Mantenimiento QSX 15

QSX15 Engine Maintenance Training
PGBU AE
Engine Dataplate
• The data on the dataplate are mandatory when sourcing service Parts:
1. Engine serial number (ESN)
2. Control parts list
3. Model
4. Advertised horsepower and rpm

Front View
1. Accessory Drive belt

2. Water pump/fan drive belt
3. Lubricating oil fill
4. Water pump/fan drive belt
tensioner
5. Accessory drive belt
tensioner.
Left Side View 1. Gear cover
2. Engine dataplate
3. Air intake
4. Fuel pump
5. Fuel filter
6. Starter
7. Lubricating oil pan
8. Lubricating oil drains
9. Crankshaft timing pin port
10. Lubricating oil dipstick
11. Vibration dampers
12. Lubricating oil fill/barring
device
13. Fan hub.
1. Exhaust manifold
Right Side View 2. Lubricating oil inlet to turbocharger
3. Turbocharger
4. Thermostat housing vent
5. Thermostat housing
6. Engine coolant outlet
7. Coolant temperature sensor
8. Water pump
9. Coolant filter
10. Lubricating oil drains
11. Combination full-flow/bypass
lubricating oil filter
12. Lubricating oil cooler assembly
13. Flywheel housing
14. Engine serial number
15. Turbocharger lubricating oil drain
Fuel System - Left Side View
1. Intake manifold
pressure/temperature sensor
2. Fuel outlet
3. Fuel inlet
4. Fuel shutoff valve
5. Oil pressure/temperature sensor
6. ECM/engine harness port(OEM)
7. ECM
8. ECM/engine harness port
(actuator)
9. ECM/sensor port
10. Cooling plate (behind ECM)
Fuel System - Left Side View
11. Camshaft position sensor

12. Crankshaft position sensor
13. Ambient air pressure sensor
14. Water-in-Fuel sensor
15. Fuel pressure sensor
16. Front and rear rail sensors
17. Timing actuators
18. Fuel actuators.
Fuel Delivery Housing – Front View
1. Priming bypass valve (internal)
2. 320 psi pressure regulator
3. 36-micron filter screen
4. Fuel inlet
5. Quick disconnect pressure tap –
suction side
6. Water-in-Fuel sensor
7. 250 psi pressure regulator
8. Fuel shutoff valve
9. Quick disconnect pressure tap –
pressure side
10. Fuel pressure sensor
11. Front rail actuator
12. Front timing actuator
13. Rear timing actuator
14. Rear rail actuator
Fuel Delivery Housing – Rear View
1. Fuel pump assembly

2. Front rail pressure sensor
3. Fuel filter
4. Rear rail pressure sensor
QSX Engine Fuel System
1.Fuel Supply from tank 2. Fuel lift pump 3.Fuel Pump 4. Pressure fuel filter
5.Fuel shutoff valve 6.Fueling actuator 7.Timimg Actuator 8.Fueling supply to
injector 9.Timing fuel supply to injector 10.Injector 11.Fuel drain to tank
QSX Engine Fuel System
1.Fuel Supply from tank 2.Fuel filter 3.Gear pump 4.Fuel shutoff valve
5.Rail metering actuator 6.Timing Actuator 7.Rail metering supply to
injector 8.Timing fuel supply to injector 9.Injector 10.Fuel drain to tank
IFSM – Fuel Delivery Housing --- Front Review
Fuel pump 1.The assembly could be replaced.

2.The max full inlet resistance---
12 in. Hg
Aluminium IFSM frame
FSO –Fuel shutoff valve
Fuel inlet
250 psi pressure regulator Fuel Drain
10 Micron fuel filter

FS1007
1.The assembly could be replaced.

12 in. Hg
Rear rail actuator
Rear timing actuator
Front rail actuator

Rail actuator Timing actuator
Resistance 0.8 ± 0.1 ohms 1.3 ± 0.1 ohms

Front timing actuator °F
@ 70°
1.The assembly could be replaced.

