Troubleshooting and repair manual is intended to aid in determining the cause of engine related problems and to provide recommended repair procedures of Cummins Engines ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4, QSL9.
This manual is divided into sections. Each section is equivalent to a group used in Cummins' filmcard system. Some sections contain reference numbers and procedure numbers. Reference numbers provide general information, specifications, diagrams, and service tools where applicable. Procedure numbers are used to identify and reference specific repair procedures for correcting the problem.
This manual does not contain fuel systems electronic troubleshooting. Use the troubleshooting trees in this manual, if there are no electronic fault codes.
This manual is designed so the troubleshooting trees are used to locate the cause of an engine problem.
Troubleshooting and repair manual comes in PDF format. We recommend using Adobe PDF Reader, to be sure all images/graphics will display correctly.
Models covered:
ISC,
ISCe,
QSC8.3,
ISL,
ISLe3,
ISLe4,
QSL9.
Contents of Troubleshooting and Repair Manual (Volume 1):
- Section i - Introduction
- About the Manual
- Acronyms and Abbreviations
- General Cleaning Instructions
- General Repair Instructions
- General Safety Instructions
- How to Use the Manual
- Illustrations
- Symbols
- Section E - Engine and System Identification
- Cummins® Service Engine Model Product Identification
- Engine Diagrams
- Engine Identification
- Section F - Familiarization
- Air Intake System - Overview
- Complete Engine - Overview
- Compressed Air System - Overview
- Cooling System - Overview
- Electrical Equipment - Overview
- Engine Testing - Overview
- Exhaust System - Overview
- Flow Diagram, Air Intake System
- Flow Diagram, Compressed Air System
- Flow Diagram, Cooling System
- Flow Diagram, Exhaust System
- Flow Diagram, Fuel System
- Flow Diagram, Lubricating Oil System
- Fuel System - Overview
- Injectors and Fuel Lines - Overview
- Lubricating Oil System - Overview
- Rocker Levers - Overview
- Vehicle Braking - Overview
- Troubleshooting Symptoms
- Troubleshooting Symptoms (New Format)
- Product - Group 00
- Cylinder Block - Group 01
- Cylinder Head - Group 02
- Rocker Levers - Group 03
- Cam Followers/Tappets - Group 04
- Section TS - Troubleshooting Symbols
- Troubleshooting Procedures and Techniques
- Troubleshooting Symptoms Charts
- Troubleshooting Overview
- Section TT - Troubleshooting Symptoms (New Format)
- Engine Performance Troubleshooting Tree - CM554 Electronic Control System with CAPS Fuel System
- Engine Performance Troubleshooting Tree - ISC/QSC/ISL/QSL with CM850 Electronic Control System
- Engine Performance Troubleshooting Tree for QSC and QSL Marine Engines with CM850 ECM
- Fuel Economy Troubleshooting Tree
- Vibration Excessive
- Section 0 - Product - Group 00
- Engine Installation
- Engine Mounting Bolts
- Engine Removal
- Engine Storage - Long Term
- Service Tools
- Section 1 - Cylinder Block - Group 01
- Bearings, Connecting Rod
- Bearings, Main
- Block Stiffener Plate
- Camshaft
- Camshaft Bushings
- Camshaft Gear (Camshaft Installed)
- Camshaft Gear (Camshaft Removed)
- Connecting Rod
- Crankshaft
- Crankshaft Gear, Front (Crankshaft Removed)
- Crankshaft Seal, Front
- Crankshaft Seal, Rear
- Crankshaft Speed Indicator Ring
- Crankshaft Wear Sleeve, Front
- Crankshaft Wear Sleeve, Rear
- Cylinder Block
- Cylinder Liner
- Gear Cover, Front
- Gear Housing, Front
- Piston
- Piston and Connecting Rod Assembly
- Piston Cooling Nozzle
- Piston Rings
- Vibration Damper, Rubber
- Vibration Damper, Viscous
- Section 2 - Cylinder Head - Group 02
- Crosshead
- Cylinder Head
- Cylinder Head Gasket
- Service Tools
- Valve Guide Seal, Cylinder Head
- Section 3 - Rocker Levers - Group 03
- Closed-Crankcase Ventilation System Filter
- Crankcase Breather (External)
- Crankcase Breather (Internal)
- Crankcase Breather Tube
- Overhead Set
- Rocker Lever
- Rocker Lever Cover
- Rocker Lever Housing
- Service Tools
- Section 4 - Cam Followers/Tappets - Group 04
- Push Rods or Tubes
- Service Tools
- Tappet
Contents of Troubleshooting and Repair Manual (Volume 2):
- Section i - Introduction
- About the Manual
- Acronyms and Abbreviations
- General Cleaning Instructions
- General Repair Instructions
- General Safety Instructions
- How to Use the Manual
- Illustrations
- Symbols
- Section 5 - Fuel System - Group 05
- Engine Fuel Heater, Electric
- Fuel Consumption
- Fuel Injection Pump
- Fuel Lift Pump
- Fuel Pump
- Fuel Pump Accumulator Module
- Fuel Pump Actuator Housing
