_eaks, Air Intake and Exhaust S y s t e m s QSX15

5-6 Section 5 Maintenance Procedures at 1500 Hours or 1 Year

Compressor housing sealing surface air leak.

• Tighten the v-band.
Torque Value: 9 N»m [ 80 in-lb ]
• Check for an air leak.
• If an air leak is still present, remove and replace the
turbocharger. Refer to Procedure 010-033.

Variable Geometry

AWARNINGA
Removing the turbine housing v-band tamper proofing
on any variable geometry turbocharger will void the
Cummins Inc. warranty coverage.
Turbine housing sealing surface air leak: For variable
geometry turbochargers, the turbine v-band nut has a
tamper proof clamp. Therefore the torque specifications
for the turbine v-band will not be able to be checked.
The purpose of the tamper proofing is to prevent
disturbing this joint. Any loosening of the v-band or
adjusting of the orientation of the turbine housing will
affect the sliding nozzle clearances and will damage the
turbocharger and result in poor performance.
Indications of leakage are soot streaks from the joint and/
or an audible whistle from the engine. The turbochargers
must be replaced if there are any indications of leakage
from the turbine housing v-band joint.

EGR plumbing sealing joints leak:

Check for soot streaks from the EGR crossover tube and
hoses.
Tighten the hose clamps. Refer to Procedure 011-025.
Check for an exhaust leak. If an exhaust leak is still
present, remove and replace the EGR crossover tube or
hose.
QSX15 Air L e a k s , Air Intake and Exhaust S y s t e m s
Section 5 - Maintenance Procedures at 1500 Hours or 1 Year Page 5-7

Check for soot streaks from the EGR valve gasket and
seal rings.
nspect for signs of leakage such as soot streaks. If signs
of leakage are present, replace the EGR valve gaskets.
Refer to Procedure 011 -022.

Check for leakage from the EGR valve weep hole.

Soot leakage at the EGR valve weep hole is normal and
can be expected. Do not replace the EGR valve if soot
streaks are found at the EGR valve weep hole.

Check for leakage from the EGR cooler bellows.

inspect for signs of leakage such as soot streaks. If signs
of leakage are present, replace the EGR cooler or gasket.
Refer to Procedure 011-019.

Check for soot leakage at the EGR differential pressure

sensing tubes.
Inspect for signs of leakage such as soot streaks,
appearing yellowish brown or black.
If signs of leakage are present, replace the EGR
differential pressure tubes. Refer to Procedure 011-026.
Air Cleaner Restriction QSX15
Page 5-8 Section 5 - Maintenance Procedures at 1500 Hours or 1 Year

Check for soot leakage on the exhaust adapter pipe.

Inspect for signs for leakage such as soot streaks ,
appearing yellowish brown or black.
If signs of leakage are present, replace the gasket and v-
band clamp. Refer to procedure 011-043.
Clean all soot stains and paint the components in order to
detect future leaks.

Air Cleaner Restriction

Maintenance Check
Mechanical Indicator
© C u m m i n s Inc.
ACAUTIONA
Never operate the engine without an air cleaner.
Intake air must be filtered to prevent dirt and debris
from entering the engine and causing premature wear.
tmins Inc. NOTE: Do not remove the felt washer from the indicator.
The felt washer absorbs moisture.
ac4iaga A mechanical restriction indicator is available to indicate
excessive air restriction through a dry-type air cleaner.
This instrument can be mounted in the air cleaner outlet
or on the instrument panel. The red flag (1) in the window
gradually rises as the cartridge loads with dirt. After
changing or replacing the cartridge, reset the indicator by
pushing the reset button (2).
Restriction or vacuum indicators need to be installed as
close as possible to the turbocharger air inlet in order to
obtain a true indication of restrictions.

Vacuum Indicator
Vacuum switches actuate a warning light on the
instrument panel when the air restriction becomes
excessive.
QSX15 Engine Wiring Harness
Section 5 - Maintenance Procedures at 1500 Hours or 1 Year Page 5-9

Industrial Gas Mechanical Indicator

A mechanical restriction indicator is available to indicate
excessive air restriction through a dry-type air cleaner.
This instrument is mounted in the air cleaner outlet. The
red flag (1) in the window gradually rises as the cartridge
loads with dirt. When air restriction is indicated the air filter
must be replaced. After changing or replacing the
cartridge, reset the indicator by pushing the reset button
(2)

Engine Wiring Harness

Maintenance Check

AWARNINGA
To reduce the possibility of personal injury, do not
touch any ignition wires or components while the
engine is operating, unless using suitably insulated
tools.
Check all wire connections and the wiring harness for
damage. Faulty wiring can cause improper engine
operation and poor performance.
Engine Wiring Harness QSX15
Page 5-10 Section 5 - Maintenance Procedures at 1500 Hours or 1 Year

Notes
QSX15

Section 6 - Maintenance Procedures at 6000 Hours or 2 Y e a r s Page 6-a

Section 6 - Maintenance Procedures at 6000 Hours or 2 Years
Section Contents
Page
Cold Weather Starting Aids 6 - 2

Maintenance Check 6-2

Crankcase Breather (Internal) 6 - 3

Replace 6 - 3

Crankcase Breather Tube 6 - 1

Maintenance Check 6 - 1

Engine Mounts "

6 3

Inspect 6' 3

Engine Steam Cleaning 6 - 2

Clean . 6 - 2

Maintenance Procedures - Overview 6 - 1

General Information • 6"!

Overhead Set 6 - 4

Adjust 6 - 8

Measure ••• 6 - 4

General Information .,. 6 - 4

Radiator Hoses 6-2

Maintenance Check • 6 - 2

Vibration Damper, Viscous 6 - 3

Inspect 6 - 3
 QSX15
Page 6-b Section 6 - Maintenance Procedures at 6000 Hours or 2 Y e a r s

This Page Left Intentionally Blank

QSX15 C r a n k c a s e Breather Tube
Section 6 - Maintenance Procedures at 6000 Hours or 2 Y e a r s Page 6-1

Maintenance Procedures - Overview

General Information
All maintenance checks and inspections listed in previous
maintenance intervals must also be performed at this
time, in addition to those listed under this maintenance
interval.

Crankcase Breather Tube

Maintenance Check
Inspect the breather tube for sludge, debris, or ice in the Cummins
tube.
Inspect the tube more frequently in icy conditions.

Currim

If sludge, debris, or ice is found clean the tube with

detergent and warm water or a solvent. Dry the tube with
compressed air.

Visually inspect the tube for cracks or damage. If damage

is found, replace the crankcase breather tube. Contact
your Cummins Authorized Repair Location.

03900083
Engine Steam Cleaning QSX15
Page 6-2 Section 6 - Maintenance Procedures at 6000 Hours or 2 Y e a r s

Radiator Hoses
Maintenance Check
Check all hoses for cracks, cuts, or collapsing.
NOTE: The silicone engine coolant hose will exhibit
swelling due to the elasticity of the hose.
If damage is found, replace damaged hoses. Contact your
local Cummins Authorized Repair Location.

Cold Weather Starting Aids

Maintenance Check
^S^» Check the shutterstats and the thermatic fan.
NOTE: Parallel control systems are required for automatic
radiator shutters and thermatic fans. Shutters must
open and fans turn on whenever the intake manifold air
temperature, the engine coolant outlet temperature, or the
freon compressor pressure rises above their sensor set
points. Any one of the following conditions must activate
the shutters and/or fan:
• High coolant temperature
• High intake manifold temperature
• High freon compressor pressure.
Shutterstat and thermatic fan controls must operate in the
same temperature range as the thermostat with which
they are used. Refer to the Thermal Control Settings
Graph in this section.

\ Engine Steam Cleaning

Clean

AWARNINGA
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
Steam is the best method of cleaning a dirty engine or a
piece of equipment. If steam is not available, use a solvent
to wash the engine.
Protect all electrical components, openings, and wiring
from the full force of the cleaner spray nozzle.

-
QSX15 Crankcase Breather (Internal)
Section 6 - Maintenance Procedures at 6000 Hours or 2 Y e a r s Page 6-3

Engine Mounts
Inspect
Check the torque on the engine-mounting nuts and bolts.
Tighten any that are loose. Refer to the OEM service
manual or manufacturer for torque specifications.
Inspect the rubber for deterioration and age hardening.
Replace any broken or lost bolts, capscrews, or damaged
rubber.

Vibration Damper, Viscous

Inspect

ACAUTIONA
The silicone fluid in the vibration damper will become
solid after extended service and will make the damper
inoperative. An inoperative vibration damper can
cause major engine or drivetrain failures.
Check the vibration damper for evidence of fluid loss,
dents, and wobble. Inspect the vibration damper thickness
for any deformation or raising of the damper cover plate.
If any of these conditions are identified, contact your local
Cummins Authorized Repair Location to replace the
vibration damper.
For vibration damper location, refer to Engine Diagrams
in Engine Identification (Section E).

Crankcase Breather (Internal)

Replace
Replace the crankcase breather (internal).
Contact a Cummins® Authorized Repair Location to
schedule this maintenance.
 QSX15
Section 6 Maintenance Procedures at 6000 Hours or 2 Y e a r s

Overhead Set
Measure
General Information
All overhead lash measurements must be made when the
engine is cold. Stabilized coolant temperature must be at
60°C[140°F] or below.

Remove the rocker lever cover. Refer to Procedure

003-011 (Rocker Lever Cover) in Section 3.
Make sure the engine base timing is properly set before
attempting to measure, adjust, or set the overhead. Refer
to Procedure 001-088 (Engine Base Timing) in Section 1.

Early engine vibration dampers are marked with BRAKE

SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4. The engine
brakes must be set at the appropriate mark on these
engines. Newer engine vibration dampers are marked
with only A, B, or C, and are adjusted with the valves and
injector on the same cylinder.
Locate the valve set marks on the outside of the vibration
damper.
The set marks are A, B, and C:
Set to mark A to adjust cylinder 1 or 6.
Set to mark B to adjust cylinder 2 or 5.
Set to mark C to adjust cylinder 3 or 4.
Two complete revolutions are required to set all valves,
engine brakes, and injectors.

is If the engine is equipped with an air compressor:

Remove the oil fill connector from the lower gear case
cover.

1 Insert a 3/4-inch drive ratchet and extension into the air

compressor drive.
Rotate the air compressor drive clockwise, as viewed
from the front of the engine.
QSX15 Overhead Set
Section 6 - Maintenance Procedures at 6000 Hours or 2 Y e a r s Page 6-5

AWARNINGA
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
'ront 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.

I the engine is not equipped with an air compressor:

_oosen the cover plate capscrews and rotate the cover or
'emove the oil fill tube, if equipped.

Jse a 1 /2 inch socket to push the barring gear into the

1

gear mesh and rotate the barring adapter

counterclockwise to bar the engine.
Rock the barring device back and forth until it disengages.
Overhead Set QSX15
Page 6-6 Section 6 - Maintenance Procedures at 6000 Hours or 2 Y e a r s

Each cylinder has four rocker levers:

• The exhaust valve rocker lever (1)
• The injector rocker lever (2)
• The intake valve rocker lever (3)
• The engine brake rocker lever (4).
The intake valve rocker lever is always the long lever on
the valve rocker lever shaft.
Early engine vibration dampers are marked with BRAKE
SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4. The engine
brakes must be set at the appropriate mark on these
engines. Newer engine vibration dampers are marked
with only A, B, or C, and are adjusted with the valves and
injector on the same cylinder.
The valves, brakes, and the injectors on the same cylinder
are adjusted at the same index mark on the vibration
damper.