12 in. Hg
320 psi pressure regulator
Fuel pressure sensor

36 Micron filter screen
Quick disconnect pressure tap-

Suction side
Drain Valve
WIF (Water in fuel sensor)

QSX Four System
Fuel System
QSX Fuel System Introduction---

QSX Engine Troubleshooting
Fuel System
Air Deaeration
Fuel Restriction
Lubricating Oil System
1.Lubricating oil flow from oil pump 2. Thermostat 3.Oil cooler bypass flow
4. Flow through oil cooler 5. Flow return to filter head 6. Filter bypass valve
7. Oil filter 8. Flow to turbocharger 9. Flow to main oil rifle 10. Oil drain
from turbocharger 11. Thermostat open – oil flows through oil cooler
12. Thermostat closed – oil flows directly to oil filter 13. Flow to oil filter
Lubricating Oil System
1.Lubricating oil flow from oil pump 2. Thermostat 3.Oil cooler bypass flow
4. Flow through oil cooler 5. Oil cooler flow return to filter head 6. Filter bypass
valve 7. Oil filter 8. Flow to turbocharger 9. Flow to main oil rifle 10. Oil drain from
turbocharger 11. Thermostat open – oil flows through oil cooler 2. Thermostat
closed – oil flows directly to oil filter 13. Flow to oil filter 14. Bypass valve open –
oil flows to oil filter 15. Bypass valve closed – oil flows directly to main rifle
LF9000 Lubrication Filter
QSX Four System
Lubrication Oil System -

Cooling System
1. Coolant inlet
2. Coolant flow from coolant
filter
3. Coolant bypass flow from
thermostat
4. Coolant flow to water pump
5. Coolant flow from water
pump
6. Coolant flow past oil cooler
7. Coolant flow to cylinder
head
Cooling System
1. Coolant flow through cylinder head 2. Coolant flow from cylinder head to
thermostat housing 3. Thermostat 4. Bypass open 5. Coolant flow through
thermostat housing to bypass passage 6. Coolant bypass passage 7. Coolant
bypass flow to water pump 8. Coolant flow to water pump 9. Bypass closed 10.
Coolant flow to radiator 11. Coolant flow from radiator
Cooling System
1. Coolant flow from cylinder block to cylinder head 2. Coolant flow from cylinder
head to thermostat housing 3. Coolant flow to radiator 4. Coolant bypass
passage 5. Coolant bypass flow to water pump 6. Coolant bypass flow to water
pump 7. Thermostats
QSX Four System
Cooling System
Cooling System Introduction---

Air Intake System
1. Intake air inlet to turbocharger 2. Turbocharger air to charger air cooler

3. Charger air cooler 4. From charge air cooler to intake manifold
5. Intake valve port 6. Intake valves
Exhaust System
1. Exhaust valve ports

2. Exhaust manifold
3. Turbocharger turbine
QSX four system
Intake/Exhaust System
QSX Engine General Structure
QSX engine structure--

QSX Electronics Control System
QSX Engine Troubleshooting
Electronics System
Maintenance Procedures at Daily Interval
Fuel-water separator – drain

Lubricating oil level – check
Coolant level – check
Fan, cooling – check
Drive belts – check
Air intake piping – check
Charger-air piping – check
Crankcase breather tube - check
Maintenance Procedures at 250 Hours or 6 Month
Lubricating oil and filters – change

Supplemental coolant additive (SCA) and antifreeze
concentration – check
Fuel filter (spin – on type) - change
Cummins Confidential
Maintenance Procedures at 1500 Hours or 1 Year
Coolant filter – change

Coolant filter head – inspect for reuse
Cooling fan belt tensioner – check
Air leaks, air intake and exhaust systems – check
Air cleaner restriction – check
Engine wiring harness - check
Crankcase breather tube – check

