Cummins has built a reputable name for itself over the decades, but how did it get to where it is today? In this guide, we’ll discuss how Cummins started as a strong partnership, then transformed into an impressive engine manufacturing company. Diesel Pro Power will take you through the ISX series’ specs, common issues and featured products, whether you have one of the original units or a modern version.
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When you know the ins and outs of your engine system, you can better prepare your marine or generator applications to make functional repairs when necessary.
A Brief History
Clessie Cummins founded Cummins Engines in 1919 and partnered with J. Irwin Miller, a knowledgeable man in business practices. By combining Cummins’ expertise in diesel and Miller’s business skills, they were able to expand the company to how we know it today. Through the decades, the Cummins brand has integrated itself into a multitude of areas within the diesel industry.
For example, in 1973, Cummins bought Holset Engineering Co., which was a company focused on engineering engine parts. Cummins also acquired Onan in 1986, a company that manufactured generator sets. The name was later changed to Cummins Power Systems.
In 1989, Cummins began working with Dodge Ram, and the name soon changed to Cummins Emissions Solutions.
Cummins is an engineering company that has its foot in multiple critical areas of the market. With growing expertise in engine manufacturing, emissions solutions, gensets and parts engineering, Cummins excels in manufacturing products and solutions for marine engines and generators.
Cummins ISX History
The initial design of the Cummins ISX began in 1998. The original engine in the series was the N14, but over time, it became an obsolete line of engines, as stricter Environmental Protection Agency (EPA) laws came into play.
In 2002, the ISX15, also known as the “Signature” series, started production. It upheld its name because it had an innovative fuel system called the “Interact System.” The “IS” in ISX stands for “Interact System.”
Since its launch, the ISX has been the core of Cummins’ diesel engine fleet. Not only has it advanced with quicker processing, but it has also increased fuel efficiency since its debut.
In 2002, the ISX became one of the first diesel engines to incorporate an exhaust gas recirculation (EGR) cooler system. The technology takes the engine’s exhaust and recirculates it back to the intake chamber, reducing NOx particles. The ventilated exhaust lowers the combustion chamber temperature.
The ISX started featuring the selective catalytic reduction (SCR) system in 2006. It injects urea, which is an active element in diesel exhaust fluid (DEF), into the exhaust. Ammonia in the urea chemically reacts with the NOx particles and converts them into nitrogen and water inside the catalytic converter. DEF reaches high temperatures in the holding tank, then pumps into the injector and decomposition tube, causing it to react to the NOx in the exhaust.
New advancements in emissions technology emerged when Cummins introduced the diesel particulate filter (DPF). The system captures the exhaust produced from the combustion chamber and neutralizes the soot through oxidation. The oxidized ash transforms into dust. Then, it’s regenerated through the turbo in a process known as regeneration.
The ISX had a dual overhead camshaft design. One cam activated the injectors, and the second initiated the valve train. This complicated injection system was cam actuated to form injection pressure and deliver fuel. However, it didn’t last into the next ISX versions after 2010.
The Cummins engine underwent a redesign to meet the 2010 EPA standards through developments in the emissions technology. The company’s advancements focused on a single overhead camshaft instead of a dual solution. They also innovated the common rail fuel system, which eradicated the need for an injector camshaft to generate pressurized fuel.
In the common rail fuel system, diesel fuel becomes pressurized via multiple piston pumps. Then, it’s distributed through the tubing to the rail system for storage under extreme pressures— about 35,000 PSI or higher.
This version of the ISX relies on an engine control module (ECM) to monitor the timing and pressure. The ECM can activate each fuel injector up to five times per combustion cycle. The single camshaft improvement creates a better fuel economy and reduces emissions to stay parallel with EPA standards.
By 2013, the ISX gained on-board diagnostics to track the engine’s emissions. This change increased fuel efficiency compared to previous versions. Each year, Cummins continues to update the ISX15 to meet EPA standards.
Cummins ISX Specs
A Cummins ISX engine is an Inline-6 diesel with a duel-fuel configuration — meaning it can run on diesel or natural gas — although, diesel is the most common. If you’re in the market for an ISX, its specification log includes:
– 400-600 hp
– 2,050 lb.-ft. maximum peak torque
– 2,000-2,100 RPM engine speed
– 1,000 lb.-ft. clutch engagement torque
– Six cylinders
Cummins Isx Bolt Torque Chart
– 14 gallons of oil capacity
– 15-liter design
– 3,093 lbs. system weight
– 3,021 lbs. dry weight
– 72 lb. aftertreatment
Throughout each improved generation, the ISX engine now has several prominent features that make it one of the most sought-after solutions. Compared to the original N14 series back in the late 1990s, the ISX now delivers an exceptional line of components that have been engineered and upgraded each year, including:
Cooled exhaust gas recirculation:If your engine was made after 2002, it has an EGR system. Recirculation within the engine lowers the combustion temperatures, which reduces optimized MPG and emissions.