Injector and Valve Adjustment Sequence

Bar Engine
Set Set Set
in Pulley
Cylinder Cylinder Cylinder
Direction Position
Injector Valve Brake
of Rotation
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Firing Order: 1-5-3-6-2-4

NOTE: For illustrative purposes, position A is shown as

the first step. It is not necessary to start with position A,
as long as the proper sequence is followed.
Use the compressor drive or barring device to bar the
engine over in the direction of engine rotation,
clockwise as viewed from the front of the engine. Align
the A mark on the vibration damper with the pointer on the
gear cover.
QSX15 Overhead Set
Section 6 - Maintenance Procedures at 6000 Hours or 2 Y e a r s Page 6-7

Check the valve rocker levers on the given cylinder to see

if both intake and exhaust valves are closed.
Both sets of valves are closed when the rocker levers and
the brake lever are loose. If both sets of valves are not
closed, rotate the compressor drive gear one complete
revolution, and align the A mark on the front damper with
the pointer again.

Valve Lash
Use feeler gauges to measure the amount of clearance
(lash) between the crosshead and the rocker lever nose.
Measure and record the intake, exhaust, and brake valve
lash. If the valve lash is not within the specifications listed
below, the valve must be adjusted. See the adjust step in
this procedure.
Press the brake lever down to verify the camshaft follower
is in contact with the camshaft prior to measurement of
the brake lash.

ISX, QSX Series Valve Lash Recheck Limits

Intake 0.23 mm minimum 0.006 in
Intake 0.48 mm maximum 0.019 in
Exhaust 0.56 mm minimum 0.022 in
Exhaust 0.81 mm maximum 0.032 in
Brake 6.87 mm minimum 0.271 in
Brake 7.13 mm maximum 0.281 in

Brake Running Clearance

Rotate the brake lever to the detent (neutral) position.
Check the clearance between the engine brake actuator
piston and the cross head guide pin (1). If the brake
running clearance is not within the specifications listed
below, the running clearance must be adjusted. See the
Adjust step in this procedure.

Brake Running Clearance

mm in
0.635 MIN 0.025
2.79 MAX 0.110
Injector Lash
There is no service procedure to check the injector free
load.
Install the rocker lever cover. Refer to Procedure 003-011
(Rocker Lever Cover) in Section 3.
Overhead Set QSX15
Page 6-8 Section 6 - Maintenance Procedures at 6000 Hours or 2 Y e a r s

Adjust
Read the entire procedure for overhead adjustment before
attempting to perform this operation.
Valves, injectors, and engine brakes (if equipped) must
be correctly adjusted for the engine to operate efficiently.
Valve, injector, and engine brake adjustment must be
performed using the values listed in this section.
After an engine rebuild or any major repair where the
injector and valve setting must be disturbed, set all of the
valves, injectors, and brakes.
Adjust the valves, injectors, and engine brakes every
6,000 hours, or 2 years (whichever occurs first).
Adjustment must be made after any major repair. After a
major repair, the adjustment interval again becomes every
6,000 hours, or 2 years (whichever occurs first).

Valve, Brake, and Injector Adjustment Values

Injector Adjustment is 8 N«m [70 in-lb]
Intake Valve 0.35 mm [0.014 in]
Exhaust Valve 0.68 mm [0.027 in]
Engine Brake 7.00 mm [0.276 in]

Early engine vibration dampers are marked with BRAKE

SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4. The engine
brakes must be set at the appropriate mark on these
engines. Newer engine vibration dampers are marked
with only A, B, or C, and are adjusted with the valves and
injector on the same cylinder.
Locate the valve set marks on the outside of the vibration
damper.
The set marks are A, B, and C:
Set to mark A to adjust cylinder 1 or 6.
Set to mark B to adjust cylinder 2 or 5.
Set to mark C to adjust cylinder 3 or 4.
Two complete revolutions are required to set all valves,
engine brakes, and injectors.

If the engine is equipped with an air compressor:

Remove the oil fill connector from the lower gear case
cover.
Insert a 3/4-inch drive ratchet and extension into the air
compressor drive.
Rotate the air compressor drive clockwise, as viewed
from the front of the engine.
QSX15 Overhead Set
Section 6 - Maintenance Procedures at 6000 Hours or 2 Y e a r s Page 6-9

AWARNINGA
Do not pull or pry on the fan to manually rotate the
engine. To do so can damage the fan blades.
Damaged fan blades can cause premature fan failures
which can result in serious personal injury or property
damage.
The crankshaft rotation is clockwise as viewed from the
front of the engine.
The cylinders are numbered from the front of the engine
(1-2-3-4-5-6).
The engine firing order is 1-5-3-6-2-4.

If the engine is not equipped with an air compressor:

Loosen the capscrews and rotate the cover or remove the
oil fill tube, if equipped.

Use a 1 /2 inch socket to push the barring gear into the

1

gear mesh and rotate the barring adapter

counterclockwise to bar the engine.
Rock the barring device back and forth until it disengages.
 - e a d Set QSX15
=-aoe 5-10 Section 6 - Maintenance Procedures at 6000 Hours or 2 Y e a r s

Each cylinder has four rocker levers:

• The exhaust valve rocker lever (1)
• The injector rocker lever (2)
• The intake valve rocker lever (3)
• The engine brake rocker lever (4).
The intake valve rocker lever is always the long lever on
the valve rocker lever shaft.
Early engine vibration dampers are marked with BRAKE
SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4. The engine
brakes must be set at the appropriate mark on these
engines. Newer engine vibration dampers are marked
with only A, B, or C, and are adjusted with the valves and
injector on the same cylinder.
The valves, brakes, and injectors on the same cylinder are
adjusted at the same index mark on the vibration damper.

Injector and Valve Adjustment Sequence

Bar Engine
Set Set Set
in Pulley
Cylinder Cylinder Cylinder
Direction Position
Injector Valve Brake
of Rotation
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Firing Order: 1-5-3-6-2-4

NOTE: For illustrative purposes, position A is shown as

the first step. It is not necessary to start with position A,
as long as the proper sequence is followed.
Use the compressor drive or barring device to bar the
engine over in the direction of engine rotation,
clockwise as viewed from the front of the engine. Align
the A mark on the vibration damper with the pointer on the
gear cover.
QSX15 Overhead Set
Section 6 Maintenance Procedures at 6000 Hours or 2 Y e a r s Page 6-11

Check the valve rocker levers on the given cylinder to see

if both intake and exhaust valves are closed.
Both sets of valves are closed when the rocker levers and
the brake lever are loose. If both sets of valves are not
closed, rotate the compressor drive gear one complete
revolution, and align the A mark on the front damper with
the pointer again.

Loosen the injector adjusting screw locknut on the

cylinder.
Do not use a click-type torque wrench.
Use a dial-type torque wrench with a range of 0 to 150 in-
lb to tighten the injector rocker lever adjusting screw. If the
screw chatters during setting, repair the screw and lever
as required.
Back out the adjusting screw one or two turns.
Hold the torque wrench in a position that allows you to look
in a direct line at the dial. This is to make sure the dial will
be read accurately.
Make sure the parts are aligned, and squeeze the oil out
of the valve and injector train by tightening the adjusting
screw.
Use this initial adjustment to preload the valve train and
injector.

Tighten the injector lever adjusting screw.

Torque Value: 8 N«m [ 71 in-lb ]
Back the adjusting lever screw out 1 or 2 turns.
Tighten the injector lever adjusting screw.
Torque Value: 8 N»m [ 71 in-lb ]
Overhead Set QSX15
Page 6-12 Section 6 - Maintenance Procedures at 6000 Hours or 2 Y e a r s

Hold the injector lever adjusting screw and tighten the

adjusting screw locknut.
Torque Value: 75 N«m [ 55 ft-lb ]
G Cummin

After setting the injector on a cylinder, set the valves and

engine brakes on the same cylinder.
Early engine vibration dampers are marked with BRAKE
SET 1-6, BRAKE SET 2-5, or BRAKE SET 3-4. The engine
brakes must be set at the appropriate mark on these
engines. Newer engine vibration dampers are marked
with only A, B, or C, and are adjusted with the valve and
injector on the same cylinder.

With the set mark aligned with the pointer on the gear
cover and both sets of valves closed on the cylinder,
loosen the locknuts on the intake and exhaust valve
adjusting screws.
Back out the adjusting screws one or two turns.

Select a feeler gauge for the correct valve lash

® specification.

Valve Lash Specification

mm in
Intake 0.36 NOM 0.014
Exhaust 0.69 NOM 0.027
Insert the feeler gauge between the top of the crosshead
and the rocker lever nose pad.
Make sure the feeler gauge is completely under the
pivoting rocker lever nose pad.
3SX15 Overhead Set
Section 6 Maintenance Procedures at 6000 Hours or 2 Y e a r s Page 6-13

Hghten the adjusting screw.

Torque Value: 0.6 N«m [ 5 in-lb ]

Jse a torque wrench and crows foot adapter to tighten the

Dcknut.
Hold the adjusting screw in this position. The adjusting
screw must not turn when the locknut is tightened.
Torque Value: 45 N»m [ 33 ft-lb ]

nfter tightening the locknut to the correct torque value,

emove the feeler gauge.

ACAUTIONA
Wo get maximum brake operating efficiency and to
: event engine damage, the brake adjustment
instructions must be followed.
-or older engines, locate the engine brake set marks on
:ne outside of the vibration damper.
The set marks are BRAKE SET 1-6, and BRAKE SET 2-5,
and BRAKE SET 3-4.
5 RAKE SET 1-6 Cylinder 1 or 6 adjust
3RAKE SET 2-5 Cylinder 2 or 5 adjust
3RAKE SET 3-4 Cylinder 3 or 4 adjust
Overhead Set QSX15
Page 6-14 Section 6 - Maintenance Procedures at 6000 Hours or 2 Y e a r s

Use the compressor drive or barring device to bar the

engine over in the direction of rotation, clockwise as
viewed from the front of the engine. Align the A mark on
the vibration damper with the pointer on the gear cover.
For illustrative purposes, position A is shown as the first
step. It is not necessary to start with position A, as long
as the proper sequence is followed.

Check the valve rocker levers on the given cylinder to see

if both intake and exhaust valves are closed.
Both sets of valves are closed when the rocker levers and
the brake lever are loose. If both sets of valves are not
closed, rotate the compressor drive gear one complete
revolution, and align the A mark on the front damper with
the pointer again.

Press the engine brake lever down to verify the camshaft

follower is in contact with the camshaft.

Loosen the locknut on the brake lever adjusting screw,

® and back out the adjusting screw one turn.
Insert the feeler gauge, Part Number 3163530, between
the bottom of the engine brake piston and the top of the
exhaust valve pin on the exhaust valve crosshead.

Brake Lever Lash Specification

mm in
7.00 NOM 0.276
QSX15
Section 6 Overhead Set
Maintenance Procedures at 6000 Hours or 2 Y e a r s
Page 6-15
Tighten the adjusting screw until drag on the feeler gauge
is felt Proper drag means that there is no motion of the
brake lever camshaft follower against the cam lobe

Hold the engine brake lever adjusting screw and tighten

ne locknut.
Torque Value: 20 N»m [ 177 in-lb ]
Remove the feeler gauge.
Overhead Set QSX15
Page 6-16 Section 6 Maintenance Procedures at 6000 Hours or 2 Years

® ACAUTIONA
Engine damage can occur if the running clearance is
not within specifications.
Check the running clearance:
1. Rotate the engine brake rocker lever to the detente
(neutral) position.
2. Check the clearance (1) between the engine brake
lever actuator piston and the crosshead guide pin.

Engine Brake Rocker Lever Running Clearance

mm in
0.635 MIN 0.025
2.790 MAX 0.110
If the running clearance does not meet specification,
loosen, but do not remove the rocker shaft capscrews,
and rotate the shaft in the direction required to bring the
running clearance within the listed specification. It is
critical that this clearance be set and verified on all six
brake levers. Engine damage can result if this task is
not completed.
Check the brake running clearance.
The rocker lever shafts m u s t be adjusted so that all three
engine brake levers fall within the given running clearance
specification.
Repeat the process to adjust all injectors, engine brakes,
and valves according to the chart shown below.