Radiator hose – check
Cold weather starting aids – check
Engine steam cleaning – clean
Engine mounting bolts – check
Vibration damper – inspect for reuse
Overhead set – adjust
Crankcase breather (internal) - replace
Fan hub, belt driven – replace
Maintenance Record Form
Maintenance Record
Engine Serial No.: Engine Model:
Owner's Name: Equipment Name/Number:
Hours or Actual Maintenance Check Check

Date Time Interval Hours Performed Performed By Comments
Daily Maintenance Procedure
Before Starting the engine, check the coolant & oil
levels. Look for
• Leaks
• Loose or damaged parts
• Worn or damaged belts
• Any change in engine appearance
• Odor of fuel
Engine Operation Report
Low lubricating oil pressure
Low power
Power increases or engine surge
Erratic or no accelerator control or response
Any warning lights flashing or staying on
Abnormal water or oil temperature
Unusable engine noise
Excessive smoke
Excessive use of coolant, fuel, or lubricating oil
Any fuel, coolant, or lubricating oil leaks
Loose or damaged parts
Worn or damaged belts
Daily Maintenance
Oil Level Check
The engine must be level when checking the level to make
sure the measurement is correct.
Shut off the engine for an accurate reading.
Wait at least 15 minutes after shutting off the engine to check
the oil level. This allows time for the oil to drain into the oil
pan.
For additional lubricating oil recommendations and oil pan
capacity information, refer to maintenance specifications.
Daily Maintenance
Fuel-water separator
Drain the water and sediment from the separator daily.
Shut off the engine.
Use your hand to open the drain valve. Turn the valve counterclockwise
approximately 3.5 turns until the valve drops down 25.4mm and draining
occurs. Drain the filter sump until clear fuel is visible.
To close the valve, lift the valve and turn clockwise until it is hand-tight.
Daily Maintenance
Coolant Level Check
Coolant level must be checked daily.
Daily Maintenance
Coolant Level Check

Coolant added to the engine must be mixed with the correct
proportion of antifreeze, supplemental coolant additive, and
water to avoid engine damage.
Daily Maintenance
Fan, Cooling Check
A visual inspection of the cooling fan is required daily. Check
for cracks, loose rivets, and bent. Check the fan to make
sure it is securely mounted. Tighten the capscrews, if
necessary.
Daily Maintenance
Drive Belts Check
Inspect the belts daily. Check the belt for intersecting
cracks. Traverse cracks are acceptable. Longitudinal
cracks that intersect with transverse cracks are not
acceptable. Replace the belt if it is frayed or has pieces
of material missing. Refer to section A for belt
adjustment and replacement procedures.
Daily Maintenance
Drive Belts Check
Inspect the belts daily replace the belts if they are cracked, frayed, or have
chunks of material missing small cracks are acceptable.
Adjust the belts that have a glazed or shiny surface, which indicates belt
slippage. Correctly installed and tensioned belts will show even pulley
and belt wear. Refer to section A for belt adjustment and replacement
procedures.
Measure the belt tension in the center span of the pulleys.
An alternate method can be used to check belt tension by applying 110 N
force between the pulleys on V-belts. If the deflection is more than one
belt thickness per foot of pulley
center distance, the belt tension
must be adjusted.
Daily Maintenance
Air Intake Pipe Check
Visually inspect the intake piping daily for wear points
and damage to piping, loose clamps, or punctures that
can damage the engine.
Replace damaged pipes, and tighten loose clamps, as
necessary, to prevent the air system from leaking.
Torque value: 8 n.m
Check for corrosion under the clamps and hoses of the
intake system piping. Corrosion can allow corrosive
products and dirt to enter the intake system.
Disassemble and clean, as required.
Daily Maintenance
Charge Air Piping Check

Inspect the charge air piping and hoses for leaks, holes,
cracks, or loose connections. Tighten the hose clamps
if necessary. Refer to the vehicle or equipment
manufacture’s specifications for the correct torque
value.
Daily Maintenance
Crankcase Breather Tube Check

Inspect the breather tube for sludge, debris, debris, or ice in
the tube.
Inspect the tube more frequently in ice conditions.
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.
Maintenance Procedures at 250 Hours or 6 Months
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.
49 3/24/2015 Cummins Confidential

Lubricating Oil and Filters
Operate the engine until the water temperature reaches
60℃. Shut off the engine. Remove the oil drain plug.
Drain the oil immediately to make sure all the oil and
suspended contaminants are removed from the engine.