Crankcase ventilation system:The ISX’s advanced crankcase ventilation only needs replacement after every third or fourth oil change, allowing you to operate for longer.
Cummins Intebrake™: The Intebrake™ can reach up to 600 braking HP, which helps control the machine and reduce brake wear.
Dual overhead camshafts: If your ISX was manufactured before 2010, it has a dual camshaft system. The first cam creates high-pressure fuel injection for clean power while the second has a set of lobes to operate the integrated engine brake. The second set of camshafts also moves the intake and exhaust valves. With a high-pressure fuel injection system, a marine engine can produce complete combustion.
High-pressure fuel injection system:The high-pressure system forms a clean and complete combustion phase.
Integrated electronic controls: Engines produced after 2010 rely on an ECM. The engine’s ECM controls the aftertreatment. It also synchronizes interactions between the ABS, transmission, engine brake, cooling fan and other components.
Low maintenance: An ISX engine can run up to 15,000 miles between oil and filter changes.
Cummins M11 Rocker Arm Torque
Mid-stop cylinder liners: Cylinder liners within the ISX have a strong design to allow for variations in coolant chemistry.
Particulate filter:An ISX engine has a fully integrated particulate filter for uncompromised performance by reducing particulate matter.
Single overhead camshaft: Versions made after 2010 have a single camshaft system with a common rail fuel operation that relies on piston pumps to inject diesel.
Variable geometry turbocharger:The turbocharger has a sliding nozzle to boost durability and reliability. Its electric actuation enhances its responses and control for adjustment. The component also delivers a definite increase at any RPM.
Cummins has mastered the engineering process by integrating each possible solution into one unit.
Common Cummins ISX Issues
When you find your ISX engine is experiencing issues, refer to your manufacturer’s manual. Address any problems right away to avoid more severe damage. Here are some tips to keep in mind before making engine repairs:
– Check the dual or single overhead cams.
– Inspect the spring-loaded cam gear and release the tension before unloading.
– Set the idol gear.
– Use a puller tool for the front and back seal.
– Use heavy-duty cams.
– Work with specified parts for ISX engines.
Do you have a single or dual cam ISX? Does it have an EGR system?
When it comes to common ISX issues, some problems may not affect your engine, depending on the year it was made. It’s important to know what version of the marine engine you operate to understand what troubleshooting and repairs are necessary.
For example, engines engineered before 2002 will experience more problems with EGR compared to modern types. In 2008, Cummins began noticing the SCR system experienced failing revolving parts, interfering with the engine’s horsepower. Clogged inlets came about in 2010 when recirculation was occurring, also affecting HP.
Depending on the version you have, common Cummins ISX engine problems involve the turbocharger, EGR, camshafts and timing wedge:
Variable Geometry Turbocharger
The turbocharger is one of the most notorious ISX failures and is expensive to fix. While they are ideal for direct throttle response, VGTs often experience a buildup of carbon, soot, rust and other contaminants. You may feel no response from the engine or an extreme retort at low RPMs. The best fix is to clean the exhaust side of the VGT, replace its parts or swap it for a fixed unit.
EGR System
Another common problem is an EGR valve that leaks. It can cause black smoke and power loss to your ISX engine. Although it’s tricky to diagnose, you can monitor the unit’s coolant to see if leaks are present. If you’re using more coolant than usual, it can be an indication of a leak. Another sign is if you notice white residue from the burnt coolant. EGR system issues are more common in older versions of ISX engines.
Camshaft
Rocker arms within your ISX may be damaging the camshafts, which causes an improper amount of oil to pass. When the rockers hit the camshaft lobes, it flattens them. This deprivation causes your marine or generator application to experience performance issues. You can replace both the camshaft and rockers to deter the problem. Swapping rocker arms for new ones is vital. Otherwise, they will flatten the new camshaft as well.
Timing Wedge
Problems with a timing wedge often happen after you repair or overhaul the camshaft. Wedges have a tendency to wear, which inadvertently alters the camshaft timing, therefore, wrecking the engine’s balance. Fuel injection that occurs at the wrong time can affect the entire system. If it’s too late, it can create soot, contaminating the oil. Over time, a buildup of contamination can form in the oil filter, resulting in a drop in oil pressure.