Injector and Va ve Adjustment Sequence

Bar Engine
Set Set Set
in Pulley
Cylinder Cylinder Cylinder
Direction Position
Injector Valve Brake
of Rotation
Start A 1 1 1
Advance to B 5 5 5
Advance to C 3 3 3
Advance to A 6 6 6
Advance to B 2 2 2
Advance to C 4 4 4
Firing Order: 1-5-3-6-2-4
3SX15
Section 7 - Maintenance Procedures at 10,000 Hours or 5 Years Page 7-a

Section 7 - Maintenance Procedures at 10,000 Hours or 5

Years
Section Contents
Page
Air Compressor Discharge Lines 7-1
General Information -» 7-1
Maintenance Check 7-2
=an Hub, Belt Driven 7-1
Maintenance Check . 7-1
Maintenance Procedures - Overview 7-1
General Information 7-1
 QSX15 QSX
Page 7-b Section 7 - Maintenance Procedures at 10,000 Hours or 5 Years Sect
QSX15 Air Compressor Discharge Lines
Section 7 - Maintenance Procedures at 10,000 Hours or 5 Years Page 7-1

Maintenance Procedures - Overview

General Information
All maintenance checks and inspections listed in previous
maintenance intervals m u s t also be performed at this
time, in addition to those listed under this maintenance
nterval.

Fan Hub, Belt Driven

Maintenance Check
nspect the fan hub for the following:
• Freedom of rotation
• Cracks
• Grease seal leakage.
Repair or replace the fan hub if the fan hub does not rotate
•'eely or if there is evidence of cracks or grease seal
eakage.

Measure the fan hub end clearance. Fan hubs with "step-
Dore" shafts and not bearing spacers m u s t be 0.08 to 0.25
mm [0.003 to 0.010 in] end clearance.
ra n hubs with "through-bore" shafts with inner and outer
searing spacers m u s t be 0.08 to 0.41 mm [0.003 to 0.016
n] end clearance.

Air Compressor Discharge Lines

General Information
All air compressors have a small amount of lubricating oil
carryover that lubricates the piston rings and moving
oarts. When this lubricating oil is exposed to normal air
compressor operating temperatures over time, the
ubricating oil will form varnish or carbon deposits. If the
'ollowing maintenance check are not performed, the air
compressor piston rings will wear and not seal correctly.
Air Compressor Discharge Lines QSX15
Page 7-2 Section 7 - Maintenance Procedures at 10,000 Hours or 5 Years

Maintenance Check

AWARNINGA
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Shut off the engine.
Open the drain valve on the wet tank to release the system
©CumminsIr AST" © Cummins Inc. air pressure.

cp8tbmh

Remove the air compressor discharge line from the air

compressor. Location of the air compressor discharge line
can be found in Flow Diagram, Compressed Air System in
System Diagrams (Section D).

Measure the total carbon deposit thickness inside the air

discharge line as shown. If the total carbon deposit (X +
X) exceeds 2 mm [1/16 in], clean and inspect the cylinder
head, the valve assembly, and the discharge line. Replace
if necessary. Contact the Cummins Authorized Repair
Location for procedures.

If the total carbon deposit exceeds specifications,

continue checking the air discharge line connections up
to the first tank until total carbon deposit is less than 2 mm
[1/16 in]. Clean or replace any lines or connections that
exceed this specification.
QSX15
Air Compressor Discharge Lines
Section 7 - Maintenance Procedures at 10,000 Hours or 5 Years Page 7-3
Inspect any air driers, splitter valves, pressure relief £ZS
valves, and alcohol injectors for carbon deposits or r^M
malfunctioning parts. Inspect for air leaks. Maintain and
repair the parts according to the manufacturer's
specifications. >S^» is Inc. I

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ca8cnga
QSX15
Section A - Adjustment, Repair, and Replacement Page A-a

Section A - Adjustment, Repair, and Replacement

Section Contents
Page
Air Starting Motor .....A-1
General Information A-1
Battery Cables and Connections A-1
Initial Check A-1
Belt Tensioner, Automatic (Water Pump) A-15
Finishing Steps A-22
Drives Alternator A-22
Initial Check A-15
Without EGR A-15
Inspect for Reuse A-18
Drives Alternator A-18
Without EGR A-19
Install A-20
Drives Alternator A-20
Automotive Applications Without EGR A-20
Industrial and Power Generation Application Without EGR A-21
Preparatory Steps A-15
Drives Alternator A-15
Remove A-16
Drives Alternator A-16
Automotive Applications Without EGR A-16
Industrial and Power Generation Application Without EGR A-17
Drive Belt, Cooling Fan A-9
Clean and Inspect for Reuse A-9
Drives Alternator A-9
Install A-10
Drives Alternator.. A-10
Remove A-9
Drives Alternator A-9
Fan Hub, Belt Driven A-10
Clean and Inspect for Reuse . A-12
With EGR A-12
Without EGR... A-12
Finishing Steps A-15
With EGR A-15
Install '. A-13
With EGR A-13
Automotive Applications Without EGR A-13
Industrial and Power Generation Application Without EGR A-14
Preparatory Steps A-10
With EGR A-10
Remove A-10
With EGR A-10
Automotive Applications Without EGR A-11
Industrial and Power Generation Application Without EGR A-11
Fuel Shutoff Valve A-7
Inspect for Reuse A-7
Install A-8
Remove A-7
Turbocharger A-2
Finishing Steps A-6
Install A-3
Preparatory Steps A-2
Remove .A-2
QSX15 Battery Cables and Connections
Section A - Adjustment, Repair, and Replacement Page A-1

Air Starting Motor

General Information
The air starting motor system (tanks, line sizes, and valves) is designed and installed by the original equipment
manufacturers and the starting motor suppliers. Reference any questions about the air starting systems to the
manufacturer.
• Do not operate the air starting motor with air pressure lower than 480 kPa [70 psi].
• Maintain the air starting motor according to the manufacturer's recommendations.
• For maximum efficiency, the hoses, tubes, and lines m u s t not leak.
• Refer to the OEM service manual and manufacturer manuals for specific information regarding the starting
motors, valves, and systems.

Battery Cables and Connections

AWARNINGA
Batteries can emit explosive gases. T o reduce the
possibility of personal injury, always ventilate the
c o m p a r t m e n t before s e r v i c i n g t h e batteries. T o
reduce t h e possibility of a r c i n g , r e m o v e the negative
(-) battery cable first a n d attach the negative (-) battery
cable last.
Remove and inspect the battery cables and connections
*Dr cracks or corrosion.
Replace broken terminals, connectors, or cables.

* the connections are corroded, use a battery brush or

•vire brush to clean the connections until shiny.
Make sure all debris is removed from the connecting
surfaces.
Turbocharger QSX15
Page A-2 Section A - Adjustment, Repair, and Replacement

AWARNINGA
Batteries can emit explosive g a s e s . 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 cables and tighten the battery connections.
Coat the terminals with grease to prevent corrosion.

I ealcohd

Turbocharger
Preparatory Steps
^g^, ISX Automotive with CM570, QSX15 with CM570, and
Power Generation with CM570
Remove the wastegate actuator hose. Refer to
Procedure 010-050 in Section 10.

> Cummins Inc.

Remove

AWARNINGA
This component weighs 23 kg [50 lb] or more. T o
reduce the possibility of personal injury, use a hoist
or get assistance to lift this component.
Automotive, Industrial, and Power Generation with
CM570
• Remove the oil supply, oil drain tube, and brace (if
equipped) from the turbocharger.
QSX15 Turbocharger
Section A - Adjustment, Repair, and Replacement Page £-3

Remove the clamp, o-ring, and discharge elbow from the

turbocharger.
Discard the o-ring.

NOTE: In some applications, the turbocharger will not

clear the lubricating oil cooler assembly during removal
and installation. It will, perhaps, be necessary to remove
:he exhaust manifold and turbocharger together, and then
separate the two components. If the two components
must be removed together for the removal and installation
of the exhaust manifold. Refer to Procedure 011-007 in
Section 1 1 .
f the turbocharger mounting nuts do not loosen freely,
split the nuts to avoid breaking a mounting stud.
Remove the four turbocharger mounting nuts.
Remove the turbocharger and discard the gasket.

Install
ISX Automotive with CM570, QSX15 with CM570, and
Power Generation with CM570
Apply a film of high-temperature anti-seize compound,
Part Number 3823097, or equivalent, to the
turbocharger mounting studs.

Anti-Seize
Compound
Turbocharger QSX15
Page A-4 Section A - Adjustment, Repair, and Replacement

AWARNINGA
This component weighs 23 kg [50 lb] or more. T o
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, see the_ following
procedure for installation of the exhaust manifold. Refer
to Procedure 011-007 in Section 11.
Install a new mounting gasket, the turbocharger, and the
four mounting nuts.
Tighten the mounting nuts.
Torque value for the standard nut:
Torque Value: 61 N«m [ 45 ft-lb ]
Torque value for the Spiralock™ nut (identified by "SPL"
on the nut flange):
Torque Value: 81 N«m [ 60 ft-lb ]

Install the discharge elbow and clamp onto the charge-air

fcpjjfe! cooler pipe connection.
Do not tighten the clamp until the elbow is installed on the
CuH turbocharger.

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tbltbhc

If a new turbocharger is being installed, the variable

geometry turbocharger actuator from the original
turbocharger must be reused.
Refer to Procedure 010-134 in Section 10.
Install a new o-ring, the clamp, and the discharge elbow
to the turbocharger.
Tighten the clamp.
Torque Value: 9 N»m [ 80 in-lb ]
QSX15 Turbocharger
Section A - Adjustment, Repair, and Replacement Page A-5

Install a new gasket, oil drain tube, and capscrews.

Tighten the capscrews.
Torque Value: 25 N»m [ 221 in-lb ]

Install the turbocharger anti-rotation brace (if equipped) .

The end rests on the oil cooler housing.
This brace requires longer, 1.25 mm [0.049 in],
#
capscrews.
Tighten the capscrews.
Torque Value: 25 N«m [ 221 in-lb ]

Pour approximately 50 to 60 cc [1.7 to 2 oz] of clean

engine oil into the turbocharger oil supply opening.
Turbocharger QSX15
Page A-6 Section A - Adjustment, Repair, and Replacement

ACAUTIONA
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 [ 1 0 6 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 ]

Install the intake and exhaust pipes to the turbocharger.

Tighten the clamp.
Torque Value: 9 N»m [ 80 in-lb ]

Finishing Steps
ISX Automotive with CM570, QSX15 with CM570, and
Power Generation with CM570
ns Inc. Install the wastegate actuator hose. Refer to
Procedure 010-050 in Section 10.
Start and operate the engine until the coolant
temperature reaches 82°C [180°F] and check for air,
coolant, and oil leaks.
D Cummins inc.

ck800wa
QSX15 Fuel Shutoff Valve
Section A - Adjustment, Repair, and Replacement Page A-7

Fuel Shutoff Valve

Remove
Use a wrench to hold the nut at the base of the post.
Use a 3/8-inch wrench to remove the nut holding the
electrical connection of the fuel shutoff valve coil.
Remove the connection.

Remove the four Allen head capscrews.

Remove the coil (1) and the fuel shield (2).
Remove the valve spring washer (3), valve disc (4), and
actuator disc (5) from the actuator housing (7) from the
IFSM (8).
Discard the o-rings (6).

Inspect for Reuse

AWARNINGA
W h e n u s i n g s o l v e n t s , acids, or alkaline materials f o r
c l e a n i n g , f o l l o w the m a n u f a c t u r e r ' s r e c o m m e n d a t i o n s
for use. Wear g o g g l e s and p r o t e c t i v e c l o t h i n g t o
reduce the possibility of personal injury.

