Section TT - Troubleshooting Symtoms PDF

ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J • . .
Section TT - Troubleshooting Symptoms (New Format) Page TT-a
Section TT - Troubleshooting Symptoms (New Format)
Section Contents
Page
ECM - No Communication Troubleshooting Tree TT- 1
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Engine Performance Troubleshooting Tree - ISB Engines Equipped with EGR (CM850 Electronic Control
System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TT- 1 70
Engine Performance Troubleshooting Tree - ISB, ISBe, and QSB engines without EGR (CM 800 and CM850
Electronic Control System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TT-55
Engine Performance Troubleshooting Tree - ISC/QSC/ISL/QSL with CM850 Electronic Control System TT-
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Engine Performance Troubleshooting Tree for QSB5.9 Marine Engines with CM 850 Electronic Control
System TT- 1 02
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Engine Performance Troubleshooting Tree for QSC and QSL Marine Engines with CM 850 ECM TT- 1 36
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Fuel Economy Troubleshooting Tree TT-227
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ISB, ISBe2, ISBe3, ISBe4, QSB4 [... ]
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ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . • • ECM - No Communication Troubleshooting Tree
Section TT - Troubleshooting Symptoms (New Format) Page TT-1
ECM - No Communication Troubleshooting Tree
This troubleshooting procedure should be followed for the following symptoms:

• No com m u n ication and e n g i n e w i l l not start
• No com m u n ication and e n g i n e w i l l start
• No com m u n ication related I N SITE™ electronic service tool e rrors
• Com m u n i cation with some ECMs but not all ECMs on a m u lti-mod u le e n g i n e .
How t o Use This Troubleshooting Procedure:

This troubleshooti n g proced u re can be used to troubleshoot J 1 939 and J 1 587 data l i n k com m u n ication issues between
the electronic service tool and the EC M . There are fou r proced u res that can be used to s u p port this troubleshooti ng
tree:
• Proced u re 022-999 (Service Tools and Hardware - Overview) in Section F , in the appropriate electronic control
system trou bleshoot i n g and repai r man ual .
• Proced u re 0 1 9- 1 65 (Data Li n k C i rcuit, SAE J1 939) i n Section 1 9 i n the appropriate electro n i c control system
troubleshooting and repai r man ual .
• Proced u re 0 1 9- 1 66 (Data Li n k C i rcuit, SAE J1 587) i n Section 1 9 i n the appropriate e lectro n i c control system
troubleshoot i n g and repair manual .
The troubleshooti n g steps i n this p roced u re b u i ld upon i nformation obtai ned i n previous steps. The troubleshooting
steps must be performed i n the seq uence specified i n the tro u b leshooti ng p roced u re .
T h i s troubleshooti ng p roced u re su pports several e n g i n e fam i l ies, therefore some i nstructions are stated i n a general
manner. Apply the req uested proced u res and actions to the specific e n g i n e fam ily with the suppo rt of engine specific
doc u m entation that can be fou n d in the Troubleshooting and Repai r manuals for the specific e n g i n e fam ily.
Shop Talk:
Th ree basic princi ples were used to defi ne and seq uence the tro u b leshooti ng steps that are l i sted i n this tree .
• Verify high level system operation prior to troubleshooting i n d ividual com ponents of the syste m . The pu rpose for
this is to learn from the behavior of the system in order to d i rect the next steps for tro u b l eshooti n g .
• U s e t h e Bench Top H arness t o separate t h e E C M from t h e veh icle s o t h e E C M c a n be isolated from vehicle issues
that could be causi ng no com m u n icatio n .
• U s e a second veh icle or a second E C M t o isolate h i g h level system issues before tro u b leshooting ind ividual
com ponents of the system.
ECM - No Communication Troubleshooting Tree ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Page TT-2 Section TT - Troubleshooting Symptoms (New Format)
TROUBLESHOOTING SUMMARY
STEPS SPECIFICATIONS SRT CODE

STEP 1: INSITE™ electronic service tool error code check
STEP 1A: Check for INSITE'M electronic Is INSITE™ electronic service
service tool error code 5023. tool error code 5023 present?
STEP 1B: INSITE'M electronic service tool Is INSITE™ electronic service

error code 5080 or 5081 check. tool error code 5080 or 5081
present?
STEP 1C: INSITE™ electronic service tool Are any INSITETM electronic
other error code checks. service tool error codes present
other than 5023, 5080, or 5081?
STEP 1D: ECM password check Does INSITE™ electronic service

tool indicate the ECM is
password protected?
STEP 2: Initial data link adapter and INSITE™ electronic service tool check
STEP 2A: Initial data link adapter check Are the communication lights on
the data link adapter flashing?
STEP 2B: data link adapter reset check Does the ECM communicate?
STEP 2C: Initial INSITE™ electronic service Does the ECM communicate?
tool check
STEP 2D: data link adapter verification Is an Inline or Inline I being use
check to communicate with the ECM?
STEP 2E: data link adapter firmware check Is firmware version compatible
with ECM?
STEP 3: Bench communication setup checks

STEP 3A: Bench setup availability check Is a bench setup available?
STEP 3A-1: Engine start check Will engine start?
STEP 3B: Initial bench setup Does the ECM communicated

communication check using bench setup?
STEP 3B-1: Engine start check Will engine start?
STEP 3C: Second vehicle or second ECM Is second vehicle or second ECM
availability check for bench available to connect to the
setup bench setup?
STEP 3D: Initial bench setup functionality Does the second ECM
check communicate using bench
setup?
STEP 3E: Troubleshoot bench setup Does bench setup check OK?
STEP 3F: data link adapter replacement Does bench setup communicate
check with the second ECM using a
replacement data link adapter?
STEP 4: ECM power up circuit check

STEP 4A: Engine configuration check Is the engine equipped with a
fuel shutoff valve?
STEP 4A-1: Check fuel shutoff valve Is the fuel shutoff valve voltage
voltage within 1-VDC of vehicle system
voltage?
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J ECM - No Communication Troubleshooting Tree
STEP 4A-2: Coolant temperature sensor Is the coolant temperature signal

signal voltage check voltage greater than 4 . S-VDC?
STEP 48: ECM keyswitch voltage check Is the keyswitch voltage within
1-VDC or vehicle system
voltage?
STEP 4C: Check the ECM power and

Is the ECM battery supply
ground
voltage equal to the battery
voltage?
STEP 5: Initial electronic tool check

STEP SA: 8ench setup previously used for In Step 3 checks, was bench
troubleshooting check setup used to successfully
communicate with the ECM?
STEP S8: Second vehicle availability

Is a second vehicle available to
check for electronic tool
connect to the electronic tool?
STEP SC: Initial electronic tool

Does the second ECM
functionality check
communicate using electronic
tool?
STEP 6: data link adapter power check

STEP 6A: data link adapter determination Is an Inline I data link adapter
check being used to communicate with
INSITE™ electronic service tool?
STEP 68:
Check data link adapter power Is the data link adapter power
light on?
STEP 6C:
Determination if communication Is the communication being
is being attempted at OEM dash attempted at the OEM data link
connector dash connector?
STEP 60: OEM data link dash connector Is the voltage equal to or greater
voltage check than 9-VDC?
STEP 6E: Check voltage at data link Is the voltage equal to or greater
adapter auxiliary power supply than 9-VDC?
STEP 6F: Check voltage at vehicle battery Is the voltage equal or greater
than 11-VDC?
STEP 6G: Computer serial port voltage

Is a minimum of S VDC available?
check
STEP 7: data link circuit check

STEP 7A: Check J1939 or J1S87 circuits Does the circuit check OK?

STEP 8A: Second vehicle availability
Is a second vehicle available to
check for electronic tool
connect to the electronic tool?
STEP 88: Initial electronic tool

Does the second ECM
functionality check
communicate using the
electronic tool?
STEP 9: Detailed electronic tool check

STEP 9A: Troubleshoot electronic tool
Does the electronic tool
hardware
hardware check OK?
STEP 10: Serial cable and computer check

STEP 10A: Troubleshoot serial cable and
Do the serial cable and computer
computer
check OK?
ECM - No Communication Troubleshooting Tree ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]
STEP 11: ROM boot ECM

STEP 11A: ROM boot tool availability check Is the ROM boot tool available?
STEP 118: ROM boot ECM Does the ECM communicate?
TROUBLESHOOTING STEP
STEP 1: INSITE™ electronic service tool error code check

STEP 1A" INSITE™ electronic service tool error code 5023 check
Condition:
• Connect I N S ITE™ electronic service too l .
• T u r n keyswitch O N .
Action Specification/Repair Next Step
Check for IN SITETM electronic service tool error Is IN SITE™ electronic service tool error code 2A
code 5023 . 5023 present?
• U se I N SITE™ electronic service tool to read the YES

error codes.
Is I N SITE™ electronic service tool error code 1B

5023 present?
NO
STEP 18· INSITE™ electronic service tool error code 5080 or 508 1 check
Condition:
• Connect I N S ITETM electronic service too l .
Check for I N S ITE™ error code 5080 or 508 1 . Is I N SITE™ electronic service tool error code Repai r
• Use I N S ITE™ electronic service tool to read the 5080 or 508 1 p resent? complete
error codes. YES
Repair:
Perform the ECM cal ibration download
Is I N SITE™ electronic service tool error code 1C

5080 or 508 1 p resent?
NO
STEP 1C' INSITE™ electronic service tool other error code checks
Condition:
• Connect Is I N S ITE™ electronic service too l .
• Turn keyswitch O N .
Are any I NS ITE™ electronic service tool error Are any I N S ITE™ electronic service tool error Repai r
codes present other than 5023 , 5080 , or 508 1 ? codes present other than 5023 , 5080, or Com plete
• Use I N S ITE™ electro n i c service tool to read the 508 1 ?
erro r codes. YES
Repair:
See the I N S ITE™ Electronic Service Tool

manual for troub l eshooti ng g u id e l i nes .
Are any I N S ITE™ electronic service tool error 1D

codes p resent other than 5023 , 5080 , or
508 1 ?
NO
STEP 10: ECM Dassword check
Condition:
Does I N SITE™ electronic service tool i n d i cate the Does I N S ITE™ el ectronic service tool i nd i cate Repai r
ECM is password p rotected? the ECM is password p rotected ? complete
• U se I N S ITE™ electronic service tool .
YES
Repair:
E nter correct password

If password is u n available, contact customer
to req u est password i nformatio n . If customer
can not s u p ply password i nformation , see
the I N S ITE™ electronic service tool manual
for password removal i n formati o n . N o rmal
warranty g u ideli nes will apply if ECM
password removal is req u i red .
Does I N S ITE™ electronic service tool i ndicate 2A

the ECM is password protected ?
NO
STEP 2: Initial data link adapter and INSITE™ electronic service tool check
STEP 2A: Initial data link adapter check
Condition:
• data l i n k adapter con nected to OEM data l i n k con n ector i n veh icle.
• I N SITE™ electro n i c service tool com puter must not be con nected .
• Note : If con nected to the 3 p i n e n g i n e data l i n k connector the com m u n ication l i g hts w i l l not b l i n k , continue to
Step 2B.
Turn keyswitch o n . Are the com m u n ication l i g hts on the data l i n k 2C

adapter flash i ng?
• J1 708 l ig ht for I n l i ne
• J1 708 or J1 939 for I n l i n e I I , I n l i n e 4, and
Inline 5.
YES
Repair:
No Repai r
Are the com m u n ication l i g hts on the data l i n k 2B

adapter flash i n g ?
• J 1 708 l i g ht for I n l i n e
• J1 708 o r J1 939 for I n l i n e I I , I n l i n e 4 , and
I n l i n e 5.
NO
STEP 26 data r In k adapter reset check
Condition:
I N SITE™ electronic service tool con nected to veh icle.
Data l i n k adapter reset check Does the ECM com m u n icate? Repai r
• Disconnect power from the data l i n k adapter. YES com plete
• Leave discon n ected for 30 seconds
• Connect power agai n to the I n l i ne adapter
• Tu rn keyswitch O N .
Does the ECM com m u n icate? 3A
NO
STEP 2C· Initial INSITE™ electronic service tool check
Condition:
• I N SITE™ el ectronic service tool con nected to vehicle
Reboot I N S ITE™ electronic service tool PC . Does the ECM com m u n i cate? Repai r
• Lau nch I N S ITE™ electronic service tool YES
complete
• Check for com m u n icatio n .
Does t h e E C M com m u n i cate? 20

NO
STEP 20: data r In k adaDter veri Icatlon check
Condition:
None
Verify if an I n l i n e or I n l i n e I data l i n k adapter is Is an I n l i ne or I n l i n e I bei n g used to 8A

being used to com m u n icate with ECM . com m u n i cate with the ECM?
Reference Proced u re 022-999 (Service Tools YES
and H ardware - Overview) i n Section F, for
General I nformation - data l i n k Adapters , i n the Is an I n l i n e or I n l i n e I bei n g used to 2E
appropriate electro n i c control system com m u n i cate with the ECM?
trou bleshooti ng and repai r manual for data l i n k
NO
adapter identification i nformation.
STEP 2E : data r In k adaDter fIrmware c h eck
Condition:
None
Verify data l i n k adapter firmware version is Is fi rmware version compatible with the 8A
compatible with ECM . ECM?
General I nformation - data l i n k Adapters , in the Is fi rmware version com patible with the 2C
appropriate E lectro n i c Control System ECM?
Troubleshoot i n g and Repai r man ual for data l i n k
NO
adapter identification i nformation .
Repair:
Load correct fi rmware version
STEP 3: Bench communication setup checks

.
STEP 3A: Bench setuD aval , a bTt
IUVC

heck
Condition:
• Bench setup avai lab l e .
Verify bench setup is avai lab l e . Is a b e n c h set u p avai lable? 3B