- Fuel Pump Cam Housing Module
- Fuel Pump Delivery Valve
- Fuel Pump Distributor and Injection Control Valve Module
- Fuel Pump Distributor Inlet Fitting
- Fuel Pump Gear Pump
- Fuel Pump Gear Pump Module
- Fuel Pump Head
- Fuel Pump Head Outlet Fitting
- Fuel Pump Rate Shape Tube
- Fuel Pump Timing
- Injection Control Valve
- Pumping Control Valve
- Rotor, CAPS Fuel Injection Pump
- Service Tools
- Section 6 - Injectors and Fuel Lines - Group 06
- Air in Fuel
- Engine Control Module Cooling Plate, Fuel Cooled
- Fuel Connector (Head Mounted)
- Fuel Cooler
- Fuel Drain Line Restriction
- Fuel Drain Lines
- Fuel Filter (Spin-On Type)
- Fuel Filter Head
- Fuel Filter Head Bracket
- Fuel Inlet Restriction
- Fuel Pressure Relief Valve
- Fuel Pump Air Bleed Line
- Fuel Rail
- Fuel Rail High Pressure Fitting
- Fuel Supply Lines
- Injector
- Injector Supply Lines (High Pressure)
- Service Tools
- Section 7 - Lubricating Oil System - Group 07
- Engine Oil Heater
- Lubricating Oil and Filter Analysis
- Lubricating Oil Contamination
- Lubricating Oil Cooler
- Lubricating Oil Dipstick
- Lubricating Oil Dipstick Tube
- Lubricating Oil Filter (Spin-On)
- Lubricating Oil Filter Bypass Valve
- Lubricating Oil Filter Head
- Lubricating Oil Filter Head (Remote-Mounted)
- Lubricating Oil Filter Head Adapter
- Lubricating Oil High Pressure Relief Valve
- Lubricating Oil Leaks
- Lubricating Oil Lines
- Lubricating Oil Pan
- Lubricating Oil Pressure Regulator (Main Rifle)
- Lubricating Oil Pump
- Lubricating Oil Suction Tube (Block-Mounted)
- Lubricating Oil System
- Service Tools
- Section 8 - Cooling System - Group 08
- Belt Guard
- Belt Tensioner, Automatic (Water Pump)
- Bracket, Fan Idler Pulley
- Coolant Filter
- Coolant Filter Head
- Coolant Filter Valve
- Coolant Heater
- Coolant Return Junction Block
- Coolant Thermostat
- Coolant Thermostat Housing
- Coolant Thermostat Housing Support
- Coolant Thermostat Seal
- Coolant Vent Lines
- Cooling System
- Cooling System Diagnostics
- Drive Belt, Cooling Fan
- Expansion Tank
- Fan Clutch, On-Off
- Fan Spacer and Pulley
- Fan, Cooling
- Heat Exchanger
- Keel Cooler
- Marine Gear Oil and Fuel Cooler Assembly
- Marine Gear Oil Cooler
- Pulley, Fan Idler
- Radiator
- Radiator Hoses
- Radiator Pressure Cap
- Radiator Shutter Assembly
- Sea Water Pump
- Sea Water Strainer
- Sea Water System Diagnostics
- Service Tools
- Water Inlet Connection
- Water Pump
- Zinc Anode
- Section 9 - Drive Units - Group 09
- Belt Tensioner, Refrigerant Compressor, Automatic
- Drive Belt, Refrigerant Compressor
- Engine Barring Device
- Hydraulic Pump Drive
- Refrigerant Compressor
- Refrigerant Compressor Mounting Brac
- Section 10 - Air Intake System - Group 10
- Aftercooler Assembly (Sea Water)
- Air Cleaner Assembly (Engine-Mounted)
- Air Crossover
- Air Inlet Connection
- Air Intake Connection
- Air Intake Connection Adapter
- Air Intake Manifold Cover
- Air Intake Restriction
- Charge-Air Cooler
- Cold Starting Aid
- Inline Air Filter
- Intake Manifold Pressure
- Service Tools
- Turbocharger
- Turbocharger Actuator Air Line
- Turbocharger Coolant Hoses
- Turbocharger Exhaust Connection Adapter
- Turbocharger Oil Drain Line
- Turbocharger Oil Supply Line
- Turbocharger Wastegate Actuator
- Turbocharger Wastegate Valve Body
- Variable Geometry Turbocharger Actuator, Pneumatic
- Section 11 - Exhaust System - Group 11
- Aftertreatment Diesel Exhaust Fluid Dosing Unit
- Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Side Flushing
- Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter
- Aftertreatment Diesel Exhaust Fluid Line Restriction Test
- Aftertreatment Diesel Exhaust Fluid Tank Filter
- Aftertreatment Nozzle
- Aftertreatment Selective Catalytic Reduction (SCR) Catalyst
- Exhaust Gas Pressure Sensor
- Exhaust Gas Temperature Sensor
- Exhaust Gas Treatment Monitor Harness
- Exhaust Gas Treatment Monitor Unit
- Exhaust Manifold, Dry
- Exhaust Manifold, Wet
- Exhaust Outlet Connection
- Exhaust Restriction
- Heat Shield
- Service Tools
- Section 12 - Compressed Air System - Group 12
- Air Compressor
- Air Compressor (Oil Carryover)
- Air Compressor Carbon Buildup
- Air Compressor Coolant Lines
- Air Compressor Cylinder Head, Single Cylinder
- Air Compressor Rear Bearing Housing, Two Cylinder
- Air Compressor Unloader and Valve Assembly
- Air Leaks, Compressed Air System
- Air Pressure Relief Valve
- Service Tools
- Section 13 - Electrical Equipment - Group 13
- Alternator
- Alternator Bracket
- Batteries
- Battery Cables and Connections
- Charging System Indicator
- Drive Belt, Alternator
- ECM Unswitched Power Terminal Blocks .