AWARNINGA Cummii is \ncn

Some s o l v e n t s are f l a m m a b l e and t o x i c . Read the
0 ^
m a n u f a c t u r e r ' s i n s t r u c t i o n s before u s i n g .
Use mineral spirits. Clean all of the parts except the coil gr8vaka
assembly.
NOTE: Do not get solvent on the coil. Clean the coil with
a dry cloth. Use a 200-grit emery cloth and a flat surface
to polish the coil surface.
Check the valve disc, valve seat, and actuator disc for dirt,
metal parts, bonding separation, corrosion, cracks, or
wear. Replace if necessary.
Fuel Shutoff Valve QSX15
Page A-8 Section A - Adjustment, Repair, and Replacement

Use a wire brush to clean any corrosion from the coil

terminal.
s

) Cummins inc.

Check the coil assembly with a multimeter. Replace the

Ohms solenoid if the resistance is not to specification.

Fuel System Shutoff Valve Solenoid Specifications

Voltage Resistance Resistance
Minimum (Ohms) Maximum (Ohms)
6 VDC 1 5
12 VDC 6 15
is snc. 24 VDC 24 50
32 VDC 42 80
36 VDC 46 87
fvSetka
48 VDC 92 145
74 VDC 315 375
115 VAC 645 735

NOTE: If the coil assembly shows 0 ohm, there is an

electrical short in the coil.

Install
Assemble the shutoff valve as shown. Install these parts
as follows.
Install a new o-ring between the spacer and the electronic
control valve body.
Install the spacer o-ring groove toward the coil.
Install the actuator disc with the cup side toward the coil.
Install the spring washer with the cup side toward the coil.
QSX15 Drive Belt, Cooling Fan
Section A - Adjustment, Repair, and Replacement Page A-9

Align the actuator disc, spacer, and valve disc on the

electronic control valve body.
Install a new o-ring.
Put the spring washer on the valve disc with the cavity side
positioned upward.
NOTE: The coil m u s t be oriented with the electrical
connection post on the bottom.
NOTE: Make sure the shutoff valve coil is the correct
voltage (12 VDC). The coil voltage and part number are
cast into the terminal connection end of the coil.
Install the fuel shield and coil onto the front cover.
Install a new o-ring and tighten the Allen head capscrews.
Torque Value: 3.4 N»m [ 30 in-lb ]

Install the electrical connection on the fuel shutoff valve.

Install the nut onto the threaded post of the coil.
Use a wrench to hold the nut at the base of the post firmly
while tightening the connection nut.
Torque Value: 3 N»m [ 25 in-lb ]

Drive Belt, Cooling Fan

Remove
Drives A l t e r n a t o r

ACAUTIONA
The belt t e n s i o n e r is s p r i n g loaded and m u s t be
pivoted away f r o m t h e d r i v e belt. P i v o t i n g in the
w r o n g d i r e c t i o n can result in damage t o t h e belt
tensioner or cause personal injury.
Pivot the automatic tensioner down to relieve tension on
the belt. Remove the belt.

Clean and Inspect for Reuse

Drives A l t e r n a t o r
Inspect the alternator pulley, the water pump pulley, the
fan clutch pulley, and the crankshaft pulley for cracks,
burrs, and broken or deformed grooves.
Use a wire brush to clean debris found in the pulley
grooves.

fa8pusa
Fan Hub, Belt Driven QSX15
Page A-10 Section A - Adjustment, Repair, and Replacement

Inspect the belt for cracks, glazing, tears or cuts, and

excessive wear. Replace the belt if necessary.

Install
Drives Alternator

ACAUTIONA
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 c a u s e personal injury.
Pivot and hold the belt tensioner. Install the drive belt and
release the tensioner.

Fan Hub, Belt Driven

Preparatory Steps
With E G R
Remove the following:
• Fan. Refer to Procedure 008-040.
• Cooling fan drive belt. Refer to Procedure 008-002.
• Automatic belt tensioner (water pump). Refer to
Procedure 008-080.
QSX15 Fan Hub, Belt Driven
Section A - Adjustment, Repair, and Replacement Page A-11

Automotive Applications Without E G R

Remove the fan. Refer to Procedure 008-040.
Remove the alternator and water pump belts. Refer to
Procedure 008-003 and Procedure 013-005.

AWARNINGA
This assembly weighs 23 kg [50 lb] or more. To avoid
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.

Industrial and Power Generation Application Without

EGR
Remove the fan. Refer to Procedure 008-040.
Remove the fan and water pump belt. Refer to Procedure
008-003.

Remove the alternator drive belt. Refer to Procedure

013-005.
Fan Hub, Belt Driven QSX15
Page A-12 Section A - Adjustment, Repair, and Replacement

NOTE: The fan support m u s t be removed prior to

0M P ^Jl removing the fan hub.
0 lo
Remove the fan hub from the fan hub support. Refer to
1°
0 0
9J ° )
0 0 F "
Procedure 008-088.
0 1°
0 1° :
p
b'
(fS Jo '

0 1°
0
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0 p
hi
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Clean and Inspect for Reuse

With E G R
Inspect the fan hub for the following:
• Freedom of rotation
• Cracks
• Grease seal leakage.
Repair or replace the fan hub if the fan hub does not rotate
freely or if there is evidence of cracks or grease seal
leakage.
Refer to the OEM service literature for repair of the fan
hub.

Measure the fan hub end clearance play. The end

clearance is dependent upon the fan hub style.
Replace the fan hub if the end clearance is not within the
manufacturer's specifications.
Refer to OEM service manual for additional inspection
steps.

. •Am.iv- M ,..
5

Without E G R
Inspect the fan hub for the following:
• Freedom of rotation
Cummins Inc. • Cracks
• Grease seal leakage.
Repair or replace the fan hub if the fan hub does not rotate
freely or if there is evidence of cracks or grease seal
leakage.
QSX15 Fan Hub, Belt Driven
Section A - Adjustment, Repair, and Replacement Page A-13

Install
With EGR

AWARNINGA
This assembly weighs 23 kg [50 lb] or more. To avoid
personal injury, u s e 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 [ 8 3 ft-lb ]

Automotive Applications Without EGR

AWARNINGA
This assembly weighs 23 kg [50 lb] or more. To avoid
personal injury, u s e 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.

Install the belts. Refer to the Procedure 008-003 and

013-005.
Install the fan. Refer to Procedure 008-040.

08c00172
Fan Hub, Belt Driven QSX15
Page A-14 Section A - Adjustment, Repair, and Replacement

Industrial and Power Generation Application Without

EGR
NOTE: The fan hub must be installed in the correct
location on the fan support to allow proper clearance
between the fan and fan shroud. Refer to the OEM service
manual.

N O T E : The fan hub must be installed prior to installing

the fan support.
Install the fan hub on the fan support using four capscrews
and washers.
NOTE: Make certain the correct fan center is used for the
application.
Tighten the capscrews.
Torque Value: 90 N»m [ 66 ft-lb ]
Install the fan support. Refer to Procedure 008-088.

Install the fan and water pump drive belt. Refer to

Procedure 008-003.
Install the cooling fan. Refer to Procedure 008-040.
QSX15 Belt Tensioner, Automatic (Water Pump)
Section A - Adjustment, Repair, and Replacement Page A-15

Finishing Steps
With E G R
Install the following:
• Automatic belt tensioner (water pump). Refer to
Procedure 008-080.
• Cooling fan drive belt. Refer to Procedure 008-002.
• Fan. Refer to Procedure 008-040.

Belt Tensioner, Automatic (Water

Pump)
Preparatory Steps
Drives A l t e r n a t o r

ACAUTIONA
The belt t e n s i o n e r is s p r i n g loaded and must be
p i v o t e d away f r o m t h e d r i v e belt. P i v o t i n g in t h e
w r o n g d i r e c t i o n can result in damage t o the belt
t e n s i o n e r or personal injury.
Remove the cooling fan belt. Refer to Procedure 008-062.

Initial Check
Without EGR
With the engine turned off and with the water pump/fan
belt installed, check that neither the top nor bottom
tensioner arm stop is touching the cast boss on the
tensioner body. If either of the stops is touching a boss,
the water pump/fan belt m u s t be replaced. Check to make
sure the correct belt part number is being used if either
condition exists.

Check the tensioner pulley and body for cracks. If any

cracks are noticed, the tensioner must be replaced.
Belt Tensioner, Automatic (Water Pump) QSX15
Page A-16 Section A - Adjustment, Repair, and Replacement

Using a 1/2-inch square drive, lift belt tensioner to relieve

tension on the belt.
Remove the water pump/fan belt.
NOTE: The belt tensioner is spring-loaded and m u s t be
pivoted away from the drive belt. Pivoting in the wrong
direction can result in damage to the belt tensioner.
If the tensioner pulley touches the accessory drive pulley
after the tensioner has been fully relaxed, the bottom
tensioner arm stop boss has broken and the tensioner
m u s t be replaced.

^ \k that the bottom tensioner arm stop is in contact with

the bottom tensioner arm stop boss on the tensioner body.
If these two are not contacting, the tensioner must be
replaced.

Remove
Drives Alternator
Remove the mounting capscrew and the belt tensioner
from the bracket.

Automotive Applications Without E G R

4 Using a 1/2-inch square drive, lift belt tensioner to relieve
tension on the belt.
Remove the belt.
NOTE: 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.
QSX15 Belt Tensioner, Automatic (Water Pump)
Section A - Adjustment, Repair, and Replacement Page A-17

Low-Mount:
NOTE: Different engine configurations utilize different belt
tensioner bracket and belt tensioner arrangements.
Remove the belt tensioner mounting capscrew and belt
tensioner from the bracket.
Remove the belt tensioner bracket from the water pump.

Mid-Mount:
Remove the belt tensioner mounting capscrew and the
belt tensioner from the bracket. .
NOTE: The mid-mount aluminum belt tensioner/idler
•racket is part of the water pump removal and installation
due to common capscrew usage. Refer to Procedure
008-062.

Industrial and Power Generation Application Without

EGR
Using a 1/2-inch square drive, lift belt tensioner to relieve
:ension on the belt.
Remove the belt.
NOTE: 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.

Low-Mount (Small Version)

Remove the belt tensioner mounting capscrew and belt
tensioner from the bracket.
Belt Tensioner, Automatic (Water Pump) QSX15
Page A-18 Section A - Adjustment, Repair, and Replacement

Remove the belt tensioner bracket from the front engine

$9 support.

Low-Mount (Large Version)

Remove the belt tensioner mounting capscrew and belt
tensioner from the bracket.

Remove the belt tensioner bracket from the front engine

support.

Inspect for Reuse

Drives Alternator

© Cummins i n ^ ^ . © Cummins Inc. AWARNINGA

The belt tensioner is spring loaded. Do not attempt to
disassemble the tensioner. Severe bodily injury can
result.
Check the tensioner for dirt buildup. If the tensioner has
© Cummins inc. • : dirt buildup, remove and clean with safety solvent.

09c00061
QSX15 Belt Tensioner, Automatic (Water Pump)
Section A Adjustment, Repair, and Replacement Page A-19

Pivot the tensioner through the full range of motion.

Tensioner must move with resistance while pivoting the
tensioner down. If not, replace the tensioner.
Check and make sure the correct belt part number is being
used.

Check the belt tensioner pulley and body for cracks or

damage. If any are found, replace the tensioner.
Inspect the tensioner arm stop bosses, for cracks or
damage. If cracks or damage is found, replace the
tensioner.
Belt Tensioner, Automatic (Water Pump) QSX15
Page A-20 Section A - Adjustment, Repair, and Replacement

Inspect the tensioner for evidence of the pivoting

tensioner arm contacting the stationary circular base. If
there is evidence of these two areas contacting, the pivot
tube bushing has failed and the tensioner must be
replaced.