Avoid the timing wedge issue by changing the oil filter. If the problem seems to improve, you need to retime the ISX engine using a dial indicator. It’s a sensitive procedure, so you may need to rely on the professionals to take over.
Certain ISX engines experience more problems than others, but each issue has a set of simple troubleshooting procedures. One of the best ways to eliminate problems with your Cummins is to conduct preventative and regular maintenance according to your manufacturer’s manual.
Why the Cummins ISX May Be Ideal for You
The Cummins ISX trumps other engine solutions by living up to EPA emission standards and having an advanced fuel economy. The ISX may be the ideal provision, whether you’re a yacht or a workboat owner. Several of the engine’s featured products include:
Cylinder head with valves: With a cylinder head remanufactured to advanced conditions, it functions like new. The new internal components are tested for air decay and are also wet tested. It has chased threads, and mechanics weld any cracks to avoid leaks.
Inframe engine rebuild kit:The rebuild kit includes new parts. The pistons are made from heat-treated steel and have a modern closed-skirt design. With induction-hardened cylinder liners, it delivers improved wear resistance. The rod bearings are made from bi-metal for better strength, durability and fitment.
Fuel injector: A remanufactured ISX fuel injector has new parts ranging from the spill valve, shim and NOP spring to screws and the actuator assembly. It also includes new external O-rings and filters.
Inframe engine rebuild kit with re-ring and fewer pistons: The ISX has an inframe rebuild option for when your pistons are in good shape. It has oil control rings made with precise tangential tension for ideal control, and the gaskets are made with premium materials.
Valve camshaft:If your engine has worn camshafts, they can reduce the amount of horsepower and affect the valve timing. The valve camshaft involves precise remanufacturing.
ISX variable speed propulsion engines are perfect for recreational, commercial and government marine applications. Cummins strives to upgrade and improve each component in their ISX engine series to deliver superior dependability and performance. The marine engine has an exceptional fuel economy compared to other big-bore engines and outstanding braking features.
Cummins continues to expand the X15 series’ components, even into 2020, where their latest version already meets 2021 greenhouse gas regulations and fuel economy standards.
The ISX also has unmatched fuel economy, emissions, performance and cooling systems:
Fuel economy: The ISX has efficient water and fuel pumps which deliver more usable horsepower to your operations. Cummins uses technology to generate optimized combustions and fewer regenerations of the aftertreatment system. The ISX undergoes better fuel economy advancements with each new version.
Emissions: Current ISX engines meet EPA standards along with DOT regulations because of on-board diagnostics that look at optimal emission performances.
Performance: The ISX has a massive range of horsepower, depending on which version suits your application. With a max 2,050 lb.-ft. of peak torque, the engine’s SmartTorque adds 200 lb.-ft. of extra torque when needed. You can tailor the unit’s performance to your specific needs.
Cooling system: The cooling system underwent a size reduction without losing power to increase aerodynamics. It also reduces losses seen in the alternator’s performance and other water pumps. A smaller cooling solution creates an open room, forming cooled air around the engine.
Cummins also continues to improve the combustion chamber to result in fewer active regenerations of the aftertreatment. The ISX has advanced components and featured products to support your marine and generator applications.
Diesel Pro Power Has What You Need
Diesel Pro Power has a vast inventory of ISX marine engine components, including freshwater parts and Cummins ISX cables for when you experience problems with your system. With more than 15,000 satisfied customers, we provide 24-hour worldwide shipping through our easy-to-use website. Our specialists deliver complete solutions for your specific applications and needs by working with you one-on-one.
Browse our ISX engine parts or reach out to our customer care team by calling 1-877-597-1353. We deliver solutions with precision to your specific demands.
The first Cummins ISX engine was produced in 1998 and Capital Reman Exchange is proud to offer support for the Cummins brand workhorse. Wheter you have a heavy duty truck application, mining or power generation application, Capital Reman Exchange has the ability and expertise to offer the Cummins ISX Engine and parts.
Our remanufactured Cummins ISX Engines are rebuilt to OEM specifications in our ISO 9001 level machine shop. This helps ensure older model ISX engines are rebuilt using updated parts and technology.