YES
Is a bench setup avai lable? 3A-1

NO
STEP 3A 1 -
E name st ar t check

Condition:
• None
Verify if engine wi l l start. Wi l l e n g i n e start? SA

YES
Wi l l e n g i n e start? 4A
NO
STEP 38: Initial bench setuD communication check.
Condition:
• Use the same I N SITE™ el ectro n i c service tool PC as was used for the previous checks
• Bench setup con nected to ECM
• Bench top cal ibration harness keyswitch ON .
Attem pt to com u n i cate with the ECM using bench Does the ECM com m u n i cate with bench 3B-1
setu p . setup?
YES
Does the ECM com m u n i cate with bench 3C

setup?
NO
STEP 38 1-
En!:lme start check
Condition:
• None
Disconnect the bench top cal ibration cable from Wi l l the e n g i n e start? SA
the ECM . Recon nect the ECM to the origi nal YES
engine or OEM wiring harness con n ector. Verify
if the engine w i l l start.
Wi l l the e n g i n e start? 4A
NO
STEP 3C or second ECM aval'1 a bTt

Second veh'IC 1 e IUVCheck for bench set UD
Condition:
• Second vehicle or secon d ECM available for testi n g .
Verify if a second vehicle or second ECM is Is a secon d veh icle o r second ECM available 3D
available to con n ect to the bench set u p . t o con nect t o the b e n c h setup?
YES
Is a secon d veh icle or second ECM avai lable 3E

to con nect to the bench setup?
NO
STEP 3D: 1 mtla 1 bench setup functlona rltv check

. .
Condition:
• Use the same I N S ITE'" electro n i c service tool PC and bench setup tools that were origi nally used on the problem
veh icle.
• Bench set u p con nected to second vehicle or second ECM
• Bench top cal i b ration harness keyswitch ON .
Attem pt to com m u n icate with the ECM on the Does the secon d ECM com m u n icate using 1 1A
second vehicle o r a spare ECM using bench bench setup?
setu p . YES
Does the second ECM com m u n icate using 3E

bench setup?
NO
STEP 3E Troubleshoot bench setup hardware
Condition:
• None
Troubleshoot bench cal i b ration cabl e , bench Does bench setup check OK? 3F
cal i b ration harness , and serial cabl e . YES
• Perform troubl eshooti n g p rocedu res for
evaluati ng the bench cal ibration cab l e , bench

cal ibration harness, and serial cabl e . Does bench setup check OK? 3B
Reference Proced u re 022-999 (Service Tools NO
Repair:
Resistance Check - Serial Cab l e , Benchtop
Cal ibration H arness, Benchtop Cal i b ration Repai r or replace bench cal i b ration cab l e ,
Cab l e , i n the appropriate Electronic Control bench cal i b ration harness, or serial cab le.
System Tro u b leshooting and Repai r man ual .
STEP 3F: data r In k ad apter replacement check
Condition:
• None
Try to com m u n i cate with the bench setup using Does bench setup com m u n icate with the 38
a replacement datal i n k . second ECM u s i n g a replacement data l i n k
adapter?
YES
Repair:
Use replacement data l i n k adapter.
Does bench setup com m u n i cate with the 3E

second ECM using a replacement d ata l i n k
adapter?
NO
Repair:
Issue with bench setup shou ld h ave been

fou n d . Trou bleshoot the bench setu p agai n .
STEP 4: ECM power up circuit check

STEP 4A: .
Enaine .
conf iauratlon check
Condition:
• None
Determ i n e if the e n g i n e is eq u i pped with a fuel Is the e n g i n e eq u i p ped with a fuel s h utoff 4A- 1
shutoff valve valve?
YES
Is the e n g i n e eq u i p ped with a fuel s h utoff 4A-2

valve?
NO
STEP 4A 1 :
-
Check fueI shutoff va ve vo taae
Condition:
Measu re the voltage from the fuel shutoff valve Is the fuel sh utoff valve voltage with i n 1 -VDC SA
post to engine b lock g rou n d . o f vehicle system voltage?
There are 1 2 and 24 volt systems, the fuel sh utoff YES
valve voltage needs to be with i n 1 -VDC of the
vehicle system voltage. Is the fuel sh utoff valve voltage with i n 1 VDC 48
of vehicle system voltage?
NO
STEP 4A 2-
C00 ant t emDera ture sensor slana voItaae check
Condition:
• Disconnect t h e coolant temperatu re sensor con n ector.
M easure the voltage across the two p i n s of the Is the coolant tem perature signal voltage SA
cool ant temperatu re sensor on the wiring greater than 4 . S-VDC?
harness con nector. YES
Reference the wiring d i ag ram or c i rcuit d i ag ram
for con nector p i n i dentificatio n . Is t h e coo lant tem perat u re sig nal voltage 4B
greater than 4 . S-VDC?
NO
STEP 46: ECM kevswitch vo taae check
Condition:
• Turn keyswitch OFF.
• Disconnect the wiring harness connector that contai ns the keyswitch sig nal fro m the EC M .
• Turn the keyswitch O N .
M easu re the voltage from the keyswitch i n p ut Is the keyswitch voltage with i n 1 -VDC of 4C
SIG NAL wire of the wiring harness to e n g i n e vehicle system voltage?
b l o c k g rou n d . YES
Reference the w i r i n g d i ag ram o r circuit d i ag ram
for con nector p i n identification . Is the keyswitch voltage with i n 1 -VDC of Repai r
vehicle system voltage? com plete
NO
Repair:
Repai r or replace the wiring harness that

contains the keyswitch Signal , or repair o r
replace the keyswitc h , o r c h e c k the battery
con nectio n . Reference Proced u re 0 1 9-064
(Key Switch Battery S u pply C i rcu it) in Section
19 i n the appropriate troubleshooti ng and
repair manual .
See the E n g i n e Perform ance
Troubleshoot i n g Tree in the appropriate
troubleshooting and repai r manual , if the no
start con d ition is sti l l present.
STEP 4C: Check the ECM Dower and

around
Condition:
• Tu rn keyswitch OFF
•
D isconnect from the ECM the wiring harness con nector that contai ns the ECM battery S U P P LY (-) and S U PPLY
(+) wiri n g .
M easu re the voltage from each ECM battery Is the ECM battery supply voltage eq ual to Repai r
S U P P LY (+) p i n to all battery S U P P LY ( ) p i ns i n
- the battery voltage? complete
t h e wiring harness con n ector. YES
Reference the w i r i n g d i ag ram o r c i rcuit d i ag ram Repair:
for connector pin identificatio n .
Cal l for authorizatio n .
Replace t h e ECM . Reference Proced u re
0 1 9-03 1 (Electro n i c Control Mod u l e (ECM)) i n
Section 1 9 i n t h e appropriate tro u b l eshooti ng
and repai r manual .
Is the ECM battery supply voltage equal to Repai r

the battery voltage? complete
NO
Repair:
Repai r or replace the wiring harness that

contains the ECM battery S U P P LY (+ ) and
battery S U P PLY (-) w i ri n g .
See t h e E n g i n e Performance
Troubleshooti ng Tree if no start cond ition is
sti l l present.
STEP 5 : Initial electronic tool check

STEP SA Bench setuD DreVlouslV
I used fo r trou bleshootlng check
Condition:
• None
I n Step 3 checks , was bench set u p used to I n Step 3 checks, was bench set u p used to 6A
successfu l ly com m u n icate with the ECM? successfu l ly com m u n i cate with the ECM?
YES
Repair:
ECM is OK, repai r com plete if

com m u n ication is not req u i red thro u g h OEM
data link con n ector or harness.
If com m u n ication is req u i red thro u g h the
OEM data l i n k con nector or harness conti n u e
t o Step 6A.
In Step 3 checks , was bench setup used to 58

successfu lly com m u n i cate with the ECM?
NO
ISB, ISBe2, ISBe3, ISBe4, QSB4 [.. . J ECM - No Communication Troubleshooting Tree
STEP 5B I I[VCheck for e 1 ectromc t00

Second veh·IC 1e aval· 1 a bTt
Condition:
• Second veh icle available for testing
Verify a second vehicle is avai lable to con nect to Is a secon d vehicle available to con n ect to 5C
the electronic tool . the electro n i c tool ?
YES
Is a secon d veh icle avai lable to con nect to 6A

the electronic tool?
NO
. .
STEP 5C: 1mtla1 e 1 ectromc too 1 functlona rltv check
Condition:
• Electronic tool con nected to a secon d veh icle.
• Keyswitch O N .
Attempt to com m u n icate with the ECM on the Does the secon d ECM com m u n i cate using
6A
secon d vehicle using the same electronic tool el ectro n i c tool ?
hardware used on t h e problem veh icle.

YES
Does the secon d ECM com m u n i cate using 9A

el ectro n i c too l ?
NO
STEP 6: data link adapter power check

STEP SA data r In k adapter determlnatlon check
Condition:
• None
Determ i n e if an I n l i n e I datal i n k adapter is being Is an I n l i n e I data link adapter b e i n g used to 6G

used to com m u n i cate with I N S ITE™ electronic com m u n i cate with I NS ITE™ electro n i c
service too l . service tool ?
and Hardware - Overview) i n Section F, for
General I nformation - data l i n k adapter, in the Is an I n l i n e I data l i n k adapter b e i n g used to 68
appropriate e lectro n i c control system com m u n i cate with I N S ITE™ electro n i c
troubleshooti ng and repai r manual . service tool ?
NO
ECM - No Communication Troubleshooting Tree ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J
. • •
STEP 68: Check data link adaDter Dower
Condition:
• 00 not use an I n l i n e I
• El ectronic tool hardware connected to the vehicle.
• I N S ITE'M el ectro n i c service tool lau nched
• Keyswitch O N .
N ote: For all datal i n k adapters except I n l i ne I . I s the data l i n k adapter power l i g ht o n ? 7A
Attem pt to com m u n icate with I N S ITE'M electronic YES
service tool and check to see if the data l i n k
adapter power l ight is o n . Is t h e data l i n k adapter power l i g ht o n ? 6C
Reference Proced u re 022-999 (Service Tools NO
and Hardware - Overview) i n Section F, for
General I nformation - data l i n k Adapter, i n the
appropriate electro n i c control system
troubleshooti ng and repai r man ual .
STEP 6C: .
Determination if commUnication I. S belna attemDted at the OEM data r In k dash connector
Condition:
• None
Check to see if com m u n i cation is being Is com m u n ication being attem pted at the 60
attem pted at the OEM datal i n k dash con n ector. OEM data l i n k dash con nector?
YES
Is com m u n ication being attem pted at the 6E

OEM data l i n k dash con nector?
NO
STEP 6D: OEM data r Ink dash connector vo tage check
Condition:
M easu re voltage across the S U P P LY and g round Is the voltage equal to or g reater than 9 VOC? Repai r
p i ns of the OEM d atal i n k con nector. YES com plete
Reference Proced u re 022-999 (Service Tools Repair:
and H ardware - Overview) i n Section F , for I n Cab
data l i n k Connector or 6-pi n In Cab data l i n k Replace d ata l i n k adapter
co n n ector, in the appropriate E lectronic Control
System Troubleshooting and Repair manual for Is the voltage eq ual to or greater than 9 VOC? 6F
p i n locations.
NO
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...] ECM - No Communication Troubleshooting Tree
STEP 6E: Chec k vo taae at data r In k adapter auXITlarv power SUPPIV
Condition:
• Turn keyswitch ON .
M easu re the data l i n k adapter su pply voltage at Is the voltage equal to or g reater than 9-VDC? Repai r
the datal i n k adapter harness con n ector. YES
com plete
Reference Proced u re 022-999 (Service Tools Repair:
and H ardware - Overview) i n Section F, for 3-p i n
data l i n k Cab l e , i n the appropriate E lectronic Replace data link adapter.
Control System Troubleshooti n g and Repai r
manual for p i n locations. Is the voltage eq ual to o r g reater than 9-VDC? 6F
NO
STEP 6F Chec k vo taae at veh·IC Ie batterv
Condition:
• None
Measu re veh icle battery voltage i n all cases Is the voltage equal to or g reater than 1 1 - Repai r
except if using an I n l i n e I . VDC? com plete
If using an I n l i n e I meas u re data l i n k adapter YES
voltage supply from com p uter. Repair:
Repai r or replace damaged w i ri n g .
Is t h e voltage eq ual t o or g reater t h a n 1 1 - Repair

VDC? complete
NO
Repair:
Clean the battery con n ections or replace the

batteries.
STEP 6G: .
C omputer senaI port vo taae chec k
Condition:
• None
N ote: For I n l i ne I only. Is a m i n i m u m of 5 VDC avai lable? Repai r

YES
complete
Measu re voltage across the S I G NAL g round p i n
and the data term i nal ready p i n and the S I G NAL Repair:
grou nd pin and the req uest to send p i n on the
com p uter serial port . Replace data l i n k adapter
Reference Proced u re 022-999 (Service Tools
and Hardware - Overview) i n Section F, for Serial Is a m i n i m u m of 5 VDC avai lable? Repai r
Cab l e , i n the appropriate Electro n i c and Control NO com plete
System Troubleshooting and Repai r manual for
Repair:
p i n locations.
Contact PC ad m i n istration s u p port .
ECM - No Communication Troubleshooting Tree ISB, ISBe2, ISBe3, ISBe4, QSB4 [... ]
STEP 7: data link circuit check

STEP 7A· . Check J1939 or J1587 circuits
Condition:
• None
Use the fol lowi n g p roced u res to perform J1 939 Does the c i rcuit check OK? 1 1A
or J1 587 circuit checks depen d i n g on the YES
datal i n k circuit being used .
Reference Proced u re 0 1 9- 1 65 (Data Li n k C i rcuit, Does the c i rcuit check OK? Repai r
SAE J1 939) i n Section 1 9 i n the appropriate com p l ete
NO
troubleshooting and repai r manual .
Repair:
Th is proced u re g ives i nformation for a com p l ete
resistance check, check for short circ u it to Repai r or replace the harness with the data
g rou nd , and check for short circuit from p i n-to- l i n k problem , either the e n g i n e o r O E M
pin. harness.
Reference Proced u re 0 1 9- 1 66 (Data L i n k C i rcuit,
SAE J1 587) i n Section 1 9 i n the appropriate
troubleshooting and repai r manual.
This proced u re g ives i nformation for a com plete
resistance check, check for short circ u it to
grou n d , check for short circ u it from pi n-to-p i n ,
a n d voltage check.
Reference Proce d u re 0 1 9-428 (Engine data
l i n ks) in Section 1 9 i n the appropriate
troubleshooting and repai r manual . Complete
resistance check, check for short circuit to
grou n d , and check for short circuit from p i n-to-
pin.