Install
Drives Alternator
Install the belt tensioner and mounting capscrew.
Tighten the capscrew.
Torque Value: 50 N»m [ 37 ft-lb ]

Automotive Applications Without E G R

Low-Mount
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 ]

Mid-Mount:
Install the belt tensioner mounting capscrew and the belt
tensioner from the bracket.
NOTE: The mid-mount aluminum belt tensioner/idler
bracket is part of the water pump removal and installation
due to common capscrew usage. Refer to Procedure
008-062.
QSX15 Belt Tensioner, Automatic (Water Pump)
Section A - Adjustment, Repair, and Replacement Page A-21

Using a 1/2-inch square drive, lift and hold the tensioner.

Install the water pump/fan drive belt and release the
tensioner.

Industrial and Power Generation Application Without

EGR
Low-Mount (Small Tensioner)
Install the belt tensioner bracket to the front engine
support with three mounting capscrews.
Torque Value: 56 N»m [ 41 ft-lb ]

Install the belt tensioner.

Torque Value: 56 N»m [ 41 ft-lb ]

Low-Mount (Large Tensioner) r^fe

Install the belt tensioner bracket to the front engine ^53?
support with three mounting capscrews.
Torque Value: 56 N»m [ 41 ft-lb ]
Belt Tensioner, Automatic (Water Pump) QSX15
Page A-22 Section A - Adjustment, Repair, and Replacement

Install the belt tensioner.

<3£7 Torque Value: 56 N»m [ 41 ft-lb ]

Using a 1/2-inch square drive, lift and hold the tensioner.

Install the water pump/fan drive belt and release the
tensioner.

Finishing Steps
Drives Alternator

ACAUTIONA
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 008-062.
QSX15
Section D - System Diagrams Page D-a

Section D - System Diagrams

Section Contents
Page
Flow Diagram, Air Intake System D-13
Flow Diagram D-13
Automotive, Industrial with CM570 and Power Generation without CM570 D-13
With CM870 . D-14
Flow Diagram, Compressed Air System D-22
Flow Diagram : D-22
Flow Diagram, Cooling System D-10
Flow Diagram D-10
Flow Diagram, Exhaust System D-15
Flow Diagram..... D-15
Automotive, Industrial with CM570 and Power Generation without CM570 D-15
With CM870 D-17
Automotive With CM871 D-19
Automotive With CM871 D-20
Automotive With CM871 D-21
Flow Diagram, Fuel System D-2
Flow Diagram D-2
Industrial CM570 and Power Generation without CM570 D-2
Flow Diagram, Lubricating Oil System D-4
Flow Diagram D-4
With CM870 D-6
Automotive With CM871 D-9
System Diagrams - Overview D-1
General Information D-1
QSX15 System Diagrams - Overview
Section D - System Diagrams Page D-1

System Diagrams - Overview

General Information
The following drawings show the flow through the engine systems. Although parts can change between different
applications and installations, the flow remains the same. The systems shown are:
• Fuel System
• Lubricating Oil System
• Coolant System
• Intake Air System
• Exhaust System
• Compressed Air System.
Knowledge of the engine systems can help you in troubleshooting, service, and general maintenance of your engine.
Flow Diagram, Fuel System QSX15
Page D-2 Section D - System Diagrams

Flow Diagram, Fuel System

Flow Diagram
Industrial CM570 and Power Generation without CM570

QSX15 With Lift Pump

1. Fuel supply from tank 7. Timing actuator
2. Fuel lift pump 8. Fueling supply to injector
3. Fuel pump 9. Timing fuel supply to injector
4. Pressure fuel filter 10. Injector
5. Fuel shutoff valve 11. Fuel drain to tank.
6. Fueling actuator
33X15 Flow Diagram, Fuel System
Section D - System Diagrams Page D-3

Flow Diagram, Fuel System

Flow Diagram
Industrial CM570 and Power Generation without CM570

9 8 10 810

00C00001

QSX15 Without Lift Pump

1. Fuel supply from tank 6. Timing actuator
2. Fuel filter 7. Rail metering supply to injector
3. Gear pump 8. Timing fuel supply to injector
4. Fuel shutoff valve 9. Injector
5. Rail metering actuator 10. Fuel drain to tank.
Flow Diagram, Lubricating Oil System QSX15 2SX
Page D-4 Section D - System Diagrams Se::

Flow Diagram, Lubricating Oil System

Flow Diagram Fla

1
2

r^yfc- 13

Vertical Bypass
Lubricating oil flow from oil pump 8. Flow to turbocharger
Thermostat 9. Flow to main oil rifle
Oil cooler bypass flow 10. Oil drain from turbocharger
Flow through oil cooler 11. Thermostat open - oil flows through oil cooler
Flow return to filter head 12. Thermostat closed - oil flows directly to oil filter
Filter bypass valve 13. Flow to oil filter.
Oil filter
QSX15 Flow Diagram, Lubricating Oil System
Section D - System Diagrams Page D-5

Flow Diagram, Lubricating Oil System

Flow Diagram

Horizontal Bypass
1. Lubricating oil flow from oil pump 9. Flow to main oil rifle
2. Thermostat 10. Oil drain from turbocharger
3. Oil cooler bypass flow 11. Thermostat open - oil flows through oil cooler
4. Flow through oil cooler 12. Thermostat closed - oil flows directly to oil filter
5. Oil cooler flow return to filter head 13. Flow to oil filter
6. Filter bypass valve 14. Bypass valve open - oil flows to oil filter
7. Oil filter 15. Bypass valve closed - oil flows directly to main oil rifle
8. Flow to turbocharger
 Diagram, Lubricating Oil System QSX15
= s?e D-6 Section D - System Diagrams

With CM870

Lubricating Oil Filter, Cooler and Bypass

1. Lubricating oil flow from oil pump 9. Flow to main oil rifle
2. Thermostat 10. Oil drain from turbocharger
3. Oil transfer to rear oil cooler 11. Thermostat open - oil flows through oil cooler
4. Flow through oil cooler 12. Thermostat closed - oil flows directly to oil filter
5. Oil cooler flow return to filter head 13. Flow to oil filter
6. Filter bypass valve 14. Bypass valve closed - oil flows to oil filter
7. Oil filter 15. Bypass valve open - oil flows directly to main oil rifle.
8. Flow to turbocharger
QSX15 Flow Diagram, Lubricating Oil System
Section D - System Diagrams Page D-7

00C00002

Lubricating Oil Pump and Power Components

Lubricating oil flow from oil pan through suction tube 9. Flow from main bearing to crankshaft
Flow from suction tube to oil pump 10. Flow to cylinder head
Pressure regulator 11. Flow to piston cooling nozzle
High-pressure relief valve 12. Flow to idler gears
Flow from oil pump to oil cooler/filter head housing 13. Oil transfer from main oil rifle
Oil return from oil cooler/filter head housing to main 14. Flow to air compressor
oil rifle 15. Rifle sensing regulator dump to inlet.
Main oil rifle
Flow to main bearing
Flow Diagram, Lubricating Oil System QSX15 •5X1
Page D-8 Section D - System Diagrams S-rCtlC

AjtO

Overhead Components
-
1. Lubricating oil flow from cylinder block to cylinder 8. Flow to valve rocker levers 2
head 9. Flow to valve camshaft journal bearings 3.
2. Flow around grooved head to drilled camshaft and 10. Intake valve rocker lever C
rocker lever shafts 11. Engine brake lever z
3. Flow to injector rocker lever shafts 12. Exhaust valve rocker lever z
4. Flow to injector rocker levers 13. Injector rocker lever ~
5. Flow to injector camshaft journal bearings 14. Oil drain from overhead (front and rear). 5
6. Flow to fuel pump
7. Flow to valve rocker lever shaft
QSX15 Flow Diagram, Lubricating Oil System
Page D-9
Section D - System Diagrams

Automotive With CM871

1. Lubricating oil flow from oil pump 9. Flow to main oil rifle
2. Thermostat 10. Oil drain from turbocharger
3. Oil cooler bypass flow 11. Thermostat open - oil flows through oil cooler
4. Flow through oil cooler 12. Thermostat closed - oil flows directly to oil filter
5. Flow return to filter head 13. Flow to oil filter
6. Filter bypass valve 14. Bypass valve closed - oil flows to oil filter
7. Oil Filter 15. Bypass valve open - oil flows directly to main oil rifle.
8. Flow to turbocharger
Flow Diagram, Cooling System QSX15 BSX1!
Page D-10 Section D - System Diagrams S e:: c

Flow Diagram, Cooling System

Flow Diagram Flow

© CuAlmin nirts

1. Coolant inlet 5. Coolant flow from water pump

2. Coolant flow from coolant filter 6. Coolant flow past oil cooler
3. Coolant bypass flow from thermostat 7. Coolant flow to cylinder head.
4. Coolant flow to water pump
QSX15 Flow Diagram, Cooling System
Section D - System Diagrams Page D-11

Flow Diagram, Cooling System

Flow Diagram

mm

Single Thermostat
1. Coolant flow through cylinder head 7. Coolant bypass flow to water pump
2. Coolant flow from cylinder head to thermostat 8. Coolant flow to water pump
housing 9. Bypass closed
3. Thermostat 10. Coolant flow to radiator
4. Bypass open 11. Coolant flow from radiator.
5. Coolant flow through thermostat housing to bypass
passage
6. Coolant bypass passage
Flow Diagram, Cooling System QSX15
Page D-12 Section D - System Diagrams

Flow Diagram, Cooling System

Flow Diagram

Dual Thermostat
1. Coolant flow from cylinder block to cylinder head 5. Coolant bypass flow to water pump
2. Coolant flow from cylinder head to thermostat 6. Coolant bypass flow to water pump
housing 7. Thermostats.
3. Coolant flow to radiator
4. Coolant bypass passage
QSX15
Section D - System Diagrams Flow Diagram, Air Intake System
Page D-13

Flow Diagram, Air Intake System

Flow Diagram
Automotive, Industrial with CM570 and Power Generation without CM570

00c00005
1. Intake air inlet to turbocharger
4. From charge air cooler to intake manifold
2. Turbocharger air to charge air cooler
5. Intake valve port
3. Charge air cooler
6. Intake valves.
Flow Diagram, Air Intake System QSX15 2SX
Page D-14 Section D - System Diagrams Seel

With CM870

- 0
Aut

fnirts li c

nins Inc
1. Intake air inlet to turbocharger 6. EGR mixer
2. Turbocharger air to charge air cooler 7. Air intake connection
3. Charge air cooler 8. Intake valve port
4. From charge air cooler to intake manifold 9. Intake valves.
5. Exhaust gas to EGR mixer
:i5 QSX15 Flow Diagram, Exhaust System
Section D - System Diagrams Page D-15
ms

Flow Diagram, Exhaust System

Flow Diagram
Automotive, Industrial with CM570 and Power Generation without CM570

IS SS S\#a

1. Exhaust valve ports 3. Turbocharger turbine.

2. Exhaust manifold
: : Z agram, Exhaust S y s t e m QSX15
- ; Z f D-1 6 Section D - System Diagrams

Flow Diagram, Exhaust System

Flow Diagram
Automotive, Industrial with CM570 and Power Generation without CM570

12200016

Wastegate OPEN; Wastegate CLOSED

QSX15 Flow Diagram, Exhaust System
Section D - System Diagrams Page D-17

With CM870

m i n s Inc.

