VDC:
No. 00..........................................................................................................................................3.7 m [12 ft]
No. 000........................................................................................................................................4.9 m [16 ft]
No. 0000 or Two No. 0*................................................................................................................6.1 m [20 ft]
Two No. 00...................................................................................................................................7.6 m [25 ft]
Battery Cable Sizes - American Wire Gauge (maximum length in cranking motor circuit):
12-VDC High Output:
No. 00............................................................................................................................................2.1 m [7 ft]
No. 000..........................................................................................................................................2.7 m [9 ft]
No. 0000 or Two No. 0*................................................................................................................3.7 m [12 ft]
Two No. 00...................................................................................................................................4.3 m [14 ft]
Battery Cable Sizes - American Wire Gauge (maximum length in cranking motor circuit):
24 to 32 VDC:
No. 00..........................................................................................................................................6.1 m [20 ft]
No. 000........................................................................................................................................8.2 m [27 ft]
No. 0000 or Two No. 0*..............................................................................................................10.7 m [35 ft]
Two No. 00.................................................................................................................................13.7 m [45 ft]
Minimum Ambient Air Temperature without Starting Aid..........................................................................-1°C [30°F]
Minimum Cranking Speed without Starting Aid.............................................................................................130 rpm
* Two strands of No. 0 cable can be used in place of one No. 0000 cable, provided that connections are carefully
made to make sure equal current flow exists in each parallel cable.
Compressed Air System Signature, ISX, and QSX15 Engi [...]
Page V-76 Section V - Specifications
Engine Testing
Specifications
Automotive with CM870
Maintain the following limits during the engine test and run-in procedures:
Due to variations in ratings of different engine models, refer to the specific Engine Rating Data Sheet for the particular
engine model being tested.
Charge Air Cooler Restriction (maximum)
Mercury...........................................................................................................................76.2 mm Hg [3.0 in Hg]
Pounds Force...........................................................................................................................10.3 kPa [1.5 psi]
Intake Restriction (maximum at advertised horsepower)
Clean Air Filter.........................................................................................................254.0 mm H2O [10.0 in H2O]
Dirty Air Filter..........................................................................................................635.0 mm H2O [25.0 in H2O]
Exhaust Back Pressure (maximum).......................................................................................76.2 mm Hg [3.0 in Hg]
Oil Pressure
Low Idle (minimum)...............................................................................................................138.0 kPa [20.0 psi]
Oil Pressure Range......................................................................................241.0 to 276.0 kPa [35.0 to 40.0 psi]
Cylinder Block Coolant Pressure (closed thermostat, maximum).................................................262.0 kPa [38.0 psi]
Coolant Temperature
Operating Temperature (maximum)...............................................................................................107°C [225°F]
Fuel Inlet Temperature (maximum).......................................................................................................71°C [160°F]
Fuel Inlet Maximum Restriction
Clean Fuel Filter............................................................................................................203.2 mm Hg [8.0 in Hg]
Dirty Fuel Filter..................................................................................................................304.8 mm [12.0 in Hg]
Pressure Side Fuel Filter Restriction (maximum).........................................................................517.0 kPa [75.0 psi]
Fuel Drain Line Restriction (maximum)................................................................................228.6 mm Hg [9.0 in Hg]
Blowby (maximum at advertised or torque peak rpm) with 9-mm [0.354-in] orifice
New or rebuilt engines (maximum) less than 100,000 miles.........................................305 mm H2O [12.0 in H2O]
Used Engine (maximum) greater than 100,000 miles...................................................457 mm H2O [18.0 in H2O]
Automotive With CM871
Maintain the following limits during the engine test and run-in procedures:
Due to variations in ratings of different engine models, refer to the specific Engine Rating Data Sheet for the particular
engine model being tested.
Charge Air Cooler Restriction (maximum)
Mercury...........................................................................................................................76.2 mm Hg [3.0 in Hg]
Pounds Force...........................................................................................................................10.3 kPa [1.5 psi]
Intake Restriction (maximum at advertised horsepower)
Clean Air Filter.........................................................................................................254.0 mm H2O [10.0 in H2O]
Dirty Air Filter..........................................................................................................635.0 mm H2O [25.0 in H2O]
Exhaust Back Pressure (maximum)...................................................................................304.8 mm Hg [12.0 in Hg]
Oil Pressure
Low Idle (minimum)...............................................................................................................138.0 kPa [20.0 psi]
Oil Pressure Range......................................................................................241.0 to 276.0 kPa [35.0 to 40.0 psi]
Cylinder Block Coolant Pressure (closed thermostat, maximum)..................................331 kPa [48 psi] @ 1600 RPM
Coolant Temperature
Operating Temperature (maximum)...............................................................................................107°C [225°F]
Fuel Inlet Temperature (maximum).......................................................................................................71°C [160°F]
Fuel Inlet Maximum Restriction
Clean Fuel Filter............................................................................................................203.2 mm Hg [8.0 in Hg]
Dirty Fuel Filter..................................................................................................................304.8 mm [12.0 in Hg]
Pressure Side Fuel Filter Restriction (maximum).........................................................................517.0 kPa [75.0 psi]
Fuel Drain Line Restriction (maximum)................................................................................228.6 mm Hg [9.0 in Hg]
Blowby (maximum at advertised or torque peak rpm) with 9-mm [0.354-in] orifice
New or rebuilt engines (maximum) less than 100,000 miles.........................................305 mm H2O [12.0 in H2O]
Used Engine (maximum) greater than 100,000 miles...................................................457 mm H2O [18.0 in H2O]
Drive Belt Tension Signature, ISX, and QSX15 Engi [...]
Page V-78 Section V - Specifications
NOTES:
1. Always use the torque values listed in the following tables when specific torque values are not available.
2. Do not use the torque values in place of those specified in other sections of this manual.
3. The torque values in the table are based on the use of lubricated threads.
4. When the ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torque
wrench. Example: 6 ft-lb equals 72 in-lb.
Notes
Index
Page X-1
Copyright© 2007
Cummins Inc.
Bulletin 3666239
Printed in U.S.A. 09-AUGUST-2007 p41