STEP 8A: Second veh·IC 1e aval·1 a bT
I ltv check for e ectromc too
Condition:
• Second vehicle avai l ab l e for testing
Verify if a second vehicle is avai lable to connect Is a second vehicle available to con n ect to 88
to electronic tool ? t h e electronic tool ?
YES
Is a second vehicle available to con n ect to 1 0A

the electro n i c tool?
NO
IS8, IS8e2, IS8e3, IS8e4, QS84 [...] ECM - No Communication Troubleshooting Tree
. .
STEP 88 ImtlaI e Iectromc too I functlona rltv check
Condition:
• Electronic tool connected to second vehicle
Attempt to com m u n icate with the ECM on the Does the second ECM com m u n icate using 1 1A
second vehicle using the electronic too l . t h e electro n i c tool ?
YES
Does the second ECM com m u n icate using 1 0A

the el ectro n i c tool ?
NO
STEP 9: Detailed electronic tool check

STEP 9A- Troubleshoot electronic tool hardware
Condition:
• None
Perform troubleshooti ng proced u res for Does the el ectronic tool hardware check OK? 1 1A
evaluating el ectro n i c tool h ardware : YES
• data l i n k adapter cable
• data l i n k adapter power s u pply cable Repair:

• data link adapter
Com m u n i cation issue fou n d .
• Serial cable
• Computer.
Does the el ectronic tool hardware check OK? Repai r
Reference Proced u re 022-999 (Service Tools complete
NO
and H ardware - Overview) in Section F, in the
appropriate tro u b leshooti ng and repai r man ual . Repair:
Complete the fol lowi n g checks: Repai r or replace damaged h ardware .

• I n itial Check - I N S ITE™ electro n i c service tool
• I n itial Check - data l i n k Adapters
• Resistance Check - Serial Cable
• Resistance Check for data l i n k adapter cab le
and data l i n k adapter power su pply cab l e .
ECM - No Communication Troubleshooting Tree IS8, IS8e2, IS8e3, IS8e4, QS84 [ J
. • •
STEP 10: Serial cable and computer check

STEP 10A: Troublesh00t serla 1 ca ble and comDU ter
.
Condition:
• None
Perform troubleshooti ng p roced u res for

Do the serial cab le and com p uter check OK? 1 1A
eval uating the serial cable and com p uter.
YES
Reference Proced u re 022-999 (Service Tools
Repair:
and H ardware - Overview) i n Section F , i n the
appropriate troubleshooti n g and repai r man ual .

Com m u n i cation issue fou n d
Complete t h e fol lowi n g checks:
Do the serial cabl e and com puter check OK? Repai r
• I n itial Check - I N S ITE™ electro n i c service tool complete
• Resistance Check - Serial Cab l e . NO
Repair:
Repai r o r replace damaged hardware.
STEP 11: ROM boot ECM

STEP 11A: ROM b00t t00 aval'1 a bTt
I !IVCheck
Condition:
• None
Verify if ROM boot tool is available for specific Is the ROM boot tool avai lable? 11B
ECM . YES
Is the ROM boot tool avai lable? Repai r

NO
complete
Repair:
Cal l for p re-authorization

Replace the ECM .
Reference Proced u re 0 1 9-03 1 (Electronic
Control M od u l e (EC M » i n Section 1 9 i n the
appropriate troubleshooti ng and repai r
manual .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
ECM - No Communication Troubleshooting Tree
Page TT-19
STEP 1 1 B' ROM boot the ECM
Condition:
• None
ROM boot the ECM . Does the ECM com m u n i cate? Repai r
YES
complete
Reference Proced u re 0 1 9-427 (ECM ROM Boot)
i n Section 1 9 i n the appropriate tro u b leshooti ng Repair:
and repai r man ual .
Cal ibrate the ECM agai n .
Does the ECM com m u n icate? Repai r

NO
complete
Repair:
Cal l for p re-authorization

Replace the EC M .
Reference Proced u re 01 9-03 1 (Electro n i C
Control M od u l e (ECM)) i n Section 1 9 i n t h e
appropriate troubleshooti ng and repai r
manual .
Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [ • . • J IS8, IS8e2, IS8e3, IS8e4, QS84 [...J
Engine Performance Troubleshooting Tree - ISC/QSC/ISL/QSL with CM850

Electronic Control System
This troubleshooting procedure should be followed for the following symptoms:

• E n g i n e Acceleration or Response Poor
• Cran king Fuel Pressure is Low
• E n g i n e Operating Fuel Press u re is Low
• E n g i n e Decelerates Slowly
• E n g i n e Difficult to Start or Wi l l N ot Start (Exhaust Smoke)
• E n g i n e Difficult to Start or Wi l l N ot Start (No Exhaust Smoke)
• E n g i n e Power Output Low
• E n g i n e Runs Roug h at I d l e
• E n g i n e Runs R o u g h or M i sfi res
• E n g i n e Speed S u rges at Low or H ig h I d l e
• E n g i n e Speed S u rges U nder Load or i n Operating Range
• S moke, Black - Excessive
• S moke , Wh ite - Excessive
• E n g i n e Sh uts Off or Dies U n expected ly or Dies During Deceleration
• Engine Starts but W i l l N ot Keep R u n n i n g
• E n g i n e Wi l l N ot Reach Rated Speed (RPM)
• I ntake Man ifold Pressure (Boost) is Below Normal
How to Use This Troubleshooting Procedure:

This symptom tree can be used to trou bleshoot all performance based sym ptoms l i sted above . Start by perform i n g
Step 1 troubleshoot i n g . Step 2 wi l l ask a series o f q u estions a n d wi l l provide a l i st o f tro u b l eshooti ng steps t o perform
depe n d i n g on the sym pto m . Perform the l i st of troubleshooting steps in the seq uence shown in the S pecificationsl
Repai r section of the tree.
Shop Talk:
Driveab i l ity is a term that i n general descri bes vehicle performance on the road . D riveabi l ity problems for an engine
can be caused by several d ifferent factors . Some of the factors are e n g i n e-related and some are not. Before
tro u b leshooti ng it is i m portant to determ i ne the exact co m plaint and whether the e n g i n e has a real driveab i l ity prob lem
or if it sim ply does not meet d river expectations.
Low power is a term that is used i n the field to describe many d ifferent performance p roblems. Low power is defi ned
as the i nabi l ity of the engine to prod uce the power necessary to move the vehicle at a speed that can be reasonably
expected under the g iven con d itions of load , g rade, w i n d , and so o n .
Poor acceleration o r response is d escribed a s t h e inabil ity o f the vehicle t o accelerate satisfactorily from a stop o r
from t h e bottom o f a g rade . It can also b e t h e lag i n acceleration d u ri n g a n attem pt t o pass or overtake another vehicle
at conditions less than rated speed and load . Poor acce leration o r response is d ifficult to troubleshoot since it can be
caused by several factors .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ ... J Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [.. . J
TROUBLESHOOTING S UMMARY
STEPS SPECIFICATIONS SRT CODE

STEP 1: Perform basic troubleshooting procedures.
STEP 1A: Check for active fault codes or
high counts of inactive fault
codes.
STEP 1B: Perform basic troubleshooting

checks.
STEP 2: Determination of engine symptom.

STEP 2A: Low power, poor acceleration,
or poor response.
STEP 2B: Engine misfire, engine speed

surge, or engine speed
unstable.
STEP 2C: Excessive white or black smoke.
STEP 20: Low intake manifold pressure.
STEP 2E: Engine will not start or difficult
to start, engine shuts off

unexpectedly.
STEP 3: No-start troubleshooting procedures.

STEP 3A: Verify the operation of cold
weather starting aids.
STEP 3B: Verify the low-pressure fuel

lines are routed correctly.
STEP 3C: Check the ECM keyswitch

voltage.
STEP 3D: Check the ECM battery supply

voltage.
STEP 3E: Check engine speed during

cranking.
STEP 3F: Verify rail fuel pressure sensor

accuracy.
STEP 3G: Check for fuel rail pressure while

cranking the engine.
STEP 3G-1: Check fuel gear pump

pressure.
STEP 3G-2: Check fuel lift pump

pressure.
STEP 3H: Check for other fault codes that

explain a no-start condition.
STEP 4: Fuel system troubleshooting procedures.

STEP 4A: Check for fault codes.
STEP 4B: Check for air in the high

pressure pump fuel supply.
STEP 4C: Measure fuel gear pump

pressure.
Engine Performance Troubleshooting Tree - ISC/QSC/ISLlQ [...] ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]
STEP 4C-1: Measure the fuel inlet

restriction.
STEP 40: Perform single cylinder cutout
test.
STEP 4E: Perform cylinder balance
diagnostic test.
STEP 4F: Measure fuel drain line
restriction.
STEP 4G: Monitor fuel pressure at idle.
STEP 5: Air handling troubleshooting procedures.

STEP SA: Inspect the turbocharger blades
for damage.
STEP S8: Check the turbocharger axial
and radial clearances.
STEP SC: Oetermination of turbocharger
type.
STEP SO: Check variable geometry

actuator rod for correct travel.
STEP SO-l: Check for air leaks and

inspect air lines.
STEP SO-2: Check for air pressure at the

turbocharger control valve
outlet.
STEP SO-3: Check for air pressure at

turbocharger control valve
outlet.
STEP SO-4: Check for vehicle air tank

pressure at turbocharger
control valve inlet.
STEP SO-S: Check for correct

turbocharger actuator
travel.
STEP SE: Check for broken shaft inside

the turbocharger.
STEP SF: Inspect wastegate actuator

wastegated turbochargers only.
STEP SG: Inspect wastegate actuator rod

for travel.
STEP SG-1: Inspect the wastegate

actuator rod for travel.
STEP 6: Electronic feature troubleshooting procedures.

STEP 6A: Verify throttle pedal travel.
STEP 68: Check ambient air pressure

sensor accuracy.
STEP 6C: Check intake manifold pressure

sensor accuracy.
STEP 60: Verify electronic feature settings

are correct.
STEP 7: Base engine troubleshooting procedures.

ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [...J
STEP 7A: Verify overhead adjustments are
correct.
STEP 78: Verify engine brake adjustment.
STEP 7C: Inspect charge c.ili cooler.
STEP 70: Check air intake restriction.
STEP 7E: Check exhaust restriction.
STEP 7F: Check engine blowby.
STEP 7F-1: Verify turbocharger

contribution to engine
blowby.
TROUBLESHOOTING STEP
STEP 1: Perform basic troubleshooting procedures.

STEP 1A: Check for active fau It codes or h'IQIh counts 0f .inactive fau It codes.
Condition:
Check for active fau lt codes. Active fau lt codes or high cou nts of i nactive Repai r
• Use I NS ITE™ electronic service tool to read the fau lt codes? complete
fault codes . YES
Repair:
Follow the electronic fau lt code trees for the

appropriate troubleshooting p roced u res.
Active fau lt codes or h i g h cou nts of i n active 18

fau lt codes?
NO
.
STEP 18 : Perform baSlc trou bleshootmQ checks.
Condition:
None.
The followi ng items m ust be checked or verified All steps h ave been verified to be correct? 2A
before conti n u i n g : YES
• Verify the fuel level i n the tan ks
• Verify there have not been any changes to
C P L components on the e n g i n e All steps have been verified to be correct? Repai r

• Verify f u e l g rade is correct f o r appl ication NO complete
• Verify the e n g i n e is operating with i n the
Repair:
recom mended altitude
• Verify engine oil is at the correct level Correct the co nd ition and verify com p laint is
• Verify engine parasitics have not changed no longer p resent after repair.
• Verify engine d uty cycle has not changed
• Verify e n g i n e cranking speed is g reater than
1 50 rpm
• Verify battery voltage is adeq uate.
Engine Performance Troubleshooting Tree - ISC/QSCflSLlQ [...J ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
STEP 2: Determination of engine symptoms.

STEP 2A Low power poor acce IerarIon or poor res onse.
Condition:
None.
I nterview the d river and verify the com plaint. Is the engine sym ptom low power, poor Perform the
acceleratio n , o r poor response? troubleshooti
YES
ng steps
suggested i n
Repair: t h e repair
Perform the tro u b leshooti ng steps i n the proced u re
recommended o rder listed below:
• Step 4 Fuel System Checks
-
• Step 5 Air Hand l i n g Checks

-
• Step 6 E lectronics Checks

-
• Step 7 Base E n g i n e Checks .

-
Is the e n g i n e sym ptom low power, poor 2B

acceleratio n , o r poor response?
NO
STEP 28 · fIre. ename speed surae or ename speed unsta ble.

Ename mls
Condition:
None.
I nterview the d river and verify the com plaint. Is the engine symptom engine m isfi re , e n g i n e Perform the
speed s u r g e , o r e n g i n e speed u nstab le? troubleshooti
YES ng steps
suggested i n
Perform the troubleshooting steps i n the p roced u re
reco m m ended order l i sted below :
• Step 4 - Fuel System Checks
• Step 5 - Air H and l i n g Checks
• Step 6 - E lectron ics Checks .
Is t h e e n g i n e sym ptom engine m isfi re , e n g i n e 2C

speed s u rg e , or engine speed u nstable?
NO
Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [...J
Page TT-25
STEP 2C' Excessive white or black smoke
Condition:
None.
I nterview the d river and verify the com plaint . Is t h e e n g i n e sym ptom excessive wh ite or Perform the
black smoke? troubleshooti
YES ng steps
suggested i n
Repair: t h e repai r
Perform the troubleshooting steps i n the proced u re .
recom mended order listed below:
-

-
Is the e n g i n e sym ptom excessive wh ite or 20

black smoke?
NO
STEP 20: Low mtake man!'f0 Id

pressure.
Condition:
None.
I nterview the d river and verify the complaint. Is the engine symptom low boost p ressu re? Perform the
YES troubleshooti
ng steps
Repair: suggested i n
Perform the troubleshooting steps i n the the repai r
recom mended order listed below: proced u re
-

-
• Step 7 Base E n g i n e Checks.