1. Exhaust gas to manifold 5. EGR valve

2. Exhaust manifold 6. Exhaust gas to EGR cooler connection
3. Exhaust gas to turbocharger 7. EGR cooler
4. Exhaust gas to EGR valve 8. Cooled exhaust gas to EGR connection tube and
EGR mixer.
Flow Diagram, Exhaust System QSX15 QSX
Page D-18 Section D - System Diagrams Secti

With CM870 Autc

11C00067

Variable Geometry
1. Exhaust in 4. Sliding nozzle closed
2. Sliding nozzle Open 5. Exhaust gas high velocity flow.
3. Exhaust gas low velocity flow
Flow Diagram, Exhaust System QSX15
Page D-20 Section D - System Diagrams

Automotive With CM871

11C00191

1. Exhaust gas to EGR cooler 6. Front EGR connection tube

2. EGR cooler 7. EGR measurement venturi
3. Cooled exhaust gas to rear EGR connection tube 8. Cooled exhaust gas to the EGR mixer
4. EGR valve mounting bracket 9. EGR differential pressure sensing tubes
5. EGR valve 10. EGR differential pressure sensor.
 Cummins® Particulate Filter
1. Exhaust from turbocharger 9. Aftertreatment particulate trap differential pressure
2. Aftertreatment fuel injector sensor tubes (High)
3. Exhaust pipe with exhaust mixture 10. Installation alignment tab
4. Exhaust gas temperature sensor (number 1) 11. Aftertreatment particulate trap
5. Aftertreatment inlet 12. Aftertreatment particulate filter differential pressure
6. Aftertreatment particulate trap differential pressure sensor tube (Low)
sensor 13. Aftertreatment outlet
7. Aftertreatment catalyst 14. Exhaust gas temperature sensor (number 3)
8. Exhaust gas temperature sensor (number 2) 15. Exhaust flow exiting aftertreatment system.
QSX15 Flow Diagram, Compressed Air System
Section D - System Diagrams Page D-23

Flow Diagram, Compressed Air System

Flow Diagram

t
^ I, J
7
< = l

©Ci I is 11

WABCO - Type System with Air Dryer

1. Governor 4. Reservoir (wet tank)
2. Discharge 5. Air compressor
3. Intake 6. Air dryer.
 C u m m i n s S e r v i c e Publications Electronic Book on DVD-ROM
Enclosed, we've included on DVD-ROM, an electronic copy of this publication in Adobe® Acrobat® format (PDF) for your
personal use and reference. Before you begin to use the DVD-ROM, you must accept the terms and conditions of
the accompanying License Agreement a s a "Licensee". This accompanying license agreement begins on the
next page. Also, please read the "Cummins Service Publications Electronic Book on DVD-ROM Information"
printed section, beginning on the page after the license agreement. This section includes information about this
DVD-ROM including System Requirements, Local Administrative Rights requirements, How to Use, Helpful Support Tips
and other information.
 Cummins
CUMMINS SERVICE PUBUCATlVf*^
ELECTRONIC BOOK ON DVD-F^ obligal
a n y

SOFTWARE LICENSE AGREEMlXo assure bad-

»wer Versions (
3 Upgrade or N
anges, update
the sole discre
All rights
THIS SOFTWARE LICENSE AGREEMENT ("License Agreement") between Cummins Inc. ("Cummins") * m e n t shall ree

Licensee sets forth the terms and conditions governing the license for use of the Cummins Service Publicati
Electronic Book on DVD-ROM media ("DVD-ROM Media"). The DVD-ROM Media and all of its contents constil f
ri a m

the entire product referred to herein, and is sometimes referred to as the "Licensed Software". The D V D - R f ^ °6 0 5 a

Media contains a written notice referring to this License Agreement. By breaking the seal on the DVD-ROM Me? subjec
you accept the terms and conditions of this License Agreement as a "Licensee". If you do not accept the terms pnditions
conditions of this License Agreement, you must return the DVD-ROM Media and all accompanying printed m a t e r ^ -
within 30 days of your purchase. Your return of the DVD-ROM Media and printed materials must be to the pie
of your original purchase, either a Cummins distributor or Gannett Direct Marketing Services, Inc. Upon return Markinqs
provided above, you will receive a full refund of your purchase price, excluding any shipping charges.
RFC I T A i icensee shaU
RECITALS. markings on th
WHEREAS, Cummins has developed certain computer programs and support documentation (which rrny copyright 0
contain electronic copies of service manuals or other information) useful in supporting, diagnosing, repairing, a
maintenance of engines manufactured or sold by Cummins;
WHEREAS, Licensee desires use the Licensed Software, as permitted in this License Agreement, to assist Licens' ™ e

in the support, diagnosis, repair, and maintenance of engines manufactured or sold by Cummins; "itle and fuH o
THEREFORE, in consideration of the above premises and the mutual covenants contained herein, Cummins a ^ o ^ u s orf
Licensee agree as follows: hinted to Lic
1. License Grant and Restrictions
a. Cummins hereby grants to Licensee a non-exclusive, non-transferable and non-sublicensable license. y ee c e n S

use the Licensed Software to assist in the support, diagnosis, repair and maintenance of engines manufacture'
or sold by Cummins. Each copy of the Licensed Software is specifically licensed only for its intended purposDosts and ex
and shall not be used for any other purpose. The Licensed Software shall not be sublicensed, sold, or otherwispecifically a
distributed or shared with others, in any media or format.
b. The Licensed Software provides you with the capability to view the support documentation and to perfor^ payment
searches. The Licensed Software does not permit you to print, copy files, change content, extract information, mak '
annotations, or perform any functions other than "view" and "search". The Licensed Software is copy protected sales p 6

encrypted, and in read-only format. The only method to view the support documentation is from the original P V I f ? ^In c , s e

ROM. The licensed product may be offered as a DVD-ROM Media bundled with a printed publication or it may fctjeensod ^ °
offered as a stand alone DVD-ROM Media product. In either case, the Licensed Software is intended for use by t h ^ -
t n e r e o r

Licensee only. Copying or distribution of the Licensed Software from the DVD-ROM Media is expressly prohibitec
The Licensed Software will not function from a network server DVD-ROM drive. The Licensed Software will functio Suooort
only in a DVD-ROM drive directly connected to your computer. Licensee is authorized to use the Licensed Softwar
on more than one computer, but only one computer at a time. Cummins m
c. Licensee agrees to use the Licensed Software in strict accordance with Cummins' published s e r v i c i ^ ^ g ^ p p Q
practices and/or product warranty guidelines for the sole purpose of assisting in the support, diagnosis, repair anj ®. * \os
maintenance of engines manufactured or sold by Cummins. P r0

7. No Mo
Licensee a
Licensed S
d. Cummins may at any time, or from time to time, offer for sale or provide free of charge upgrades or revisions
("Upgrades") to the Licensed Software, but shall be under no obligation to do so. Further, Cummins may at any
time, or from time to time, publish a newer version of the Licensed Software ("Newer Version"), but shall not be
under any obligation to do so, nor shall Cummins have any obligation to provide the Newer Version to Licensee
or to assure backward compatibility of the Newer Version of the Licensed Software. In the event an Upgrade or
Newer Versions of the Software is published, Cummins shall determine in its sole discretion the manner in which
the Upgrade or Newer Version is published, offered, and/or distributed. An Upgrade or Newer Version may include
changes, updates or revisions to the support documents included as part of the Licensed Software, as determined
in the sole discretion of Cummins.
e. All rights relating to the Licensed Software not specifically granted to Licensee pursuant to this License
Agreement shall be retained by Cummins.
f. Licensee acknowledges that the Licensed Software may include software that Cummins has obtained or
licensed from a third party, and Licensee agrees that the terms and conditions of this License Agreement shall
be subject to any such third-party software. Licensee agrees to abide by any additional or modified terms and
conditions with respect to such third-party software if reasonably requested in writing by Cummins and/or the third
party.

2. Markings
Licensee shall use its best efforts to preserve all copyright, trademark, ownership or other notices, legends or
markings on the Licensed Software as originally provided by Cummins. In the event the Licensed Software contains
any copyright or other message embedded therein, Licensee shall not modify or remove such embedded message.

3. Title
Title and full ownership rights to the Licensed Software and any Upgrades thereto, including all copyright rights
therein, shall remain with Cummins and/or its subsidiaries. Cummins expressly retains all rights that it may have
under U.S. or foreign laws or international treaties relating to the Licensed Software, except for those rights expressly
granted to Licensee herein.

4. Licensee Expenses
Costs and expenses incurred by Licensee relating to any use of the Licensed Software, or any other costs not
specifically agreed upon by the parties in writing, shall be the responsibility of Licensee.

5. Payment
The sales price for the Licensed Software does not include any federal, state, local or other governmental taxes,
excise taxes, or other tariffs which may be imposed on the sale, transportation, production, storage, or export of the
Licensed Software. Any and all such taxes and costs shall be paid by Licensee and Cummins shall have no liability
therefor.

6. Support
Cummins may provide Help Desk support to for the current version and the most recent prior version of the Licensed
Software. The Help Desk support will be limited to computer operational and functionality issues only. No Help
Desk support will be provided for substantive information published in the Licensed Software (i.e., how to use the
product to support, diagnose, repair, and maintain engines).

7. No Modification by Licensee
Licensee agrees not to translate, reverse assemble, reverse compile, adapt, alter, modify or change in any way the
Licensed Software, or any Upgrade thereto.
8. Warranties 1
Cummins warrants that the DVD-ROM Media containing the Licensed Software shall be free from defects in material
or workmanship for a period of ninety (90) days from the date of delivery to Licensee.

9. Warranty Disclaimer
THE LICENSED SOFTWARE AND ANY AND ALL UPGRADES THERETO ARE LICENSED "AS IS" WITH THE
EXCEPTION OF THE WARRANTIES SPECIFICALLY PROVIDED HEREIN. CUMMINS DOES NOT CLAIM AND
DOES NOT WARRANT THAT THE LICENSED SOFTWARE WILL RUN ERROR FREE. WITH THE EXCEPTION
OF THE WARRANTIES PROVIDED HEREIN, CUMMINS DISCLAIMS ALL WARRANTIES, EITHER EXPRESS
OR IMPLIED, REGARDING THE LICENSED SOFTWARE, ITS MERCHANTABILITY OR ITS FITNESS FOR ANY
PARTICULAR PURPOSE, OR NON-INFRINGEMENT, AND CUMMINS WILL NOT OTHERWISE BE LIABLE FOR
ANY INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM LICENSEE'S USE OF THE
LICENSED SOFTWARE OR FOR ANY ERROR OR DEFECT IN THE LICENSED SOFTWARE. THE LIABILITY
OF CUMMINS TO LICENSEE SHALL NOT EXCEED THE TOTAL AMOUNT OF PAYMENTS RECEIVED FROM
LICENSEE AND ACCEPTED BY CUMMINS IN CONSIDERATION FOR THIS LICENSE.

10. Government Licensee

If Licensee is acquiring the Licensed Software for, or on behalf of, any department, division or unit of the United
States Government, the following provisions shall be applicable:
The Government acknowledges and agrees that the Licensed Software and documentation relating thereto were
developed at private expense and no part of the Licensed Software or documentation relating thereto is in the public
domain.
The Government acknowledges Cummins Inc. representation.that the Licensed Software is "Restricted Computer
Software" as that term is defined in Clause 52.227-19 of the Department of Federal Acquisition Regulation Supple-
ment (DFARS). The Government agrees that:
(i) if the Licensed Software is supplied to the Department of Defense (DoD), the Licensed Software is classified as
"Commercial Computer Software" and the Government is acquiring only "restricted rights" in the Licensed Software
and documentation relating thereto as that term is defined in Clause 252.227-7013(c)(1) of the DFARS, and
(ii) if the Licensed Software is supplied to any unit or agency of the United States Government other than the
Department of Defense, the Government's rights in the Licensed Software and documentation relating thereto will
be defined in Clause 52.227-19(c)(2) of the Federal Acquisition Regulation (FAR).