- Service Tools
- Starter Magnetic Switch
- Starter Solenoid
- Starter Switch
- Starting Motor
- Section 14 - Engine Testing - Group 14
- Aftertreatment Testing
- Crankcase Blowby, Measure
- Engine Run-in (Chassis Dynamometer)
- Engine Run-in (Engine Dynamometer)
- Engine Run-in (Without Dynamometer)
- Engine Testing (Chassis Dynamometer)
- Engine Testing (Engine Dynamometer)
- Engine Testing (In Chassis)
- Service Tools
- Section 16 - Mounting Adaptations - Group 16
- Engine Drive Shaft
- Engine Mounts
- Engine Support Bracket, Front
- Engine Support Bracket, Rear
- Flexplate
- Flywheel
- Flywheel Housing
- Flywheel Housing, REPTO
- Flywheel Ring Gear
- Marine Vibration Isolator
- Propeller Shaft
- Service Tools
- Section 17 - Miscellaneous - Group 17
- Cup Plug
- Expansion Plug
- Pipe Plug
- Straight Thread Plug
- Section 20 - Vehicle Braking - Group 20
- Engine Brake Assembly
- Engine Brake Housing Spacer
- Engine Brake Solenoid Valve
- Engine Brake Wiring Harness
- Section L - Service Literature
- Additional Service Literature
- Cummins Customized Parts Catalog
- Service Literature Ordering Location
- Section V - Specifications
- Air Intake System
- Air Intake System - Group 10 - Specifications
- Air Intake System - Group 10 - Torque Values
- Barometric Pressure at Altitude
- Cam Followers/Tappets - Group 04 - Specifications
- Cam Followers/Tappets - Group 04 - Torque Values
- Capscrew Markings and Torque Values
- Compressed Air System
- Cooling System
- Cooling System - Group 08 - Specifications
- Cooling System - Group 08 - Torque Values
- Cummins®/Fleetguard® Filter Specifications
- Cylinder Block - Group 01 - Specifications
- Cylinder Block - Group 01 - Torque Values
- Cylinder Head - Group 02 - Specifications
- Cylinder Head - Group 02 - Torque Values
- Drive Belt Tension
- Drive Units - Group 09 - Torque Values
- Electrical Equipment - Group 13 - Specifications
- Electrical Equipment - Group 13 - Torque Values
- Electrical System
- Engine Testing
- Engine Testing - Group 14 - Specifications
- Exhaust System
- Exhaust System - Group 11 - Specifications
- Exhaust System - Group 11 - Torque Values
- Exhaust Gas Temperature
- Fraction, Decimal, Millimeter Conversions
- Fuel System
- Fuel System - Group 05 - Specifications
- Fuel System - Group 05 - Torque Values
- General Engine
- Injectors and Fuel Lines - Group 06 - Specifications
- Injectors and Fuel Lines - Group 06 - Torque Values
- Lubricating Oil System
- Lubricating Oil System - Group 07 - Specifications
- Lubricating Oil System - Group 07 - Torque Values
- Miscellaneous - Group 17 - Torque Values
- Mounting Adaptations - Group 16 - Specifications
- Mounting Adaptations - Group 16 - Torque Values
- Newton-Meter to Foot-Pound Conversions
- Pipe Plug Torque Values
- Rocker Levers - Group 03 - Specifications
- Tap-Drill Chart - U.S. Customary and Metric
- Vehicle Braking - Group 20 - Torque Values
- Weights and Measures - Conversion Factors
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