-
Is the e n g i n e sym ptom low boost p ressu re? 2E

NO
Engine Performance Troubleshooting Tree - ISC/QSC/ISLlQ [" ,J ISB, ISBe2, ISBe3, ISBe4, QSB4 [.. ,J
STEP 2E: Ename WI' I I not start or d'ff'

I ICU It to start engme shuts 0ff unexDectedlIV,
Condition:
None.
I ntervi ew the d river and verify the com plaint. Is the sym ptom engine w i l l not start or d ifficult Perform the
to start , e n g i n e sh uts off u n expected ly? troubleshooti
YES
ng steps
suggested i n
Perform the trou bleshooti ng steps i n the proced u re
• Step 3 - N o Start Checks
-
• Step 6 - E lectronics Checks .
Is the sym ptom engine wi l l not start or d ifficult Return to

to start , e n g i n e sh uts off u n expected ly? correct
NO
sym pto m
tree
STEP 3: No-start troubleshooting procedures_

STEP 3A: Verifv the oDeration of cold weather startina aids,
Condition:
M ake s u re the i ntake ai r heater and other cold Are necessary cold weather start i n g aids 3B
starting aids are operational . operating p roperly?
Refer to Proced u re 008-0 1 1 (Coolant H eater) i n YES
Section 8 i n Section 1 0 i n the Troubleshooti ng
and Repai r Manual , ISC, OSC8 . 3 , I S L and OSL9 Are necessary cold weather start i n g aids Repai r
Engi nes, B u l let i n 4021 41 8 . Refe r to Proced u re operating properly? com plete
0 1 0-029 (Cold Starting Aid) in Section 1 0 in the
NO
Troubleshooting and Repai r Manual , ISC,
OSC8 . 3 , I S L and OS L9 E n g i nes, B u l l et i n Repair:
4021 41 8 .
I nstall or repai r cold weather starting aids.
Refer to Proced u re 0 1 0-029 (Cold Starting
Aid) i n Section 1 0 i n the Troub leshooti ng and
Repai r Man ual , ISC, OSC8 . 3 , I S L and OS L9
Engi nes , B u l let i n 4021 41 8 .
STEP 38:
Condition:
None.
It is sometimes possible to get the low-pressu re Are the low-pressu re fuel l i nes con nected 3C
fuel l i nes con nected to the ECM cool i n g plate properly to the ECM coo l i ng plate?
i nstal led i m p roperly. The top con nection to the YES
ECM cool i n g plate is the i n l et and the bottom
con n ection is the outlet.
Are the low-pressu re fuel l i nes con nected Repa i r
Verify these con n ections if the l ow-pressu re fuel properly to the ECM coo l i n g plate? com p l ete
l i n es have been removed and rei n stalled on the
NO
engine.
Repair:
Properly connect the low-pressu re fuel l i nes

to the ECM cool i n g plate. The fuel i n l et is the
top con necti o n .
Engine Performance Troubleshooting Tree - ISC/QSC/ISLlQ [...J ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
STEP 3C: Check the ECM ke switch volta e.
Condition:
• D isco n n ect the OEM harness from the ECM .
M easu re the signal voltage from the keyswitch Is the keyswitch voltage equal to battery 3D
i n put SIG NAL w i re of the OEM harness to the voltage?
engine block g ro u n d .
YES
M easu re t h e keyswitch voltage with the
keyswitch i n the ON position and also with the

Is the keyswitch voltage eq ual to battery Repai r
keyswitch i n the Cran king positi o n .

Voltage? com p l ete
Refer t o t h e w i r i n g d i ag ram for connector p i n

NO
identification.
Repair:
Repai r or replace the OEM powe r h arness,

keyswitc h , or check the battery con n ections.
1 9c0 1 073
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . . . Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [ J. . .
STEP 3D: Check the ECM batter
Condition:
• Turn keyswitch OFF .
• D isconnect the ECM power harness from the ECM .
Measu re the voltage from the ECM battery Is the ECM battery supply voltage eq ual to 3E
S U P P LY ( ) p i n to the ECM battery S U PPLY (+ )

- the battery voltage?
pi ns i n the ECM power harness connector. YES

Meas u re the ECM voltage with the keyswitch in
the O N position and also with the keyswitch i n the

Is the ECM battery supply voltage eq ual to Repai r
Cran king positio n . the battery voltage? complete
Refer t o t h e wiri n g d iagram for con nector p i n NO
identificatio n .
Repair:
Repai r or replace the ECM power h arness.

Check the battery con n ections and fuse
term i n als.
1 9c01 070
STEP 3E .
Check engine SDeed durlna crank'Ina.
Condition:
Use I N SITE™ electronic service tool to monitor Is the e n g i n e cran king speed g reater than 3F
E n g i n e Speed while cran king the e n g i n e . 1 50 rpm?
YES
Is the e n g i n e cran king speed g reater than Repai r

1 50 rpm? complete
NO
Repair:
Fi nd and correct the cause for low cran king

speed . C h eck the batteries, e n g i n e starting
motor, and accessory loads.
STEP 3F: Verify rail fue pressure sensor accuracy.
Condition:
• Con nect I N S ITE™ electronic service too l .
Use I N S ITE™ electronic service tool to mon itor Is the rai l fuel p ress u re sensor (m easu red) 3G
the Rai l Fuel Press u re Sensor (Measu red) with val ue less than 30 Bar [435 psi] ?
the keyswitch O N and the e n g i n e not ru n n i n g . YES
Is the rai l fuel press u re sensor (measu red) Repai r

val ue less than 30 Bar [435 psi] ? complete
NO
Repair:
Replace the rai l fuel press u re sensor.

Refer to Proced u re 0 1 9- 1 1 5 (Ra i l Fuel
Pressure Sensor) i n Section 1 9 in the
Troubleshooti ng and Repai r M an ual , C M850
Electronic Contro l Syste m , ISC and I S L
Engi nes , B u l letin 4021 41 6.
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . . . Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [ J
. . .
STEP 3G Check for fue rail pressure while cranking the engine.
Condition:
• Connect I N S ITE™ electronic service tool .
Attem pt to start the engine by engag i n g the Did Fau lt Code 221 5 become active d u ri n g 3G- 1
engine starting motor for at least 30 conti nous t h e fai led the start attem pt?
seconds. YES
• Use I N SITE™ electro n i c service tool to mon itor
Fuel Rail Press u re (Measu red) and Fuel Rai l

Pressu re (Com manded) . Did Fau lt Code 221 5 become active d u ri n g 3H
• Use I N S ITE™ electronic service tool to read the
t h e fai led the start attem pt?
fau lt codes. NO
Attem pting to start the e n g i n e for 30 conti n uous
seconds al l ows the fau lt code logic time to run. If
Fau lt Code 221 5 becomes active , fuel rai l
pressu re is not being developed .
If the engine starts d u ri n g this attem pt , it is
possible that fuel prime to the high p ress u re
p u m p has been lost. Look for l oose fuel l i nes or
fi lters that al low for loss of fuel prime.
STEP 3G- 1 : ressure.
Condition:
• I nstall a press u re g a u g e a t the press u re s i d e f u e l fi lter head . Refer t o Proced u re 005-025 ( F u e l P u m p Gear
P u m p) in Section 5 i n the Troubleshooting and Repair Manual , ISC, QSC8 . 3 , ISL and QS L9 E n g i nes, B u l leti n
4021 41 8 .
M easu re the fuel gear p u m p o utput press u re Is the fuel gear p u m p press u re g reater than Repair
wh i l e cran king the e n g i n e . 1 38 kPa [20 psi] while cran king? com plete
Cran king speed must be g reater t h a n 1 50 rpm . YES
Refer to Proced u re 005-025 (Fuel P u m p Gear Repair:

P u m p) i n Section 5 in the Tro u b l eshooting and Fol l ow Fau lt Code 221 5 troubleshoot i n g tree.
Repai r Manual , ISC, QSC8 . 3 , ISL and QS L9
Engi nes , B u l letin 4021 4 1 8 .
Is the fuel gear p u m p press u re g reater than 3G-2
1 38 kPa [20 psi] while cran king?
NO
Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [...J ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
STEP 3G-2: ressure.
Condition:
• Instal l a pressu re gauge at the i n l et port of the h i g h press u re p u m p gear p u m p .
Measu re the fuel lift p u m p o utput press u re . Is the fuel l ift p u m p p ressure g reater than the Repai r
specifications outl i ned i n Proced u re 005-045 com plete
Refer t o Proced u re 005-045 ( F u e l Lift P u m p) i n
in the Troubleshooting and Repai r Manual ,
Section 5 i n t h e Troubleshooti n g a n d Repai r
ISC, QSC8 . 3 , I S L and QS L9 E n g i nes,
Manual , ISC, QSC8 . 3 , I S L and QSL9 E n g i nes,
B u l leti n 4021 4 1 8?
B u l let i n 4021 41 8 .
YES
At i n itial key-on , t h e l ift p u m p wi l l run for 30
seconds and then stop. Repair:
Replace the gear p u m p .

Refer t o Proced u re 005-025 (Fuel P u m p Gear
P u m p) in Section 5 in the Troubleshooti ng
and Repai r Manual , ISC, QSC8 . 3 , I S L and
QS L9 E n g i nes, B u l l et i n 4021 4 1 8 .
Is t h e f u e l l i ft p u m p pressu re greater t h a n t h e Repai r

specifications outl i ned i n Proced u re 005-045 complete
in the Tro u bleshooting and Repair Manual ,
ISC, QSC8 . 3 , I S L and QS L9 E n g i nes,
B u l l etin 4021 4 1 8?
NO
Repair:
Verify fuel pri me by making s u re the O E M

f u e l fi lter is fu l l or f u e l a n d air is pu rged from
the low pressu re fuel l i nes. Perform I N S ITE™
el ectronic service tool Lift P u m p Override
Test if necessary.
If the low pressu re fuel system is primed ,
replace the fuel l i ft p u m p .
Refer t o Proced u re 005-045 (Fuel Lift P u m p)
i n Section 5 i n the Troubleshooting and
Repai r Manual , I SC , QSC8 . 3 , ISL and QSL9
Engines , B u l l etin 4021 41 8 .
Engine Performance Troubleshooting Tree - ISC/QSC/ISLlQ [...J
Page TT-33
STEP 3H . a no-start con d·Itlon.

Check for other fau t codes that eXD Il am .
Condition:
• Connect I N S ITE"" electronic service too l .
Use I N S ITE™ electronic service tool to read fault Do any fau lt codes that can cause a no-start Repai r
code i nformatio n . con d ition com e active d u ri n g cran k i n g ? complete
Look for fault codes that come active d u ri n g a
YES
fai led start attem pt that can be the cause for a
Repair:
no-start cond iti o n .
Fol l ow the electronic fau lt code trees for the

appropriate tro u b l eshooting p roced u res.
Do any fau lt codes that can cause a n o-start 4A

con d ition com e active d u ri n g cran king?
NO
STEP 4: Fuel system troubleshooting procedures.

STEP 4A· Check for fault codes
Condition:
• Connect I N S ITE™ el ectro n i c service too l .
Use I N S ITE™ electronic service tool to read the Are fuel system fault codes active? Repai r
fau lt code i nformation . YES complete
Determ i n e if there are active fuel system fau lt Repair:
codes related to the com pl a i nt .
Fol l ow the electronic fau lt code trees f o r t h e
appropriate tro u b l eshooting proced u res.
Are fue l system fau lt codes active? 48

NO
STEP 48: Check for air in the hiah-Dressure DumD fuel SUDDl v.
Condition:
• Refer to Proced u re 006-003 (Ai r i n Fuel) i n Section 6 i n the Troubleshooting and Repai r Manual , ISC, OSC8 . 3 ,
I S L a n d OS L9 E n g i nes, B u l leti n 4021 41 8 .
Check for air i n the fuel . Is air present i n the fuel supply? Repai r
YES
complete
Refer to Proced u re 006-003 (Ai r i n Fuel) i n
Section 6 in the Troubleshoot i n g and Repai r Repair:
Manual , I SC , OSC8 . 3 , I S L and OSL9 E n g i nes,
B u l let i n 4021 41 8 . Locate and correct the cause o f ai r i ngestion
i n the fuel supply system . Sources of air
i ngestion i nclude loose fuel fi lters , l oose fuel
l i n e fittings, loose or cracked fuel tank stand-
pi pes , o r severe restrictions in the fuel su pply
l i nes and fi lters .
Is ai r p resent i n the fuel supply? 4C

NO
STEP 4C: ressure.
Condition:
• Refer to Proced u re 005-025 (Fuel P u m p Gear P u m p) i n Section 5 i n the Troubleshoot i n g and Repai r Man u a l ,
ISC, OSC8 . 3 , I S L a n d OS L9 E n g i nes, B u l l etin 402 1 41 8.
Check the fuel gear p u m p pressu re . Is the fuel gear p u m p p ress u re with i n 4D
specification?
Refer t o Proced u re 005-025 ( F u e l P u m p Gear
P u m p) in Section 5 in the Troubleshooting and YES
Repai r Man ual , ISC, OSC8 . 3 , ISL and OSL9
Engi nes, B u l leti n 4021 41 8 . Is the fuel gear p u m p press u re with i n 4C- 1
specification?
NO
STEP 4C-1: Measure the fuel inlet restriction.
Condition:
• M easu re the fuel p u m p i n let restriction at the d iag nostics port on the fuel gear p u m p . Refer to P roced u re 006-020
(Fuel I n let Restriction) i n Section 6 i n the Troubleshoot i n g and Repai r Manual , ISC, QSCB . 3 , I S L and QSL9
Engi nes, B u l l eti n 4021 4 1 B .
Check the fuel i n l et restrictio n . Is the fuel i n let restriction above Repai r
specification? complete
Refer t o Proced u re 006-020 (Fuel I n l et
Restriction) i n Section 6 i n the Troubleshooting YES
and Repair Manual , ISC, QSCB . 3 , ISL and QS L9

Repair:
Engi nes , B u l leti n 4021 41 B.
Find and correct the cause of h i g h i n let
restrictio n . Look for plugged O E M fuel fi lters
or screens, or a restricted ECM cooler,
restricted l ift pump bypass check valve (in the
ECM cooler) , pi nched OEM fuel l i n es or
restricted stand-pipe i n the OEM fuel tan k.
Is the fuel i n let restriction above Repai r

specificatio n ? com p lete
NO
Repair:
Replace the fuel gear p u m p .