11. Restricted Rights Legend

Use, duplication, or disclosure by the Government is subject to restrictions set forth in subparagraph (c)(1)(H) of the
Rights in Technical Data and Computer Software clause at DFARS 252.227-7013, Cummins Inc., P.O. Box 3005,
Columbus, IN 47202.

12. Confidentiality •
a. Licensee hereby acknowledges that the Licensed Software contains confidential proprietary information.
Consistent with the purpose of this License Agreement, Licensee agrees to use its best efforts not to release,
disclose or otherwise permit unauthorized access to such confidential information.
b. Cummins and Licensee agree to clearly mark written materials as "confidential" if they are to be treated
as confidential. Verbal communications that are confidential in nature will be identified as so before, during, or
immediately after the communication.
c. Licensee will use its best efforts to ensure that all individuals who are provided access to the Licensed
Software under this License Agreement will observe and perform this nondisclosure covenant.
13. Termination of License Agreement
a. Cummins may terminate this agreement for cause, such cause including, but not limited to, supporting,
diagnosing, repairing, modifying or the maintenance of Cummins engines or any component thereof when such
activities are not authorized by the owner of such engines.
b. In the event of termination of this License Agreement, all rights granted by this License Agreement shall
revert to Cummins. Upon termination of this License Agreement, Licensee will deliver to Cummins all DVD-ROM
Material and other material furnished by Cummins pertaining to the Licensed Software or certify that all such
materials have been destroyed.
c. In the event of termination of this License Agreement, Licensee and Cummins shall remain obligated with
respect to the provisions of this License Agreement relating to confidentiality of information.

14. Completeness
Licensee and Cummins agree that this License Agreement constitutes the complete agreement and understanding
between the parties relating to Licensed Software and Upgrades thereto. This License Agreement supersedes all
prior agreements, understandings, and negotiations whether written or verbal with respect to the subject matter
hereof. This License Agreement can only be modified by a written agreement signed by both parties.

15. Notices
Any questions concerning this License Agreement, any inquiries related to the Licensed Software, and any notices
to Cummins pursuant to this License Agreement should be directed to Cummins Inc., Electronic Publications
Support, MC 95030, 1460 National Road, Columbus, IN 47201. Cummins Inc. may direct that notices be sent to a
different person and/or address by so requesting in writing to the other party.

16. Export Regulations

Licensee understands that the Export Administration Regulations of the Department of Commerce of the United
States may prohibit the export of the Licensed Software to certain countries and agrees to conform to those
regulations. Licensee also agrees to conform to these regulations. Licensee shall indemnify Cummins against any
loss related to Licensee's failure to conform to those regulations.

17. Governing Law

This License Agreement shall be governed by and construed in accordance with the laws of the State of Indiana.

18. Attorneys' Fees

In the event of any legal action or other proceeding that is brought about to enforce this License Agreement, the
prevailing or successful party shall be entitled to recover reasonable attorneys' fees as well as other costs incurred
in that action or proceeding in addition to any compensation to which it may be entitled.

19. License Agreement Successors and Assigns

This License Agreement is not assignable by Licensee without the prior written consent of Cummins, and any
assignment by Licensee in contravention of this provision shall be void and without effect. The terms and conditions
of this License Agreement shall inure to the benefit of and be enforceable by Cummins and the successors and
assigns of Cummins' interest in this License Agreement and/or Cummins' ownership of the Licensed Software.
 Cummins Service Publications Electronic Book on DVD-ROM Information Cu
The enclosed DVD-ROM provides you with the capability to view this publication electronically as well as perform
searches. This DVD-ROM is copy protected and will not allow Printing, Changing of Content, Extracting Content or
Commenting / Annotating of the PDF file. I Aboul
I • Thi
This DVD-ROM is read only, and you will not be able to copy files from the DVD-ROM and have them open or function in ^ s s

any manner. The only method to view the electronic publication is from the original DVD-ROM. o t n

Pul
This DVD-ROM is intended for use by the owner of the publication only. Copying or distribution of content from this DVD- I
ROM is expressly prohibited. This DVD-ROM will not function from a network server DVD-ROM drive. It will function only I How
in a DVD-ROM drive directly connected to your computer. | To usi
I Acrob
This DVD-ROM requires that you have Local Administrative rights in order to use. See the System requirements I pre-lo
section for additional details.
Help
System Requirements: • if\
Use of the Cummins Service Publications Electronic Book on DVD-ROM requires Adobe Acrobat, Adobe Acrobat Reader, I do
or Adobe Reader software to be pre-installed on your computer. This product has been tested for compatibility with att
Adobe Acrobat software versions 7, 8 and 9. It may function properly with versions later than Adobe Acrobat 9.0, but j • If 1
testing has not been performed. Adobe Reader is available as a free download from www.adobe.com. re
co
The Cummins Service Publications Electronic Book on DVD-ROM product requires the following system • W
components: ce
• Microsoft Windows Auto-Play must be enabled on your computer (it is enabled by default when Windows is installed)
• DVD-ROM Drive Spe
• Color Monitor with at least 800x600 resolution graphics This
• Microsoft Windows XP Professional SP3, Microsoft Windows Vista SP1, Microsoft Windows Vista x64 SP1, Microsoft
Windows 7, or Microsoft Windows 7 x64. Testing has not been performed with the x64 bit versions of Vista and :-dei
Windows 7, but the product is believed to be compatible. Use on other Microsoft Operating Systems may be DVD
compatible but testing has not been performed, and while it may function, it is not supported. While we try to maintain The
compatibility with all popular Microsoft Operating Systems, compatibility with the listed Microsoft Operating Systems is Once
subject to change. Soft\
• Recommended memory, processor speed and available hard-disk space is in accordance with respective Microsoft
Operating System Guidelines, as well as Adobe Acrobat system requirements.

Note: The Cummins Service Publications Electronic Book on DVD-ROM product is not Macintosh compatible.

About required Local Administrative Rights:

The copy protection software requires direct access to the DVD-ROM on which the protected content is stored. Protected
content may not be accessible when logged in using restricted accounts.

In order to allow the software to enable direct access to DVD-ROM drives rights under Microsoft Operating Systems, your
logon account/profile must have Local Administrative Rights on the computer you will be using your Cummins Service
Publications Electronic Book on DVD-ROM with. If this computer is set up in Restricted Mode, and your logon account/
profile does not have Local Administrative Rights, then, with approval of your IT. department or the owner of your
computer, you can choose from the following options to allow the Cummins Service Publications Electronic Book on DVD-
ROM to function properly:

• Have your computer account enabled to have Local Administrative rights and then you can run the Cummins Service
Publications Electronic Book on DVD-ROM - OR -
• Have a user with Local Administrative Rights logon to your computer and run the DVD-ROM content one time. By
doing this, the necessary files will be loaded to your computer and your computer will be enabled to have direct access
to DVD-ROM drives. Then restart this computer. It is very important to restart the computer after you have done this.
For all future needs, you can run the Cummins Service Publications Electronic Book on DVD-ROM under your own
account, without requiring your logon account/profile to have Local Administrative Rights. (Note: This needs to be
done only once for any Cummins Service Publications Electronic Book on DVD-ROM and then does not need to be
done again for other Cummins Service Publications Electronic Book on DVD-ROM titles you may own that are of the
same version of protection software).
 Cummins Service Publications Electronic Book on DVD-ROM Information
(continued)
About the Copy Protection Software:
• This product may upgrade the proprietary copy protection software files it uses that are placed on your computer
system to a new version, if an older version exists on your computer. If you have DVD-ROM copy protected items from
other companies and they use older versions of the same TrusCont copy protection software that the Cummins Service
Publications Electronic Book on DVD-ROM uses, it may render them incompatible for use on your computer.

How to Use the Cummins Service Publications Electronic Book on DVD-ROM:

To use the DVD-ROM, simply insert the DVD-ROM into your computer and it should automatically run, open Adobe
Acrobat and open the Electronic Book. (This happens with Microsoft Windows Auto-Play functionality, and Adobe Acrobat
pre-loaded by you on your computer).

Helpful Support Tips:

• If Windows Auto-Play is not enabled, try re-enabling it, or navigate with Windows Explorer to your DVD-ROM drive and
double click on the DVD-ROM drive letter to open it. Then double-click on the program named "clickhere". (Do not
attempt to directly open the PDF file by clicking on the PDF document).
• If the Cummins Service Publications Electronic Book on DVD-ROM does not function, see the prior section on "About
required Local Administrative Rights:" in this documentation and verify you have. Local Administrative Rights on your
computer in order to run the DVD-ROM.
• While this product has been known to be very compatible with DVD-ROM drives available in computers, there are
certain models of DVD-ROM drives that may be incompatible with this product.

Special Instructions for Cummins PowerSweep P C Users:

(This only applies to Cummins Inc. & Distributor Employees):
Cummins PowerSweep PC users that DO NOT have Local Administrative rights to their PC will require you to place an
order from the Cummins Software Shelf. If you are a Cummins Inc. or Distributor Employee who wants to use these
DVD-ROM's, and you have a PowerSweep PC - please order the TrusCont' software from the Cummins Software Shelf.
The Software Shelf personnel will contact you to arrange a desk side installation from the DVD-ROM that you have.
Once software is installed, first reboot your PC, then attempt to read your encrypted DVD-ROM manual while Cummins
Software Shelf personnel are present.
 Cummins Service Publications Electronic Book on DVD-ROM Information
(continued)
Electronic Book Technical Support:
Support for this product is available from Monday through Friday weekly, excluding Holidays, from 8 a.m. to 5 p.m.
You may call (502) 540-4981 for telephone support. For e-mail support, please e-mail ebooksupport@merrickind.com.

DVD-ROM Media Repiacement Options:

Up to 90 days from date of purchase:
Within the first 90 days from your date of purchase, if your copy of an Electronic Book on DVD-ROM does not function,
and after a Cummins Electronic Book Technical Support Technician has confirmed the situation and authorized its
replacement by providing you an RMA#, you may send back the DVD-ROM for a free replacement. To do so, you must
package the DVD-ROM and ship/mail, with postage pre-paid by you, to the below address. You must also include a
photocopy of the original invoice for proof of purchase of the publication clearly indicating the bulletin # and the purchase
date. The RMA# must be on the address information of the package. If the proof of purchase copy of the invoice is
not enclosed, your request will not be able to be processed and will not be returned. Delivery of the replacement will
be shipped to you at no charge. Allow 3 to 4 weeks for your receipt of replacement copy. Note: Return only the non-
functional DVD-ROM, do not return the entire printed publication. The replacement DVD-ROM maintains the original
purchase/invoice date for the purposes of this replacement policy. This policy is subject to change at any time, without
notice. For a copy of the most current replacement options policy, please e-mail ebooksupport@merrickind.com with your
request.

Media Replacement Ship to Address:

Attn: Cummins Service Publications Electronic Book Technical Support
RMA#: XXXXXX (where XXXXXX is the RMA#)
808 E. Liberty Street
Louisville, KY 40204 U.S.A.

Cummins Service Publications Electronic Book on DVD-ROM is Copyright © Cummins Inc.