The “ISX” in Cummins ISX stands for “Interact System” which is the on-highway fuel system Cummins developed to vastly improve performance. Cummins ISX Engines are a very popular for on-highway and commercial trucking applications having the ability to pull between 430hp – 620hp at 2050 ft/lbs. Consequently, the brother of the Cummins ISX is the Cummins QSK which is part of the “Quantum” series. The Cummins QSX engine is the primary workhorse for off-highway, industrial, marine, heavy equipment and oil & gas applications. The Cummins QSX delivers between 365hp – 665hp at 1875 ft/lbs. of torque. We have the ability to do both Cummins ISX and Cummins QSX engine rebuilds.
Cummins Isx Rocker Arm Torque Specs
Cummins ISX Fuel System
The Cummins 15L ISX is the latest engine in the ISX family which debuted in 2013. With the ISX 15 the fuel efficiency is increased 10%+ over previous models. The foundation of the ISX 15L is the reduction of the size of the radiator and multiple cooling panels. This reduction in size of the cooling system without the loss of cooling power mean overall better aerodynamics within the engine. The new Cummins ISX engine cooling system allows for losses from the engine’s alternator and various other water pumps to be mitigated. The new technology also allows for more open room which creates cooled air for the engine. The new cooling technology will likely save around 2,000 gallons of fuel per year for a class 8 truck which also means less particulate emissions. In addition to improved efficiency of the cooling system Cummins has also refined the combustion chamber to provide fewer active re-generations of the after treatment system.
The Cummins 15L ISX engine is the newest engine with the improved fuel system. Up until 2010 the traditional Cummins ISX engine featured the antiquated dual overhead camshaft design. One of the camshafts activated the injectors and the other camshaft activated the valve train. This type of injection system is called high pressure injection and operates to create injection pressure by the camshaft actuation. The dual cam design uses an integrated fuel system model (IFSM) which contains pressure regulators, gear pump, lift pump, metering and timing actuators and shutoff valve to accurately deliver diesel fuel directly to the injectors. The IFSM typically has a one section valve cover that is either plastic or chrome plated on older models of the Cummins ISX.
The latest versions of the Cummins ISX15 Engine keeping getting more fuel efficient as the technology keeps advancing. Cummins has stated that the newest ISX15 can deliver up to 2% better fuel economy than previously thought. The newest Cummins ISX15 operational efficiency actually delivers more horsepower than in older ISX Engine models.
The ratings on the ISX15 range from 400-600 hp (298-447 kW) with 2050 lb-ft of peak torque. The SmartTorque system Cummins developed adds roughly 200 lb-ft of extra torque to the top two gears of the engine. This means that Class 8 trucks can drive up steeper grades with much fewer downshifts making the ride that much smoother and less strenuous on the engine. For other models of the Cummins ISX engine the additional torque from the SmartTorque system is applied to the lower gears where it is needed the most. Capital Reman Exchange can provide a remanufactured Cummins ISX15 for half the cost of a new model without loss of efficiency or horsepower.
Cummins ISX Fuel Efficiency Physics
The fuel efficiency technology of the Cummins ISX Engine uses the power of steam. Harnessing the power of steam for propulsion purposes has been around for almost 2000 years. The steam engine was first patented in 1606 by Spanish inventor Jerónimo de Ayanz y Beaumont It was in 1698 that Thomas Savery patented a steam pump which condensed steam to create a vacuum to draw water into the chamber, then applied the pressurized steam to further a piston. The same basic steam technology is used today in the Cummins ISX. This scientific process is called the Organic Rankine Cycle.
Applying the Organic Rankine Cycle (ORC) to the diesel engine is quite a different process. Heat in a standard reciprocating engine if often looked as something to be avoided at all costs but with new technology it is utilized to aid in better fuel efficiency. The technology is called Exhaust Gas Recirculation (EGR) which turns excess heat from a major problem into the key to improved efficiency. In the Cummins ISX Engine the heat comes out of the engine and travels directly to a superheater system. The superheater increases the temperature of the wet steam from the boiler into an extremely dry superheated steam.
This concept of “dry steam” is steam that is heated beyond boiling. The dry steam contains a lot of energy which then turns a turbine in power plant systems. The turbine then turns a generator which converts waste heat into electricity. In the Cummins ISX engine the electricity is used to power a small electric motor built into the crankshaft. After the superheated dry steam’s energy is transferred into the turbine it later is sent to a recuperator then to a condenser where it is condensed and routed back into the boiler producing a closed loop system. This is quite a revolutionary concept for the Cummins ISX having both the internal and external combustion in one engine.
The extra energy that is recovered comes from four different sources: 6% increase in energy will come from the EGR, 2% will come from exhaust energy, and 2% will come from other accessories that used to drain additional power. All of this additional energy adds up to about 10% increase in overall fuel efficiency for the Cummins ISX 15.