Refer t o Proced u re 005-025 (Fuel P u m p Gear
P u m p) i n Section 5 i n the Troubleshooti ng
and Repai r Man ual , ISC, QSCB . 3 , I S L and
QS L9 E n g i nes, B u l leti n 4021 4 1 B .
STEP 40: Perform smale cvlinder cutout test.
Condition:
• E n g i n e ru n n i ng at low idle.
Operate the engine at load . Can the m iss or excessive smoke be Repai r
attrib uted to a single cyl i nder? com pl ete
Use I N SITE™ electronic service tool to perform
the Cyl i nder Cutout Test to d isable i n d ividual YES
i njectors.
Repair:
Look for a cause of the complaint i n c l u d i n g

valve lash a n d excessive cran kcase p ress u re
that can i n d icate power cyl i nder damage or
camshaft lobe wear. If no other damage is
fou n d , replace the fuel i njector i n the cyl i n der
identified by the single cyl i nder cutout test.
Refer to Proced u re 006-026 ( I njector) i n
Section 6 i n the Troubleshoot i n g and Repai r
Manual , ISC, QSC8 . 3 , I S L and QSL9
Engi nes, B u l letin 4021 41 8 .
C a n the m iss o r excessive smoke b e 4E

attributed t o a single cyl i nder?
NO
STEP 4E: Perform cvlinder balance diaanostic test.
Condition:
• Con nect I N S ITE™ electronic service too l .
Use I NS ITE™ electronic service tool to run the Does the Cyl i nder Perform ance Test identify Repai r
Cyl i nder Performance Test to determ i ne if a any cyl i n d e r that is contri buting to a power com p l ete
single cyl i nder is contri buti ng to the e n g i n e i m balance?
sym pto m .
YES
Repair:
Look for a cause of the power i m balance

i nc l u d i n g valve l ash and excessive
cran kcase p ressure that can i n d icate power
cyl inder damage or camshaft lobe wear. If no
other damage is fou n d , replace the fuel
i njector i n the cyl i nder contri buti ng to the
power i m balance . Refer to Proced u re
006-026 ( I njector) i n Section 6 i n the
Troubleshooti ng and Repai r Manual , ISC,
QSC8 . 3 , I S L and QS L9 E n g i nes, B u l l etin
4021 41 8 .
Does the Cyl i nder Performance Test ide ntify 4F

any cyl i n d e r that is contri buti ng to a power
i m balance?
NO
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J Engine Performance Troubleshooting Tree - ISC/QSC/ISLlQ [...J
STEP 4F· Measure fuel drain line restriction
Condition:
• Refer to Proced u re 006-0 1 2 (Fuel Drai n Line Restriction) i n Section 6 i n the Tro u b l eshooting and Repai r Manual ,
ISC, QSC8 . 3 , I S L and QSL9 E n g i nes , B u l letin 4021 4 1 8 .
Check the fuel d rain l i n e restriction . Refer to Is the d ra i n l i n e restriction less than 4G
Proced u re 006-0 1 2 i n Troubleshooting and specification?
Repai r M an u a l , I S C , QSC8 . 3 , I S L and QS L9

YES
Is the d rain l i n e restriction less than Repai r

NO
Repair:
Look for causes of h i g h d rai n l i ne restriction ,

such as ki n ked or bl ocked fuel l i nes.
Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [...] ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]
STEP 4G: Monitor fuel ressure at idle.
Condition:
• Start engine.
R u n engine at idle for at least one m i n ute to Does measu red fuel rai l press u re deviate Repai r
purge air ind uced from previous steps. more than 200 bar [2900 psi] from com plete.
com m anded p ress u re and surge at i d l e , or
Use I NS ITE™ electronic service tool to m o n itor
does the e n g i n e start and stal l ?
com m anded fuel rai l p ress u re and measu red fuel
rai l p ressure for a m i n i m u m of 1 0 seconds. YES
To verify you r resu lts , repeat this step with the Repair:
Fuel System Leakage Test active i n the I N SITE™ Replace the fuel p u m p actuator. Refer to
el ectronic service too l . Proced u re 0 1 9- 1 1 7 (Fuel P u m p Actuator) i n
Section 1 9 i n t h e Troubleshooting and Repai r
Manual , CM850 E lectronic Control System ,
ISC and I S L E n g i nes, B u l let i n 4021 4 1 6 .
Does measu red fuel rai l pressu re deviate 7A

more than 200 bar [2900 psi] fro m
com m anded p ressure and surge at i d l e , or
does the engine start and stall?
NO
STEP 5: Air handling troubleshooting procedures.

STEP SA Inspect the tur bocharger blades for damage.
Condition:
• Remove the i ntake and exhaust pi pes from the tu rboch arger.
I nspect the com pressor and tu rb i ne blades for Damage or wear found o n tu rbocharger Repai r
damage or wear. blades? complete
Refer to Proced u re 0 1 0-033 (Tu rbocharger) i n YES
Section 1 0 i n the Troubleshooting and Repai r Repair:
Man ual , ISC, OSC8 . 3 , I S L and OSL9 E n g i nes,
Bul leti n 4021 4 1 8 . Replace the tu rbocharger assembly. Refer to
Proced u re 0 1 0-033 (Tu rbocharger) in Section
1 0 i n the Troubleshoot i n g and Repai r
Manual , I S C , OSC8 . 3 , I S L and OS L9
Engi nes, B u l leti n 4021 4 1 8 .
Damage or wear found on tu rbocharger 5B

blades?
NO
STEP SB: .
Check the tur bocharger aXlaI and rad'laI c I earances.
Condition:
Check the tu rbocharger for correct axial and Are the tu rbocharger axial and rad ial beari ng 5C
rad ial clearance. clearances with i n specification?
Refer to Proced u re 0 1 0-033 (Tu rbocharger) in YES
Section 1 0 i n the Troubleshooting and Repai r
Man ual , ISC, OSC8 . 3 , I S L and OSL9 E n g i nes,

Are the tu rbocharger axial and rad ial beari ng Repai r
B u l leti n 4021 4 1 8 . clearances with i n specification? complete
NO
Repair:
Replace the tu rbocharger. Refer to

Proced u re 0 1 0-033 (Tu rbocharger) in Section
1 0 i n the Tro u bleshooting and Repair
Manual , ISC, OSC8 . 3 , I S L and OS L9
Engi nes, B u l l et i n 4021 4 1 8 .
. Determmatlon 0f tur boch araer t[VDe .

STEP 5C
Condition:
None
Determine if the tu rbocharger is a wastegated or Is the tu rbocharger a variable geometry 5D

variable geometry tu rbo. tu rbocharger?
YES
Is the tu rbocharger a variab le geometry 5F

tu rbocharger?
NO
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . . . Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [ J
. . .
STEP 50: Check variable
Condition:
• Verify vehicle air tan ks are fu l ly charged (g reater than 689 k P a [ 1 00 psi]).
Use I N S ITE™ electronic service tool to start the Does the tu rbocharger actuator rod extend 5E
Tu rbocharger Actu ator Test between 1 0 . 8 and 1 1 .8 m m [0.43 and 0 . 46
• Adj ust the delay timer in the Tu rbocharger in]?
Actuator Test so that the rod movement can be

YES
observed .
• Select the Retract Actuator position with
I NS ITE™ e lectro n i c service too l .

Does the tu rbocharger actuator rod extend 5 0- 1
• M ark or scribe t h e variable geometry actuator
betwee n 1 0 . 8 and 1 1 .8 m m [0.43 and 0.46
rod at the base of the actuator. in]?
• Sel ect the Exten d Actu ator position with NO
I NS ITE™ electro n i c service too l .
• M easu re t h e rod travel b y measuring the
distance from the base of the variable
geometry actuator to the scribe mark.
The variable geometry actuator must move
q u ickly and crisply. If the actuator rod movement
is slow, there cou l d be a p roblem with the ai r
su pply or mechan i cal problems with the variable
geometry tu rbocharger assem b ly.
)
I
Engine Performance Troubleshooting Tree · ISC/QSC/ISL/Q [...J ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Page TT·42 Section TT · Troubleshooting Symptoms (New Format)
STEP 5D·1: Check for air leaks and inSDect air lines.
Condition:
• Verify vehicle air tan ks are fu lly charged (g reater than 689 k P a [ 1 00 psi]).
Use I N S ITE™ electronic service tool to perform Ai r leaks fou n d i n the system or damaged air Repai r
the Tu rbocharger Actuator Test. l i nes? com plete
Select the Extended Actuator pOSition and l i sten YES
for air leaks i n the fol lowi ng com ponents : Repair:
• Tu rbocharger control valve
Repai r air l eaks or replace damaged or
• Tu rbocharger control valve i n let con nection
broken a i r l i nes.
• Tu rbocharger control valve outlet con n ection
• Tu rbocharger actuator i n l et con n ection
• Tu rbocharger actuator Air leaks fou nd i n the system or damaged air 50·2
• All ai r l i nes i nclud i ng OEM supply l i n e to l i nes?
tu rbocharger control valve and between the NO
tu rbocharger control valve and the variable
geometry tu rbocharger.
A smal l amount of air wi l l be heard escap i n g from
the tu rbocharger control valve . This is a normal
condition . Do not replace the tu rbocharger
control valve for this con d ition .
STEP 5D·2: Check for air Dressure at the tur bocharaer contro valve outlet.
Condition:
• Con nect I N SITETM electro n i c service too l .
• Verify vehicle air tan ks are fu l ly charged (g reater than 689 k P a [ 1 00 psi]).
Remove the ai r l i n e connection at the outlet of the Is vehicle tan k air press u re p resent at the 50·3
tu rbocharger control valve . tu rbocharger control valve outlet?
I nstall a Compuchek™ fitt i n g in the tu rbocharger YES
control valve outlet.
I nstall an air press u re gauge that is capable of Is vehicle tan k air press u re p resent at the 50·5
read i ng at least 1 034 kPa [ 1 50 psi ) . tu rbocharger control valve outlet?
Use I N S ITE™ electronic service tool to perform NO
the Tu rbocharger Actuator Test. Select the
Extend positio n .
STEP 50-3 Check for air pressure at turbocharaer control va ve outlet.
Condition:
• Verify vehicle ai r tan ks are fu l ly charged (g reater t h a n 689 k P a [ 1 00 psi)).
Remove the ai r l i n e con n ection at the outlet of the Can a i r be h eard escapi n g from the Repai r
tu rbocharger control valve . tu rboch arger control valve outlet? complete
I n stal l an air press u re gauge that is capable of YES
read i n g at least 1 034 kPa [ 1 50 psi] . Repair:
Use I N S ITE™ electronic service tool t o perform The tu rbocharger control valve is stuck ope n .
the Tu rbocharger Actuator Test. Select the It must not be allowi ng ai r t o escape w h e n i n
Retract position . the Retract positio n . Replace the
tu rbocharger control valve . Refer to
Proced u re 0 1 9-388 (Tu rbocharger Control
Valve) in Section 1 9 in the Tro u bl eshoot i n g
a n d Repai r Manual , CM850 E l ectro n i c
Control System , ISC a n d I S L E n g i nes,
Bul leti n 4021 4 1 6 .
Can a i r be heard escapi n g fro m the 50-4

tu rbocharger control valve outlet?
NO
STEP 50-4: Check for vehicle air tank Dressure at tur bocharaer control va ve .In Iet.
Condition:
• Verify vehicle ai r tan ks are fu l ly charged (g reater than 689 kPa [ 1 00 psi)).
D isco n n ect the air i n let con n ection to the Veh icle air tan k pressu re avai lable at the 5 0-5
tu rbocharger control valve . tu rbocharger control valve i n l et?
Verify vehicle ai r tan k pressu re is avai lable at the YES
tu rbocharger control valve i n let.
Vehicle air tan k p ressure available at the Repai r
tu rboch arger control valve i n let? complete
NO
Repair:
No ai r p ressu re available at the tu rbocharger

control valve i n let. Troubleshoot OEM air
p l u m b i n g and determ i n e why air p ressu re is
not present.
Engine Performance Troubleshooting Tree - ISC/QSC/ISLlQ [...] ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]
STEP 50-5: Check for correct turbochar er actuator travel.
Condition:
• Remove the variable geometry actuator from the tu rbocharger assembly. Refer to Proced u re 0 1 0- 1 1 3
(Tu rbocharger, Variable Geometry Actuator) i n Section 1 0 i n the Troubleshooting and Repai r Man ual , ISC,
QSC8 . 3 , I S L and QS L9 E n g i nes , B u l let i n 4021 41 8 .
• Connect I N S ITE™ electro n i c service too l .
Use I N S ITE™ electro n i c service tool to perform Does the variable geometry actuator rod Repai r
the Tu rbocharger Actuator Test. travel at least 1 2 mm [0.472 i n] ? com plete
Sel ect the Extend Actuator position . YES
Repair:
The variable geometry actuator has correct

air pressu re and correct travel . The variable
geometry mechanism i n the tu rbocharger is
seized .
Replace the tu rbocharger assem bly. Refer to
Proced u re 0 1 0-033 (Tu rbocharger) i n Section
1 0 i n the Troubleshooting and Repai r
M an ual , ISC, QSC8 . 3 , I S L and QSL9
Engi nes , B u l l eti n 4021 41 8 .
Does the variable geometry actuator rod Repai r

travel at l east 1 2 mm [0.472 i n ] ? com plete
NO
Repair:
The variable geometry actuator has correct

air pressu re but the variable geo m etry
actuator rod is not extend i n g .
Replace t h e tu rbocharger actuator. Refer to
Proced u re 0 1 0- 1 1 3 (Tu rbocharger, Variable
Geometry Actuator) i n Section 1 0 in the
Troubleshooti ng and Repai r M a n u al , ISC,
QSC8 . 3 , I S L and QSL9 E n g i nes, B u l l et i n
4021 41 8 .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [ . . . J
Section TT - Troubleshooting Symptoms (New Format) Page TT -45
STEP 5 E : Check f o r broken shaft i nside the tu rboc har e r.
Cond ition:
• Remove the variabl e geom etry actuator from the tu rbocharger assembly. Refer to Proced u re 0 1 0-1 1 3
(Tu rbocharger, Variable Geometry Actuator) i n Section 1 0 i n the Troubleshooti ng and Repai r Manual , ISC,
QSC8 . 3 , I S L and QS L9 Engi nes, B u l leti n 402 1 4 1 8.
Action Specification/Repair N ext Step
Check for a b roken l i n kage i nside the Does the s l i d i n g nozzle move correctly? 2A
tu rbocharger by movi ng the variable geom etry