Lubricating Oil and Filters
Replace the lubricating filters, add the specified amount of clean 15W-40
oil to fill the oil pan (capacity 83.3 liters).
Check the oil level on the dipstick, it must filled to the H(high) mark.
Operate the engine until the water temperature reaches 82℃, and
check for leaks.
Shut off the engine, wait 15 minutes for the oil to drain oil back to the oil
pan.
Check the oil level, add oil as necessary to bring the level up to the H
mark on the dipstick.

SCA Concentration Level Check
At least twice a year
At every subsequent oil drain interval if the concentration is
above 3 units
Whenever coolant is added to the cooling system between
filter changes.
Use Fleetguard® Coolant test kit, Part No. CC2602, to check
the SCA concentration level. Instructions are included with
the test kit. Use the coolant recommendations and
specifications in maintenance specifications for the correct
SCA and antifreeze level.

Antifreeze Concentration Check
Check the antifreeze concentration. Use a mixture of 50-percent water
and 50-percent ethylene glycol or propylene glycol-based antifreeze to
protect the engine to -32℃year-around.
The Fleetguard® refractometer, part number C2800, provides a reliable,
easy-to read, and accurate measurement of freezing point protection
and glycol concentration.
Antifreeze is essential in every climate.
Antifreeze broadens the operating temperature range by lowering the
coolant freezing point and raising its boiling point.
The corrosion inhibitors also protect the cooling system components from
corrosion and prolong component life.

Fuel Filter Check
Check the pressure difference between the rail fuel pressure
and fuel pump pressure by pressure gauge 3824877 on no
load, if the fuel filter restriction is above than 517KPa,
replace the filter.

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.

Coolant Filter
Remove the cooling system pressure cap.
Turn the coolant on/off valve to the off position.
Remove and discard the coolant filter, clean the gasket surface on
the filter head.
Apply a thin film of clean engine oil, or its equivalent, to the coolant
filter gasket sealing surface before installing the coolant filter.
Tighten the coolant filter ½ to ¾ of a turn after initial gasket contact.
Turn the coolant on/off valve to the on position.
Install the radiator pressure cap.
Operate the engine until the coolant temperature is above 82℃, and
check the coolant leaks.

Cooling Fan Belt Tensioner
Inspect for reuse
• With the engine turned off, verify 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 alternator belt must 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.
• Check the tensioner for dirt buildup. If this condition exists, the
tensioner must be removed and steam-cleaned.
• 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 must be replaced.
• Check 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.
Air Intake
Inspect for loose clamps or damage between the intake air piping, air
cleaner, turbocharger, charger-air cooler, and intake manifold.
Replace any damaged pipes, and tighten loose clamps.
Check for corrosion of the intake system piping under the clamps and
hoses. Corrosion can allow corrosive products and dirt to enter the
intake system. Disassemble and clean as required.
Excessive back pressure can cause exhaust leaks. Verify the exhaust
back pressure is within specified limits.
Operate the engine at full throttle and maximum load, and check for air
leaks. Listen for a whistling noise caused by high-pressure air leaks.

Exhaust System
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.
Clean all soot stains and paint the components in order to detect future
leaks.

Air Cleaner Restriction

Note: Do not remove the felt washer from the indicator. The felt washer
absorbs moisture.
A mechanical restriction indicator is available to indicate excessive air
restriction through a dry-type air cleaner. The red flag 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.

Engine Wiring Harness

Check all wire connections and the wiring harness for damage. Faulty
wiring can cause improper engine operation and poor performance.


interval.

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.

Engine Mounts.
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.
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 diagram in engine
identification.