The basic premise of the Cummins ISX Engine’s fuel efficiency is recovering waste energy. Waste energy can be described as energy that is not used for any practical purposes. Energy can be neither created nor destroyed just possess the form of kinetic energy (in motion) or potential energy (stored energy). When studying energy within the Cummins ISX Engine we can ascertain that most of the energy is stored in the diesel fuel as potential energy. When that diesel fuel is burned in the combustion engine it changes form to kinetic energy which then drives the pistons. However, most of the diesel fuel’s energy is lost as heat.
One gallon of diesel fuel contains about 139,000 Btu (British Thermal Unit) of potential energy. One Btu is defined as the amount of heat required to increase one pound of water one degree Fahrenheit. The goal with any engine is to achieve peak thermal efficiency where as peak thermal efficiency is described as the work you get divided by the energy you put in. For example a gas powered car engine is roughly 25% efficient and a heavy-duty diesel powered Cummins ISX engine is roughly 40% efficient. What that means is that if a vehicle used 10 gallons of gas only 4 gallons would go to towards propelling the tires forward; the other 6 gallons are wasted. The Organic Rankine Cycle technology in the Cummins ISX 15 aims to recovery as much energy as possible through heat recovery. Across the board, only roughly 33% of energy is used towards moving the motor.
An example of waste energy in relation to trucks is when heat escapes from the engine to the outdoors. The heat sources on a Cummins vehicle that help warm you up on a cold day include the Cummins ISX engine itself, the radiator, transfer case, transmission, differentials, U-Joints, brakes, cooling units, and your heater. Noise is also a heat source and is mostly a waste energy by product.
The second kind of energy is work energy. Work energy is harnessed energy being directed where you want it to go. However, there are always going to be other hindrances to 100% thermal efficiency. Gravity, inertia, laws of aerodynamics and drag will always be barriers to overcome to capturing 100% of an energy source. The second law of thermodynamics states that achieving 100% thermal efficiency can’t be accomplished.
ISX Emissions History
Cummins has always been on the forefront of emissions reduction and the development of technology that improves emissions output. The first technology Cummins introduced to help reduce particulate emissions was cooled exhaust gas recirculation or EGR system. This system was introduced in the Cummins ISX CM870 model in 2002 and works by taking exhaust gas and re-circulates it back into the engine intake. This process in turn radically lowers the combustion chamber temperatures in the Cummins ISX engine thus reducing the creation of Nitrogen Oxide. NOx and NOy (NOx plus other compounds that are created during the oxidation process of NOx) are the common causes of air pollution, smog and acid rain.
Another big change in emissions reduction rolled out in 2008 when Cummins introduced Diesel Particulate Filter technology for the Cummins ISX CM871 model. Diesel Particulate Filter technology or DPF is a filtration system designed to trap particulate NOx matter created by the Cummins ISX engine. The second step of the system is the Diesel Oxidation Catalyst which further breaks down the particulate matter via oxidation of the ash. The ash of the diesel particulate is oftentimes called soot.
Then again in 2010 the Cummins ISX engine made another upgrade to its emissions technology with the ISX15 CM2250 model. The Cummins ISX15 CM2250 features the improved Exhaust Gas Recirculation in addition to Selective Catalytic Reduction for diesel particulate matter. These new guidelines further confined to EPA regulations also known as Urea Injection Reduction. The selective catalytic reduction system contains a diesel exhaust fluid composed of urea and water, controller, holding tank, pump, injector and the catalyst brick.
The system works by heating up the diesel exhaust fluid which is then pumped and injected into a decomposition area which then chemically reacts with the diesel exhaust in the Selective Catalytic Reduction chamber to reduce the level of NOx. The Cummins ISX15 uses one camshaft compared to previous versions which used two. This single camshaft design in the Cummins ISX Engine is due to the introduction of the common rail fueling system in which diesel fuel is pressurized from already high pressure. The fuel is stored in multiple piston pumps and transferred through tubes to a rail where the diesel fuel is stored under extremely high pressures up to but not including 35,000 psi.
Rebuilt Engines
To remanufacture is to make as close to new as possible. Most wearable parts are automatically replaced. All core material is closely inspected and checked against original equipment specifications for correct dimensional tolerances. Replacement parts are new or requalified. If new, parts are made in the same production processes as original equipment. Testing is performed to manufacturer specifications and original production standards. All remanufactured parts are also tested to the highest standards.
Call Capital Reman Exchange Today at 1-844-239-8101 For Immediate ISX Sales Service