YES
actuator on the tu rbocharger u p and down.
The actu ator lever m ust move evenly and crisply Does the s l i d i n g nozzle move correctly? Repai r
as it is m oved . complete
NO
Repai r:
The variable geometry h as mechan ical

damage i nside the tu rbocharger. The
actuator m oves properly, but the l i n kage
attaching the actuator to the nozzle is b roke n .
Replace the tu rbocharger assembly. Refer to
Proced u re 010-033 (Tu rbocharger) in Section
1 0 i n the Troubleshooting and Repai r
Manual , I S C , QSC8.3, I S L and QSL9
Engi nes, B u l leti n 402 1 41 8 .
1 0d00 1 80
Engine Performance Troubleshooti ng Tree - ISC/QSCIISL/Q [ . . . J ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
STEP SF: Inspect wastegate actuator - wasteQate d t u rboch arQers OniV.
Cond i t i o n :
• Remove the tu rbocharger if the wastegate actuator is inaccessible.
Act i o n S pecificat ion/Repa i r Next Step
I nspect the i nteg ral wastegate actuator h ose for Holes or cracks found in the wastegate Repai r
cracks o r holes. actuator hose? complete
YES
Repai r:
Replace the wastegate actuator hose .
Holes or cracks found i n the wastegate 5G

actuator hose?
NO
STEP 5G: ate actu ator rod f o r trave l .
Cond i t i o n :
• Remove the i nteg ral boost line from the wastegate actuato r.
Act i o n S pecification/Repa i r N ext Step
Apply a reg u l ated air supply of 1 38 kPa [20 psi] Does the wastegate actuator rod m ove? Repai r
to the actuator and check for actuator m ovement. YES complete
Does the wastegate actu ator rod m ove? 5G-1

NO
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISC/QSC/ISLlQ [ . . . J
STEP 5G-1 : I n s ect the waste ate actuator rod for t rave l .
Cond ition:

• Remove the e-cl i p from the wastegate pin and d isconnect the actuator rod .
Action S pecification/Repair N ext Step
Apply a reg u l ated ai r supply of 1 38 kPa [20 psi] Does the wastegate actuator rod m ove? Repai r
to the actuator and check for actuator movement. YES
com plete
Repai r:
Move the wastegate lever on the

tu rbocharger back and forth , and check for
smooth operatio n .
Replace the tu rbocharger assem b ly if the
wastegate is seized. Refer to P roced u re
0 1 0-033 (Tu rbocharger) i n Section 1 0 in the
Troubleshooting and Repai r Manual , I SC ,
OSC8. 3 , I S L and OSL9 Engi nes, B u l l eti n
402 1 4 1 8.
Does the wastegate actuator rod m ove? Repai r

NO complete
Repai r:
Replace the wastegate actuator. Refer to

Proced u re 0 1 0-050 (Tu rbocharger
Wastegate Actuator) i n Section 1 0 i n the
Trou b l eshooting and Repai r Manual , I S C ,
OSC8.3, I S L a n d OSL9 Engi nes, B u l l etin
402 1 4 1 8.
10900084
Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [ . . . J ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . ]
Page TT-48 Section TT - Troubleshooti ng Symptoms (New Format)
STEP 6: Electro n i c featu re t ro u b l eshooti ng p roced u res .

STEP 6A v em'fv th rott i e De d a I t rave I .
Cond i t i o n :
Action S pecification/Re pair N ext Step
Use I NS ITE™ electronic service tool to mon itor Does the th rottle position read 0 percent 6B
Th rottle Position w h i l e fully depressing and when the th rottle is released and 1 00 percent
releasing the th rottle peda l . w h e n the th rottle is depressed?
YES
Does the th rottle position read 0 percent Repai r

when the th rottle is rel eased and 1 00 percent com plete
when the th rottle is depressed?
NO
Repai r:
Determ ine and correct the cause of the

th rottle pedal restriction.
STEP 6 8 Check am b'l ent air Dressu re sensor accu racy .
Cond i t i o n :
Start I N S ITE™ electronic service tool Data The I N S ITETM electronic service tool read i n g 6C
Mon itor/Logger a n d com pare I N S ITE™ electronic is with i n 50 . 8 m m-Hg [2 in-Hg] of local
service tool read i n g for Barometric Air P ressure barometric p ress u re?
to the local barometric p ressure. YES
Refer to P roced u re 0 1 8-028 (Barometric
Pressure at Altitude) i n Section V. The I N S ITETM electronic service tool read i n g Repai r
is wit h i n 50 . 8 m m-Hg [ 2 i n - H g ] o f local Complete
barometric p ressure?
NO
Repai r:
Replace the barometric pressure sensor.

Refer to P roced u re 0 1 9-004 (Barometric Air
Pressure Sensor) i n Section 1 9 i n the
Troubleshooting and Repai r Manual , CM850
Electronic Control System , ISC and I S L
Engines , B u l leti n 402 1 41 6.
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [ J ...
Section TT - Troubleshooting Sym ptoms (New Format) Page TT-49
STEP 6 C : Check i ntake man ifold o ress u re sensor accu racy .
Con d i t i o n :
Use I N S ITE™ electronic service tool to mon itor I ntake man ifold pressure read i n g is l ess than 60
the val ue of I ntake Man ifold Pressu re without the 1 02 mm-Hg [4 i n -Hgj?
engine r u n n i n g . YES
I ntake man ifold pressure read i n g is less than Repai r

1 02 m m - H g [4 in-H gj? complete
NO
Repa ir:
Replace the i ntake man ifold p ressure sensor.

Refer to P roced u re 0 1 9-06 1 (I ntake Man ifold
Pressure Senso r) for Section 1 9 i n the
Trou bleshooting and Repai r Manual , CM850
Electronic Control System , I SC and I S L
Engines, B u l leti n 402 1 41 6.
STEP 6 0 : v eru' fv e ectro m. c featu re settinas are correct .
Con d i t i o n :
• Conn ect I N S ITE™ electronic service tool .
Use I N S ITE™ electronic service tool ; to verify the Are the e lectronic featu res set correctly? 2A
followi ng adj ustab le parameters are correctly

YES
set:
• M axi m u m Vehicle Speed
• Powertrai n P rotection
Are the e lectronic featu res set correctly? Repai r

• Rear Axle Ratio NO
complete
• Tailshaft Teeth
Repa ir:
• Tire Revolutions per M i l e
• G ear-Down P rotection Use I N S ITE™ electronic service tool to

• Cruise Control D roop Settings correct p rog ram mable features.
• Cruise Control Maxi m u m Vehicle Speed .
Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [ . . . J ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
STEP 7: Base e n g i n e tro u b l eshoot i n g proced u res.

STEP 7A V e m'fv ove r h ead ad nus
' t men t s are correct .
Cond i t i o n :
• Remove the rocker lever cover. Refer to Proced u re 003-0 1 1 (Rocker Lever Cover) i n Section 3 i n the
Troubleshooti ng and Repai r Man ual , ISC, QSC8. 3 , I S L and QSL9 Engi nes, B u l let i n 402 1 4 1 8 .
Action Specification/Repai r N ext Step
Measure the overhead setti n g . Are the overhead settings with i n the reset 7B
l i m its?
Refer to Procedu re 003-004 (Ove rhead Set) i n
Section 3 in the Troubleshooti ng and Repai r YES
Manual , ISC, QSC8 . 3 , I S L and QSL9 Engi nes,
Bul letin 402 1 41 8 . Are t h e overhead settings with i n t h e reset Repai r
l i m its? com plete
NO
Repai r:
Adj ust the overhead settings. Refer to

Proced u re 003-004 (Overhead Set) in
Section 3 i n the Troubleshooting and Repair
Manual , ISC, QSC8 . 3 , I S L and QS L9
Engi nes, B u l letin 402 1 41 8 .
STEP 7 8 : Verifv e n Q l n e b rake adiustment.
Cond ition:
• Remove the rocker lever cover. Refer to P roced u re 003-0 1 1 (Rocker Lever Cover) i n Section 3 i n the
Troubleshooti ng and Repai r Man ual , ISC, QSC8 . 3 , ISL and QSL9 Engi nes, B u l let i n 402 1 4 1 8 .
Act i o n S pecification/Repair Next Step
Verify that the engine b rakes are operating Are the engine b rake settings with i n the reset 7C
correctly. l i m its?
Measure the engine b rake settings. Refer to YES
Proce d u re 020-004 (Engine Brake Assem bly) i n
Section 2 0 i n t h e Trou bleshooti ng a n d Repai r Are the engine b rake settings with i n the reset Repai r
Manual , ISC, QSC8 . 3 , I S L and QSL9 Engi nes, l i m its? com plete
B u l leti n 402 1 4 1 8 .
NO
Repai r:
Adj ust the engine b rake settings. Refer to

Proced u re 020-004 (Engine Brake Assem bly)
in Section 20 in the Troub leshooti ng and
Repai r Man ual , ISC, QSC8 . 3 , ISL and QSL9
Engines, B u l leti n 402 1 41 8.
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [ . . . J
Section TT - Troubleshooting Symptoms (New Format) Page TT-S 1
STEP 7C:
Cond ition :
• Refer t o Proced u re 0 1 0-027 (Charge-Ai r Cooler) i n Section 1 0 i n t h e Troubleshooting and Repair Man ual , I SC ,
OSC8 . 3 , I S L and OSL9 Engi nes, B u l leti n 402 1 41 8 .
Action Specification/Repa i r Next Step
I nspect the charge air cooler for cracks , holes, or Is the ch arge air cooler free of cracks or other 7D
other damage. damage?
Refer to Proced u re 0 1 0-027 (Charge-Ai r Cooler) YES

i n Section 1 0 i n the Troubleshooting and Repai r
Man ual , ISC, OSC8 . 3 , I S L and OS L9 Engi nes, Is the charge air cooler free of cracks or other Repai r
B u l leti n 402 1 4 1 8 .
damage? com plete
NO
Repa i r :
Repai r the charge air cooler assembly.

Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [ . . . J ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
Page TT-S2 Section TT - Troubleshooti ng Symptoms (New Format)
STEP 7 0 : C h e c k a i r i n take restrictio n .
Cond ition:
• Refer to Proce d u re 0 1 0-03 1 (Ai r I ntake Restriction) i n Section 1 0 i n the Troubleshooting and Repair Manual ,
ISC, QSC8 . 3 , I S L and QS L9 Engi nes, B u l l etin 402 1 41 8 .
Action S pecification/Re pai r N ext Step
Check the i ntake system restriction by instal l i ng Is air i ntake restriction g reater than 635 m m Repai r
a vac u u m gauge i nto the air i ntake system . H 20 [25 in-H 20]? com plete
Refer to P roced u re 0 1 0-03 1 (Ai r I ntake YES
Restriction) in Section 1 0 in the Troubleshooting
Repair:
and Repai r Manual , ISC, QSC8 . 3 , I S L and QSL9
Engi nes, B u l l etin 402 1 4 1 8 . Correct the cause of high i ntake air
restriction .
Check for plugged a i r fi lter or restricted air

i ntake p i p i n g .
Is air i ntake restriction g reater than 635 m m- 7E

H 20 [25 in-H 20]?
NO
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [ . . . J
STEP 7E: Check exhaust restrict i o n .
Cond i t i o n :
• Refer to P roced u re 0 1 1 -009 (Exhaust Restriction) i n Section 1 1 i n the Troubleshooting and Repair Man ual , ISC,
QSC8 . 3 , ISL and QSL9 Engines, B u l leti n 402 1 4 1 8 .
Check the exhaust system back p ress u re by Is exhaust back pressure l ess than 40 in-H 7F
instal l i ng a pressu re gauge i nto the exhaust 20 [3 i n-HgJ?
system just past the tu rboch arger outlet.
YES
Refer to Proced u re 0 1 1 -009 (Exhaust Restriction)
i n Section 1 1 i n the Tro u bl eshooting and Repai r Is exhaust back pressure less than 40 in-H Repai r
Manual , ISC, QSC8 . 3 , I S L and QSL9 Engi nes, 20 [3 i n- HgJ? complete
B u l let i n 402 1 4 1 8 .
NO
Repai r :
I nspect exhaust system for sou rce of high

restriction .
STEP 7F: Check enaine b l owbv .
Cond ition:
• Refer to P roced u re 0 1 4-005 (Engine Testing (Engine Dynamometer) in the Troubleshooting and Repai r Manual ,
ISC, QSC8 . 3 , I S L and QSL9 E n g i nes, B u l letin 402 1 41 8 .
Action Specification/Repai r Next Step
Measure the engine blowby as outl i ned in Are the engine blowby meas u rements with i n Return to
Proced u re 0 1 4-005. specification? Step 2 or
YES
contact a
C u m m i ns
authorized
repai r
location for
further
di agnostic
and
troubleshooti
ng
i nstructions.
Are the engine blowby meas u rements with i n Go t o step

