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CUMMINS ISX12 User Manual

CUMMINS ISX12
14 pages
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General Information
Preparatory Steps
The connecting rod for the ISX12/ISX11.9 CM2250 uses a
fracture-split connection between the rod cap and the rod.
Connecting rods with a fracture-split surface must be treated
with caution. The two pieces of the connecting rod can not be
rubbed together. This will damage the mating surfaces. Use
care to not drop either piece of the connecting rod. Fracture-
split connecting rods must only be handled if the two pieces of
the connecting rod are tightened to the correct specification or
are completely separated.
WARNING
To reduce the possibility of personal injury, avoid direct
contact of hot oil with your skin.
WARNING
Some state and federal agencies have determined that used
engine oil can be carcinogenic and cause reproductive
toxicity. Avoid inhalation of vapors, ingestion, and prolonged
contact with used engine oil. If not reused, dispose of in
accordance with local environmental regulations.
WARNING
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CUMMINS ISX12 Specifications

General IconGeneral
Engine Displacement11.9 liters
ConfigurationInline 6-cylinder
Fuel TypeDiesel
Horsepower Range310-500 hp
AspirationTurbocharged and Aftercooled
Stroke5.79 inches (147 mm)
EmissionsEPA 2017
Engine Type4-stroke
Bore5.12 inches
Fuel SystemHigh Pressure Common Rail

Summary

General Information and Safety

Connecting Rod Design and Handling

Introduces the fracture-split connecting rod and its specific handling requirements.

Safety Precautions for Engine Work

Highlights safety measures for hot oil contact and health hazards associated with used engine oil.

Preparatory Steps and Precautions

Coolant and Component Handling Safety

Covers safety regarding hot coolant, coolant toxicity, and safe handling of heavy engine components.

Crankshaft Rotation and Cap Caution

Warns against rotating crankshaft with loose caps and lists initial preparation procedures.

Component Removal and Cleaning

Cleaning Material Safety Warnings

Emphasizes safety when using solvents, acids, or alkaline materials for cleaning.

Cylinder Liner Cleaning Precautions

Advises against abrasive cleaning on cylinder liners and specifies approved methods.

Connecting Rod Removal Procedures

Fracture-Split Surface Protection

Details crucial precautions to prevent damage to the fracture-split surfaces of connecting rod components.

Rod Cap Removal and Identification

Explains how to loosen capscrews, remove the rod cap, and note orientation for reassembly.

Piston and Connecting Rod Handling

Bearing Shell Management

Details the process of removing, marking, and handling bearing shells for reuse.

Assembly Handling and Protection

Covers piston pusher use, assembly handling, protection, and re-use orientation.

Disassembly and Reassembly Notes

Snap Ring and Piston Pin Removal

Covers snap ring removal and cautions against using hammers for piston pin removal.

Piston and Connecting Rod Re-use

Guidelines for reusing piston and connecting rod assemblies, including marking and orientation.

Cleaning, Inspection, and Assembly

Component Cleaning and Inspection

Procedures for cleaning and inspecting pistons, piston pins, and connecting rods.

Assembly Cautions and Snap Rings

Highlights snap ring seating importance and cautions against hammer use for piston pin installation.

Piston Assembly Lubrication and Installation

Piston Pin Lubrication and Orientation

Details piston pin bore lubrication and correct orientation for reused or new pistons.

Snap Ring Seating and Piston Rings

Re-emphasizes snap ring seating and refers to piston ring installation procedure.

Connecting Rod Installation

Crankshaft Alignment and Piston Lubrication

Aligns crankshaft and lubricates piston before installing connecting rod assembly.

Bearing Shell Preparation and Installation

Covers cleaning bearing shells, installing used ones correctly, and lubricating for crankshaft contact.

Cylinder and Rod Assembly Installation

Cylinder Liner and Ring Preparation

Inspects cylinder liners and uses a compressor to prepare piston rings for installation.

Piston and Rod Assembly and Orientation

Details using an assembly kit, guide pins, and correct orientation for piston/rod installation.

Assembly Falling Hazard Warning

Warns of the risk of the assembly falling into the cylinder block during installation.

Piston Insertion and Rod Cap

CAUTION: Piston Insertion Tools

Warns against using metal drifts for piston insertion to prevent damage.

Piston Insertion and Alignment

Guides insertion through ring compressor, checks free movement, and aligns rod with crankshaft.

Rod Cap Bearing Shell Installation

Installs bearing shell into rod cap and lubricates it for crankshaft journal mating.

Connecting Rod Finalization

Rod Cap Orientation and Interaction

Ensures correct rod cap orientation and minimizes joint interactions.

Capscrew Lubrication and Torque Sequence

Details lubricating capscrews and applying torque in a specific sequence and rotation.

Connecting Rod Side Clearance Measurement

Provides instructions for measuring connecting rod side clearance.

Finishing Steps and Run-In

Connecting Rod Movement Check

Confirms free side-to-side movement of the connecting rod on the crankshaft journal.

Engine Rebuild Safety and Run-In

Reinforces safety warnings and outlines the need for engine run-in after rebuild.

Final Installation and Checks

Component Installation Procedures

Lists installation steps for oil pump, nozzles, stiffener plate, suction tube, and oil pan.

System Fill and Operational Check

Covers priming and filling the oil system, filling the cooling system, and checking for leaks.

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