Adobe Acrobat Reader is a registered trademark of Adobe Systems Incorporated.
Microsoft, Windows, Windows Vista, and Windows 7 are either a registered trademark or trademark of Microsoft
Corporation in the United States and/or other countries.
TrusCont™ is a trademark of TrusCont Ltd.
All other names and products used herein are trademarks for their respective owner.
QSX15
Section L - Service Literature Page L-a

Section L - Service Literature

Section Contents
Page
Additional Service Literature L-1
General Information L-1
Cummins Customized Parts Catalog L-3
General Information L-3
Ordering the Customized Parts Catalog L-3
Ordering by Telephone L-3
Ordering On-Line L-3
Service Literature Ordering Location L-2
Contact Information L-2
QSX15 Additional Service Literature
Section L - Service Literature Page L-1

Additional Service Literature

General Information
The following publications can be purchased:
Bulletin Number Title of Publication
3379001 Fuels for Cummins® Engines
3810340 Cummins® Engine Oil Recommendations
3387251 Coolant Additives and Filtration
3387266 Cold Weather Operation
3666209 Cooling System Maintenance Extended Interval
3666239 Troubleshooting and Repair Manual, Signature™, ISX, and QSX15 Engines
3666259 Troubleshooting and Repair Manual, Electronic Control System, Signature™, ISX, and QSX15
Engines
3666393 Troubleshooting and Repair Manual Generator-Drive Control System QSX15, QSK45, and QSK60
Engines
3666394 Troubleshooting and Repair Manual PowerCommand® Control QSX15, QSK45, and QSK60
Generator Sets
3666414 QSX15 Industrial Wiring Diagram
3666349 QSX15 Generator Drive Wiring Diagram
3666466 QSX15 PowerCommand® Control Wiring Diagram
Service Literature Ordering Location QSX15
Page L-2 Section L - Service Literature

Service Literature Ordering Location

Contact Information

Region Ordering Location

United States and Canada Cummins Distributors
or
Credit Cards at 1-800-646-5609 r ai
or
Order online at www.powerstore.cummins.com
All Other Countries Cummins Distributors or Dealers

2
QSX15 Cummins Customized Parts Catalog
Section L - Service Literature Page L-3

Cummins Customized Parts Catalog

General Information
Cummins is pleased to announce the availability of a parts catalog compiled specifically for you. Unlike the generic
versions of parts catalogs that support general high volume parts content; Cummins Customized catalogs contains
only the new factory parts that were used to build your engine.
The catalog cover, as well as the content, is customized with you in mind. You can use it in your shop, at your worksite,
or as a coffee table book in your RV or boat. The cover contains your name, company name, address, and telephone
number. Your name and engine model identification even appears on the catalog spine. Everybody will know that
Cummins created a catalog specifically for you.
This new catalog was designed to provide you with the exact information you need to order parts for your engine. This
will be valuable for customers that do not have easy access to the Cummins Electronic Parts Catalog or the Cummins
Parts Microfilm System.
Additional Features of the Customized Catalog include:
• Engine Configuration Data
• Table of Contents
• Separate Option and Parts Indexes
• Service Kits (when applicable)
• ReCon Part Numbers (when applicable)
Ordering the Customized Parts Catalog
Ordering by Telephone
North American customers can contact their Cummins Distributor or call Gannett Direct Marketing Services at
1-800-646-5609 and order by credit card. Outside North America order on-line or make an International call to Gannett
a t ( + +)502-454-6660.
Ordering On-Line
The Customized Parts Catalog can be ordered On-Line from the Cummins Powerstore by credit card.
Contact GDMS or the CUMMINS POWERSTORE for the current price; Freight may be an additional expense.
Information we need to take your Customized Parts Catalog Order. This information drives the cover content of the
CPC.
• Customer Name
• Street Address
• Company Name (optional)
• Telephone no.
• Credit Card No.
• Cummins Engine Serial Number (located on the engine data plate)
• Please identify the required media: Printed Catalog, CD-ROM, or PDF File
Unfortunately not all Cummins Engines can be supported by this parts catalog. Engines older than 1984 or newer
than 3 months may not have the necessary parts information to compile a catalog. We will contact you if this occurs
and explain why we are unable to fill your order.
Customized Parts Catalogs are produced specifically for a single customer. This means they are not returnable for a
refund. If we make an error and your catalog is not useable, we will correct that error by sending you a new catalog.
QSX15

Section S - Service Assistance Page S-a

Section S - Service Assistance

Section Contents
Page
Distributors - International S-34
Locations S-34
Distributors and Branches S-5
Australia S-25
Canada S-20
China, People's Republic S-23
New Zealand S-29
United States S-5
Division and Regional Offices S-3
Locations.. S-3
Emergency and Technical Service S-1
General Information S-1
Problem Solving S-1
General Information S-1
Regional Offices - International S-30
Locations S-30
Routine Service and Parts S-1
General Information S-1
Page S-b o QSX15 |
Section S - Service Assistance

3en»

This Page Left Intentionally Blank

QSX15 Problem Solving
Section S - Service Assistance Page S-1

Routine Service and Parts

General Information
Personnel at Cummins Authorized Repair Locations can assist you with the correct operation and service of your
engine. Cummins has a worldwide service network of more than 5,000 Distributors and Dealers who have been trained
to provide sound advice, expert service, and complete parts support. Check the telephone directory, refer to the
directory in this section, or the Service Locator at www.cummins.com for the nearest Cummins Authorized Repair
Location.

Emergency and Technical Service

General Information
The Cummins Customer Assistance Center provides a 24-
hour, toll free telephone number to aid in technical and
emergency service when a Cummins Authorized Repair
Location can not be reached or is unable to resolve an
issue with a Cummins product.
If additional assistance is required, call Toil-Free:
1-800-DIESELS
(1-800-343-7357)
• Includes all 50 states, Bermuda, Puerto Rico, Virgin
Islands, and the Bahamas.
• East Asia - Customer Assistance Center also for
Chinese Domestic Market support Toil-Free:
400-810-5252
• Outside of North America contact your Regional
Office. Telephone numbers and addresses are listed
in the International Directory.

Problem Solving
General Information
Normally, any problem that arises with the sale, service, or repair of your engine can be handled by a Cummins
Authorized Repair Location in your area. Refer to the telephone directory, the directory in this section, or the Service
Locator at www.cummins.com for the nearest Cummins Authorized Repair Location. If the problem has not been
handled satisfactorily, follow the steps outlined below:
1 If the disagreement is with a Dealer, talk to the Cummins Distributor with whom he has his service agreement.
2 If the disagreement is with a Distributor, call the nearest Cummins Division or Regional Office; however, most
problems are solved below the Division or Regional office level. Telephone numbers and addresses are listed in
this section. Before calling, write down the following information:
a Engine model and serial number
b Type and make of equipment
c Total kilometers [miles] or hours of operation
d Warranty start date
e Nature of problem
f Summary of the current problem arranged in the order of occurrence
g Name and location of the Cummins Distributor or Dealer
3 If a problem can not be resolved satisfactorily through your Cummins Authorized Repair Location or Division Office,
contact:
- Cummins Customer Assistance Center - 41403, Cummins Inc., Box 3005, Columbus, IN 47202-3005
- Telephone: + 1 800-diesels / + 1 800-343-7357 (USA Only)
- Telephone: +1 812-377-3000 (International)
QSX15 Division and Regional Offices
Section S - Service Assistance Page S-3

Division and Regional Offices - Locations

Australia Regional Cummins Engine Company 2 Caribbean Drive

Office Pty. Ltd. Scoresby, Victoria 3179
Australia
Telephone: (61-3) 9765-3222
FAX: (61-3) 9763-0079
NOTE: This office also serves New Zealand.

Cummins Americas Cummins Americas Inc. 3350 SW 148 Avenue

Regional Office Suite 205
Miramar, FL 33027
Telephone: [1-954] 431-5511
Fax: [1-954] 433-5797
NOTE: This office serves Puerto Rico and South
America excluding Brazil.

China Cummins (China) Investment 28F, Tower A, GATEWAY, No. 18, Xiaguangli
Beijing Co. Ltd North Road, East Third Ring, Chaoyang District
Beijing, Beijing i
ZIP / Postal Code: 100027
China
Telephone: [86-10] 84548888
Telefax: [86-10] 67876347

Brazil Cummins Brasil Ltda. Rua Jati, 266

07180-900 Guarulhos
Sao Paulo Brazil
Phone: [55-11] 6465-9811
Fax: [55-11] 6412-1483

Daventry Cummins Engine Company Royal Oak Way South

Ltd (Africa) Daventry, Northants
ZIP / Postal Code: NN11 5NU
United Kingdom
Telephone: [44-1327] 886000
Telefax: [44-1327] 886106
Daventry Cummins Engine Co. Ltd Royal Oak Way South
(Serving Czech Republic) Daventry, Northants
ZIP / Postal Code: NN11 5NU
United Kingdom
Telephone: [44-1327] 886000
Telefax: [44-1327] 886106

Daventry Cummins Engine Company Royal Oak Way South

Ltd (Middle East) Daventry, Northants
ZIP / Postal Code: NN11 5NU
United Kingdom
Telephone: [44-1327] 886000
Telefax: [44-1327] 886106

Dubai Cummins Middle East FZE Units ZF 5/6

United Arab Emirates Jebel AN Free Zone
P.O.Box No 17636
Dubai
United Arab Emirates
Phone: [971-4] 883 8998
Fax: [971-4] 883 7971
Division and Regional Offices QSX15
Page S-4 Section S - Service Assistance

India Cummins India Ltd. Kothrud

Pune Pune
* ZIP/Postal Code: 411038
India
Telephone: +91-20-2538 5435 or 2538 0240
Fax: +91-20-2538 0125
www.cumminsindia.com

Korea Cummins Korea Ltd. 25th floor, ASEM tower,

Seoul 159-1, Samsung-Dong
Kangnam-ku, Seoul
ZIP / Postal Code: 135-798
South Korea
Telephone: [82-2] 3420-0901
Telefax: [82-2] 3452-4113 / 539-6569

SLP Mexico Cummins, S. de R.L. de C.V. Arquimedes No. 209

Col. Polanco
Mexico, Distrito Federal
ZIP / Postal Code: 11560
Mexico
Telephone: [52-5] 254-3822 / 3783 / 3622
Telefax: [52-5] 254-3645

Russia Cummins Engine Company, Park Place

Moscow Inc. Office E708, 113/1 Leninskiy Prospect
Moscow
ZIP/Postal Code: 117198
Russia
Telephone: [7-495] 956-51-22 / 23
Telefax: [7-495] 956-53-62

Singapore Cummins Diesel Sales 8 Tanjong Penjuru

Corporation Singapore
ZIP/Postal Code: 609019
Singapore
Telephone: [65] 6265-0155
QSX15 Distributors and Branches
Section S - Service Assistance Page S-5

Distributors and Branches - United States

Alabama Birmingham Cummins Mid-South, LLC

2200 Pinson Highway
P.O. Box 1147
Birmingham, AL 35217
Telephone: (205) 841-0421
FAX: (205) 849-5926
Alabama Mobile Cummins Mid-South, LLC
1924 N. Beltline Hwy.
Mobile, AL 36617
Telephone: (334) 456-2236
FAX: (334) 452-6419

Alaska Anchorage Cummins Northwest, Inc.

2618 Commercial Drive
Anchorage, AK 99501-3095
Telephone: (907) 279-7594
FAX: (907) 276-6340

Arizona Phoenix Cummins Rocky Mountain, LLC

2239 N. Black Canyon Hgwy
Phoenix, J\Z 85009
Telephone: (602) 252-8021
FAX: (602) 253-6725

Arkansas Little Rock Cummins Mid-South, Inc.

6600 Interstate 30
Little Rock, AR 72209
Telephone:
Sales: (501) 569-5600
Service: (501) 569-5656
Parts: (501) 569-5613
FAX: (501) 565-2199

California San Leandro Cummins West, Inc.

14775 Wicks Blvd.
San Leandro, CA 94577-6779
Telephone: (510) 351-6101
FAX: (510) 352-3925

California Areata Cummins West, Inc.

4751 West End Road
Areata, CA 95521
Telephone: (707) 822-7392
FAX: (707) 822-7585

California Bakersfield Cummins West, Inc.

4601 East Brundage Lane
Bakersfield, CA 93307
Telephone: (805) 325-9404
FAX: (805) 861-8719

California Fresno Cummins West, Inc.

5333 N Cornelia Ave
Fresno, CA 93722
Telephone: (559) 277-6760
FAX: (559) 277-6769