specification? 7F- 1 .
NO
Engine Performance Troubleshooting Tree - ISC/QSC/ISL/Q [ . . . J ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J
STEP 7F-1 Ve rifv tu rbocharaer contri bution to e n a l n e blowbv.
Cond i t i o n :
• Connect the appropriate orifice to the end of the blowby d raft tube.
• Remove the tu rbocharger oil d rain line from the block and d rai n i nto a bucket.
• Start the engine.
Load engine to rated rpm on a chassis Has the total engine blowby d ropped more Repai r
dynamometer. than 30 percent of the total? com plete
Measu re the eng i n e blowby as outl ined in YES
P roced u re 0 1 4-005 {Eng i n e Testing (Engine Repair:
Dynamometer) i n the Troubleshooti ng and
Repai r Man ual , ISC, aSC8 . 3 , ISL and aSL9 Replace the tu rbocharger assembly. Refer to
Engi nes, B u l leti n 402 1 4 1 8 . Proced u re 0 1 0-033 (Tu rbocharger) i n Section
1 0 i n the Tro u bleshooti ng and Repai r
Manual , ISC, aSC8 . 3 , I S L and aS L9
Engines, B u l leti n 402 1 41 8 .
H as t h e total engine blowby d ropped more Repai r

than 30 percent of the total? Complete
NO
Repair:
The engine m i g ht need to be reb u i lt . See the

engine reb u i l d specifications.
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ J . . . Engine Performance Troubleshooting Tree - ISB, ISBe, an [ J . . .
Section TT - Troubleshooting Symptoms (New Format) Page TT 55 -
Engine Performance Troubleshooting Tree - ISB, ISBe, and aSB engines

without EGR (CMBOO and CMB50 Electronic Control System)
T h i s tro u b l eshoot i n g p roced u re s h o u l d be fol lowed for the fo l lowi ng sym pto ms:
• Engine Acceleration or Response Poor
• Engine Difficult to Start or Will Not Start (Exhaust Smoke)
• Engine Difficult to Start or Wi l l Not Start (No Exhaust Smoke)
• Engine Power Output Low
• Engine Runs Rough at I d l e
• E n g i n e Runs R o u g h or M i sfi res
• Engine Speed Su rges at Low or H ig h I d l e
• Engine Speed S u rges under Load or i n Operati ng Range
• Smoke , Black - Excessive
• Smoke, Wh ite - Excessive
• Engine S h uts Off or Dies U nexpectedly or Dies During Deceleration
• Engine Decelerates Slowly
• Engine Starts but Will Not Keep R u n n i n g
• E n g i n e Wi l l N o t Reach Rated Speed (RPM)
• I ntake Man ifold P ressure (Boost) is Below Normal
• Engine Vibration Excessive
How to Use T h i s T ro u b l eshoot i n g P rocedu re:

This sym ptom tree can be used to troubleshoot all performance-based sym ptoms l i sted above. Start by perform i n g
Step 1 tro u bleshoot i n g . Step 2 wi l l a s k a series o f q uestions and will provide a l ist o f tro u bleshooti ng steps t o perform ,
depen d i n g on the sym pto m .
Many steps w i l l reference using I N S ITE™ electronic service tool t o check for fault codes, perform tests , mon itor data,
and check featu res and parameters . It is recom mended that I N S ITE™ electronic service tool remain con n ected w h i le
using this troubleshooti ng tree , to period ically check for fau lt codes. If any fault codes becom e active d u ring use of
the troubleshooti ng tree , d iscontinue using this troubleshooting tree and troubleshoot the active fault code.
This sym ptom tree often references other proced u res and sym ptom trees . The procedu res and symptom trees
referenced may not be located in the same service l iterature as this sym ptom tree. Refer to P roced u re 205-00 1
(Add itional Service Literatu re) i n Section L for a l isti ng of the service l iteratu re avai lable for the e n g i n e being serviced.
S hop T a l k:
D riveab i l ity is a term that i n general describes vehicle performance on the road . D riveab i l ity problems for an engine
can be caused by several d i fferent factors . Some of the factors are engine-related and some are not. Before
troubleshooti n g , it is i m portant to determ i n e the exact complaint and whether the engine has a real d riveabi l ity problem
o r if it s i m ply does n o t m eet d river expectations.
Low power is a term that is used i n the field to descri be many d ifferent performance problems. Low power is defi ned
as the i nab i l ity of the engine to produce the power necessary to move the veh icle at a speed that can be reasonably
expected u nder the given cond itions of load , g rade, wind, and so on. With ind ustrial eq u i pment, low power m i g ht
relate to the i n ab i l ity of the eq u i pment to pick u p or maintain load .
Poor acceleration or response is described as the i nabil ity of the veh icle to accelerate satisfactorily from a stop o r
from the bottom of a g rade . It c a n also be the lag i n acceleration d u ring an attem pt t o pass o r overtake another veh icle
at cond itions less than rated speed and load . Poor acceleration or response is d ifficult to troubleshoot, si nce it can
be caused by several factors .
Engine Performance Troubleshooting Tree - ISB, ISBe, an [ . . . J ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
T R O U BLESH OOTI N G S U M MARY
STEPS S P E C I F I CATI O N S S RT CO D E
STEP 1 : Perfo rm bas i c trou bleshoot i n g proced u res .
STEP 1 A : C h e c k f o r active fau lt codes or Active fau lt codes or h i g h counts
h i g h cou nts of inactive fau l t of i n active fau lt codes?
codes.
STEP 1 B : Perform basic tro u b l eshooting A l l steps have been verified to

checks. be correct?
STEP 2: Dete r m i nat i o n of e n g i n e sym pto m .

STEP 2 A : En g i n e D iffi c u l t to Start or W i ll Is the e ng ine sym ptom E ng ine
Not Start (With o r Without Difficult to Start o r W i l l Not Start
Exhaust S m o ke) , Engine S h uts (With or Without Exhaust
Off or D i es U n expected ly or Dies S mo ke) , E ng ine S h uts Off or
During Decel e rat i o n , or Engine D i es U nexpectedly o r Dies
Starts but Will N ot Keep D u r i n g Deceleration, or E n g i n e
Running. Starts but W i l l Not Keep
R u n n i ng?
STEP 2 B : Engine Ru ns Rou g h a t I d l e , Is the e n g i n e sym ptom E ng ine

En g i n e Runs Rough or M isfires, R u ns Rough a t I d l e , Engine Ru ns
Engine S peed S u rges at Low or Rough or M i sfi res, Engine Speed
H i g h I d l e , E n g i n e Speed S u rges S u rges at Low or H i g h I d l e ,
under Load o r in Operating Eng i n e Speed S u rges u nder
Range. Load o r i n O pe rating Range?
STEP 2C: S m o ke , B l ack - Excessive . I s the e n g i n e sym ptom S m oke ,

Black - Excessive?
STEP 2 D : S m o ke , W h ite - Excessive . Is the e n g i n e symptom S m oke ,

W h ite - Excessive?
STEP 2D-1 : Smoke , Wh ite - Excessive . Is the e n g i n e using coolant?
STEP 2D-1 : S m o ke , W h ite - Excessive. Is the w h ite smoke excessive

c om p l a int only occurring when
th e e n g i n e is cold and d u ring
cold ambient conditions?
STEP 2 E : E n g i n e Accel e ration o r I s the e n g i n e sym ptom - E ng ine

Response P o o r , E n g i n e Power Accel e ration or Response Poor,
Output Low, E n g i n e Decelerates Engine Power Output Low,
Slowly, I n take Man ifold Press ure Eng i n e Decelerates S l owly,
(Boost) is Below Normal o r I ntake Man ifold Pressu re (Boost)
E n g i n e W i l l Not Reach Rated is Below Normal or E ng ine W i l l
S peed (RPM). N ot Reach Rated Speed (RPM)?
STEP 2F: Engine v i b ration is excessive . Is the e n g i n e symptom - Eng i n e

V i b ration Excessive?
STEP 3: E n g i n e w i l l not start or stalls trou bleshoot i n g proced u res .

STEP 3A: Verify the operation of cold Are the necessary cold weather
weather start i n g aids. start i n g aids being used and are
they operational as req u i red?
STEP 3B: Check e l ectro n i c featu res and Are electronic featu res and
prog ram mable parameters. prog ram mable parameters the
cause for the e n g i ne shutting
down o r the no-start complai nt?
STEP 3C: M o n itor the e n g i n e speed d u ri n g Is the e n g i n e speed g reate r than

cran king . 1 50 rpm during cran king?
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooti ng Tree - 158, ISBe, an [ . . . J
Section TT - Troubleshooti ng Symptoms (New Format) Page TT-57
STEP 3 D : M o n itor t h e ECM keyswitch Does the U s e r F u e l i n g State

i n pu t . i n d i cate Cranking or is keyswitch
voltage equal to battery voltage?
STEP 3 E : Mon itor the ECM batte ry supply. Is the ECM battery supply
voltage g reater than + 1 1 -VDC
for 1 2-vol t systems o r + 22-VDC
for 24-vo lt syste ms?
STEP 3 F : Check the l oad carry i n g Do the head l i g hts i l l u m i nate

capabi l ities of the E C M powe r brightly?
and ground c i rcu its.
STEP 3G: Check orientation of connector. Is the sensor correctly i nstal led?
STEP 3 H : Verify rai l fuel press u re sensor Is the Fuel Rai l P ress u re
accu racy . (measu red) l ess than 30 bar [435
psi]?
STEP 3 1 : M o n itor fuel rai l press u re w h i l e Did the Fuel Rai l Press u re
c r a n k i n g the e n g i n e . (measu red) equal the Fuel Rai l
Pressu re (com m anded)?
STEP 4: Fuel system tro u b l eshoot i n g p roced u res .

STEP 4A:
Check for a i r i n the fuel supply Is ai r present i n the fuel su pply?
l ine.
STEP 48:
C h e c k f o r a i r i n the h i g h Is the p ress u re measu red w i t h i n
press u re p u m p fuel supply. specification?
STEP 48-1 : M easu re t h e fuel i n l et Is the pressure measu red with i n

restriction . specification?
STEP 4 C : M easu re fuel p ressure a t t h e Is the p ress u re d rop across the

outlet of the o n e n g i n e f u e l fi lter. filter g reate r than the
specification?
STEP 4D: Perform I NSITE™ e lectro n i c Can the m i ss o r excessive

service t o o l s i n g l e cyl inder smoke be attributed to a s i n g l e
cutout test . cyl i nde r?
STEP 4E: Perform a manual s i n g l e D i d the e ng ine start after

cyl inder cut-out test. blocking off a cyl inder(s) or can
the m iss or excessive smoke be
attri buted to a cyl i nde r(s)?
STEP 4F: M easu re the i njector return fuel Is i njector fuel d rain flow from
drain flow from the cyl inder the cyl i nder head g reater than
head . specification?
STEP 4G: Determ i n e w h i c h cyl inder(s) is Did blocking off a cyl i nde r(s)
causi ng excessive i njector fuel decrease the flow rate below the
drain flow from the cyl i nder m ax i m u m specified flow rate?
head.
STEP 4H: M easu re fuel d ra i n l i ne Is the d rain l i ne restriction l ess

restriction . than specification?
STEP 5: A i r handl ing tro u b l eshoot i n g proced u res .

STEP 5A: C he c k i ntake man ifo l d p ressu re I ntake man ifold p ress u re read i ng
sensor accu racy. is l ess than 1 02 m m- H g [4 i n
Hg]?
STEP 58: Check the a i r i ntake system for Were any air intake system leaks
leaks. found?
STEP 5 C : Check a i r i ntake restriction . Is the a i r i ntake restriction

g reater than the specification?
Engine Performance Troubleshooting Tree - ISB, ISBe, an [ . . . J ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J
Page TT 58
- Section TT - Troubleshooti ng Symptoms (New Format)
STEP S D : I nspect t h e tu rbocharger Damage found on tu rbocharger

compressor b l ades for damage. blades?
STEP S E : Dete r m i n e if the tu rbocharger i s Is the tu rbocharger a wastegated

a wastegated tu rbocharger. tu rbocharg e r?
STEP S F : I nspect the wastegate actuator Holes or cracks fou n d i n the

hose . wastegate actuato r hose?
STEP S G : I nspect the tu rbocharger Did the wastegate actuator

wastegate capsu l e for a i r leaks. caps u l e leak a ir?
STEP SG-1 : I nspect t h e tu rbocharger Did the wastegate actu ator rod
wasteg ate for proper m ove?
o perat i o n .
S T E P SG-2 : I nspect t h e tu rbocharger Does the wastegate actuator rod

wastegate for proper m ove?
operat i o n .
STEP SH:
M easu re tu rbocharger axial and Are th e axial and rad ial
rad ial clearance. c l earances with i n specification?
STEP S I :
I nspect t h e charge a i r cooler. Does the charge a i r cooler pass
the visual i nspection as wel l as
the p ress u re test and
temperatu re d ifferential test?
STEP 6: Verify electro n ic featu res are operat i n g correctly.

S T E P 6A: Verify accel erator (th rottle) Does the accel erator (th rottl e)
pedal t ravel . position read 0 percent when the
accelerator (th rottl e) is fu l ly
released and 1 00 percent when
the accelerator (th rott l e) is fu ll y
depressed?
STEP 68: M o n itor t h e ve hicle speed . Does the veh i c l e speed read zero
when the vehicle is not movi ng?
STEP 6 C : Verify e l ectro n i c feat u re settings Are e lectro n i c featu res set
are correct. correctly?
STEP 6D: Check temperatu re sensor Are all temperatu re read ings
accu racy . with i n S . 6 ° C [ 1 0 ° F] of each
other?
STEP 6 E : Check ambient a i r p ressu re I N S I T ETMe lectronic service tool

sensor accu racy. read i n g is with i n SO.8 m m- H g [2
i n-Hg] of local barometric
p ressu re?
STEP 7: Pe rfo rm base e n g i n e mechanical chec ks .