Overhead Set
All overhead lash measurements must be made when the engine is
cold. Stabilized coolant temperature must be at 60℃ or below.
Read the entire procedure for overhead adjustment before attempting
to perform this operation.
Valves, injectors must be correctly adjusted for the engine to operate
efficiently. Valve, injector adjustment must be performed using the
listed in this section.
All the overhead set maintenance need to contact Cummins authorized
repair location.


interval.

Fan Hub, Belt Driven

Inspect the fan hub for the following:
Freedom of rotation
Cracked
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.
Measure the fan hub end clearance. Fan hubs with “step-bore” shafts and
not bearing spaces must be 0.08 to 0.25 mm end clearance.
Fan hubs with “through-bore” shafts with inner and outer bearing spacers
must be 0.08 to 0.41 mm end clearance.

Fan Hub, Belt Driven

Inspect the fan hub for the following:
Freedom of rotation
Cracked
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.
Measure the fan hub end clearance. Fan hubs with “step-bore” shafts and
not bearing spaces must be 0.08 to 0.25 mm end clearance.
Fan hubs with “through-bore” shafts with inner and outer bearing spacers
must be 0.08 to 0.41 mm end clearance.

Tool Requirements
•Most of the maintenance and operation tools can be

performed with common hand tools, the following is a list
of special service tools required for some maintenance
operations:
–3400158 Coolant Filter Wrench
–3400157 oil and fuel filter wrench
–3164795 Torque wrench
Filter Specifications
QSX15 Engine Operation & Maintenance manual 3666423

QSX15 Troubleshooting & Repair manual 3666259
QSX15 CM570 Wiring Diagram drawing 4022029
Lubricating Oil Filter LF9070
Fuel-Water Separator FS1040
Coolant Filter WF2126
Air Cleaner Element AF25708M

Mantenimiento QSX 15

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QSX15 Engine Maintenance Training

1. Engine serial number (ESN)

2. Control parts list

4. Advertised horsepower and rpm

1. Accessory Drive belt

11. Camshaft position sensor

1. Fuel pump assembly

Fuel pump 1.The assembly could be replaced.

Aluminium IFSM frame

FSO –Fuel shutoff valve

250 psi pressure regulator Fuel Drain

10 Micron fuel filter

1.The assembly could be replaced.

Rear rail actuator

Rear timing actuator

Front rail actuator

Resistance 0.8 ± 0.1 ohms 1.3 ± 0.1 ohms

1.The assembly could be replaced.

320 psi pressure regulator

Fuel pressure sensor

Quick disconnect pressure tap-

WIF (Water in fuel sensor)

QSX Fuel System Introduction---

Lubrication Oil System -

Cooling System Introduction---

1. Intake air inlet to turbocharger 2. Turbocharger air to charger air cooler

1. Exhaust valve ports

QSX engine structure--

Fuel-water separator – drain

Lubricating oil and filters – change

Coolant filter – change

Crankcase breather tube – check

Fan hub, belt driven – replace

Hours or Actual Maintenance Check Check

Coolant Level Check

Charge Air Piping Check

Crankcase Breather Tube Check

All maintenance checks and inspections listed in

49 3/24/2015 Cummins Confidential

50 3/24/2015 Cummins Confidential

51 3/24/2015 Cummins Confidential

52 3/24/2015 Cummins Confidential

53 3/24/2015 Cummins Confidential

54 3/24/2015 Cummins Confidential

All maintenance checks and inspections listed in previous

55 3/24/2015 Cummins Confidential

56 3/24/2015 Cummins Confidential

58 3/24/2015 Cummins Confidential

59 3/24/2015 Cummins Confidential

Air Cleaner Restriction

60 3/24/2015 Cummins Confidential

Engine Wiring Harness

61 3/24/2015 Cummins Confidential

All maintenance checks and inspections listed in previous

62 3/24/2015 Cummins Confidential

63 3/24/2015 Cummins Confidential

64 3/24/2015 Cummins Confidential

65 3/24/2015 Cummins Confidential