S T E P 7A: Verify overhead adj ustments are Are t h e overhead settings with i n
correct. t h e lash check l i m i ts?
STEP 78: Check exhaust restriction . Is the exhaust back press u re

g reate r than the specification?
STEP 7C: Verify e n g i n e c ran kcase Is the e ng ine crankcase press u re

press u re (bl owby) is wit h i n (blowby) less than specification?
specification .
STEP 7D: Check for i nternal e n g i n e Did cutt i n g the o i l filter open
damag e . reveal evidence of i nternal
e n g i n e damage?
STEP 8: Excessive vibrat i o n c h ec ks .

ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J Engine Performance Troubleshooti ng Tree - ISB, ISBe, an [ . . . J
Section TT - Troubleshooti ng Symptoms (New Format) Page TT-59
STEP BA: Check engine i d l e speed . Is th e e n g i n e idl e speed with i n

specification?
STEP B 8 : Check if the feat u re Fast I d l e Is th e feat u re Fast I d l e W a r m U p

Warm U p is ava i l able a n d avai lable and e nabled?
enabled .
STEP B8- 1 : M o n itor if the Fast I d l e

Is the feat u re Fast I d l e W a rm U p
W a r m U p Status.
beco m i ng active?
STEP B C : C h e c k front e n g i n e driven Did isolating the front e n g i n e

accessory(s}. d riven accessory(s} correct th e
v i b ration?
STEP B D : Check the v i b ration damper/ Is th e vi bration damper/

crankshaft speed i n d icator r i n g . crankshaft speed i n d i cator ring
damaged?
STEP B E : C h e c k the e n g i n e su pport Are th e e ng ine suppo rt b rackets ,

b rackets, m o u nts , and/or mou nts, and/or isolators or
isolators. damaged?
STEP BF: Check e n g i n e gear d riven Does the e ng ine have an e n g i n e

accessory(s}. gear d riven/a ir compressor
d riven hyd rau l i c p u m p?
STEP BF- 1 : Isol ate e n g i n e gear d riven Did iso l at i ng/remov ing e n g i n e
accessory(s}. gear d riven/a i r compressor
d riven hyd rau l i c p u m p correct
the v i bration?
STEP BF- 2 : C h e c k if the e n g i n e is

Is the e ng ine e q u i pped with an
eq u i p ped with an air
e n g i n e gear d riven a i r
co m p resso r.
com p ressor?
STEP BF-3 : U n l oad the a i r compresso r Did u n load i n g the a ir

and o pe rate . compressor sign ificantly red uce
o r e l i m i nate the vi bration?
STEP BF-4 : Check a i r compresso r

Was the air compressor
timing.
correctly ti med to the e n g i ne?
STEP B G : Check/isol ate e n g i n e d riven Did isolat i n g/remov ing any

com ponents. e n g i n e d riven component
correct the v i b ration?
STEP B H : Check t h e flywheel housing Is the flywheel housing bore and

a l i g n ment. face runout wit h i n specification?
STEP B I : Check i f e n g i n e i s e q u i pped with Is the engine e q u i pped with an

an i nternal engine balancer. i nternal engine balancer?
STEP B I - 1 : Check the i nternal e n g i n e Is th e i nternal e n g i n e balancer

balance r. t i m i n g incorrect or is the
balancer damaged?
Engine Performance Troubleshooting Tree - ISB, ISBe, an [ . . . ] ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . ]
TROU BLESHOOT I N G STEP
STEP 1 : Perfo rm basic trou bleshoot i n g procedu res .

STEP 1 A Ch ec k f or active fau I t co des o r h'lalh coun t s 0 f .macfIve fau I t co d es.
Co ndit i o n :
• Tu rn keyswitch ON.
Check for any active fau lt code . Active fau lt codes or high cou nts o f i n active Repai r
• Use I N S ITE™ electronic service tool to read the fau lt codes? complete
fau lt codes. YES
• See the corresponding Electronic Control
System Troubleshooting and Repai r Manual Repair:

for the engine being serviced . Follow the electronic fau lt code trees for the
• For engi nes eq u i pped with a CM800 Electronic
appropriate troubleshooting proced u res.
Control Mod u l e , refer to B u l l eti n 3666477.
• For engi nes eq u i p ped with a CM850 Electronic
Control Mod u l e , refer to B u l leti n 402 1 4 1 6 . Active fau lt codes or high cou nts of i n active Go to 1 B
fau lt codes?
NO
STEP 1 B Perform basic t rou b l eshootma checks.
Cond i t i o n :
Action S pecification/Repa i r N ext Step
The fol lowi ng items m ust be checked or verified All steps h ave been verified to be correct? Go to 2A
before conti n u i n g : YES
• Verify t h e f u e l l evel i n the tanks.
• Verify the veh icle is in good worki ng order
• Check if any recent mai ntenance or service

All steps h ave been verified to be correct? Repai r
work h as been performed NO complete
• Verify there have not been any changes to
Repair:
C P L components on the engine.
• Verify fuel g rade is correct for the appl ication. Correct the step and verify com plaint is no
• Verify the engine is operating with i n the longer p resent after repai r.
reco m mended altitude.
• Verify the engine o i l is i n good cond ition and
at the correct leve l .

• Verify t h e e n g i n e parasitics have not changed .
• Verify the engine d uty cycle h as not changed .
• Verify the air fi lter is not excessively pl ugged
by checki ng filter m i nder.

• Listen for air and exhaust leaks.
• Verify there are no visible external fuel leaks .
• Verify there are no visi ble coolant leaks.
• Verify the crankshaft position and the
camshaft position sensors are correctly
con nected to the engine harness.
ISB, ISBe2 , ISBe3 , ISBe4, aSB4 [ . . . J Engine Performance Troubleshooting Tree - ISB, ISBe, an [ . . . J
STEP 2: Dete r m i nat i o n of e n g i ne sym ptom .

STEP 2 A : E n g i n e D iffic u l t t o Start o r W i l l Not Start (With o r Without Exhaust S m o ke) , Engine S h u ts Off
or D i es U n expected ly or D i es During Decelerat i o n , or Engine Starts but W i l l Not Keep
Runnm . a
Cond ition:
I nterview the d river and verify the com plaint. Is the engine sym ptom Engine Difficult to Perform the
Start o r Will Not Start (With o r Without troubleshooti
Exhaust Smoke), Engine S h uts Off or Dies ng steps
U n expectedly or Dies D u ring Deceleration , o r suggested i n
Engine Starts but Wi l l Not Keep R u n n ing? the repai r
YES proced u re .
Repa ir:
Perform the troubleshooting steps i n the

Step 3 Engine wi l l Not Start or Stal ls
-
Trou bleshooting Proced u res

Step 4 - Fuel System Checks
Step 5 Air H and l i n g Checks
-
Step 6 - Electron ics Checks
Is the engine sym ptom Engine Difficult to Go to 2B

Start o r Wi l l Not Start (With or Without
Exhaust Smoke) , Engine S h uts Off or Dies
U n expectedly or Dies D u ri ng Deceleratio n , or
Engine Starts but Wi l l Not Keep R u n n i ng?
NO
Page TT -62 Section TT - Troubleshooting Symptoms (New Format)
STEP 2 B : Engine R u n s Rou g h a t I d l e , Engine R u n s R o u g h or M isfires, E n g i n e S peed S u rges a t Low o r

H i a h I d l e Enaine Speed S u raes under Load o r i n Operatina Ranae.
Cond i t i o n :
I nterview the d river and verify the com pl ai nt . Is the engine sym ptom Engine Runs Rough Perform the
at I d l e , E n g i n e R u ns Rough or M isfi res , troubleshooti
Engine S peed S u rges at Low or H i g h I d l e , ng steps
E n g i n e S peed Su rges u n d e r Load or i n suggested i n
Operating Range? t h e repair
YES proced u re .
Repair:
Perform the troubleshooti ng steps in the

reco m mended o rder listed below:
Step 6 - E lectronic Checks
Step 5 - Air H and l i ng Checks
Step 7 - Base Engine Checks
Is the engine sym ptom Engine Runs Rough G o to Step

at Idle, Engine R u ns Rough or M isfi res , 2C
Engine S peed Su rges at Low or H i g h I d l e ,
Engine S peed S u rges u n d e r Load o r i n
Operating Range?
NO
STEP 2 C · S m o ke Black - Excessive
Cond i t i o n :
I ntervi ew the d river and verify the complaint. Is the engine sym ptom Smoke, Black - Perform the
Excessive? troubleshooti
YES ng steps
suggested i n
Repai r: t h e repai r
Step 6 - E lectron i cs Checks
Is the engine sym ptom Excessive Wh ite G o to Step

Smoke and is the engine using coolant? 2D
NO
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ] Engine Performance Troubleshooti ng Tree - ISB, ISBe, an [ . . . ]
STEP 2 0 ' S m o ke Wh ite - Excessive
Cond ition:
I nterview the d river and verify the com plaint. Is the e n g i n e sym ptom Smoke , Wh ite - Go to Step
Excessive? 20-1
YES
Is the e n g i n e sym ptom Smoke , Wh ite - Go to Step

Excessive? 2E
NO
STEP 2 0 - 1 ' S m o ke W h ite - Excessive
Cond ition:
I nterview the d river and verify the com plaint. Is the engine using coolant? See the
Verify if, along with the wh ite smoke com plaint, YES Coolant Loss
coolant is bei ng used . - I nternal
Troubleshoot
Check the coolant leve l .
ing Sym ptom
(TS) Tree .
Is the engine using coolant? Go To Step

NO
20-2
Engine Performance Troubleshooting Tree - IS8, IS8e, an [ . . . J IS8, IS8e2, IS8e3 , IS8e4, QS84 [ . . . J
STEP 2 0-2' S m o ke W h ite - Excessive
Cond i t i o n :
Action S pecification/Repa ir Next Step
I nterview the d river and verify the com plaint. Is the wh ite smoke excessive com plaint o n ly Perform the
occu rri ng when the engine is cold and d u ring troubleshooti
Check if the wh ite smoke excessive com plaint is
cold ambient cond itions? ng steps
only occu rring when the engine is cold and
YES suggested i n
d u ring cold ambient cond itions?
t h e repair
Some wh ite smoke after a cold start i n cold Repair: proced u re .
am bient conditions is not u ncom mon . If wh ite Perform the checks in Step 3A only.
smoke persists once the engine has reached the
m i n i m u m operati ng cool ant temperatu re , Step 4 - Fuel System Checks
troubleshoot the wh ite smoke com plaint. Step 6 - Electronics Checks
M i n i m u m Operating Coolant Tem perature: 60°C
[ 1 40 ° Fj. Is the wh ite smoke excessive com plaint o n ly
occu rri ng when the engine is cold and d u ri n g
cold ambient conditions?
NO
Repa ir:

recom mended o rder listed below:
Step 7 - Electronics Checks
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooti ng Tree · ISB, ISBe, an [ . . . J
Section TT Troubleshooting Symptoms (New Format)

• Page TT·65
STEP 2 E : En g i n e Accel e ration o r Response P o o r , E n g i n e Power Output L o w , E ng ine Decelerates

S lowly, Inta ke Man ifo l d Press u re (Boost) is Below Normal or Eng i n e W i l l Not Reach Rated
S Deed (RP M),
Cond i t i o n :
I nterview the d river and verify the com plaint. Is the engine sym ptom Engine Accel eration Perform the
or Response Poor, Engine Power Output troubleshooti
Low, Engine Decelerates Slowly, I ntake ng steps
Manifold P ressu re (Boost) is Below N o rmal or suggested i n
Engine Wi l l Not Reach Rated S peed (RPM)? t h e repai r
YES proced u re .
Repai r:
Perform the troubleshooti ng steps i n the

reco m m ended order l i sted below:
Step 5 Air H and l i n g Checks
•
Step 4 • Fuel Systems Checks

Step 6 • E lectronic Checks
Step 7 • Base Engine Checks
Is the engine sym ptom Engine Acceleration Go t o Step

or Response Poor, Engine Power Output 2F
Low, Engine Decelerates Slowly, I ntake
Manifold P ressure (Boost) is Below N o rmal or
Engine W i l l Not Reach Rated S peed (RPM)?
NO
Page TT 66- Section TT - Troubleshooti ng Symptoms (New Format)
STEP 2 F I ratlon - Excesslve

E name V'b
Cond i t i o n :
Act i o n Specification/Repai r N ext Step
I nterview the d river and verify the com plaint. Is the engine sym ptom Engine Vibration Perform the
YES ng steps
suggested i n
Repair: the repai r
Perform the tro u bleshooti ng steps i n the proced u re .
reco m mended order listed below:
Perform Step 4E of the Fuel System Checks
Step 8 - Excessive Vibration Checks
Is the e n g i n e symptom Engine Vibration
Excessive?
Is the engine sym ptom Engine Vibration For engine

Excessive? related
NO
sym ptoms,
see the
correct
troubleshooti
ng sym ptom
(TS) tree .
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ] Engine Performance Troubleshooting Tree - ISB, ISBe, an [ . . . ]
STEP 3: Eng i ne w i l l N ot Start o r Sta l l s T ro u bleshoot i n g P rocedu res

STEP 3A: Verify the o De ration of cold weather aids.
Cond ition:
• Engine and Amb ient Conditions Cold
• Keyswitch O N .
Action S pecification/Repair Next Step
Make sure that necessary cold weather starting Are the necessary cold weather starting aids Go to Step
aids are operational as req uired : being used and are they operational as 3B
req u i red?
Note: M i n i m u m Ambient Air Temperatu re for
U naided Cold Start is m i n us 1 2. 2 ° C [ 1 0 ° F] . YES
Note: The I N S ITETM electronic service tool I ntake

Air H eater Override test can be used to d i agnose Are the necessary cold weather starting aids Repai r
i ntake ai r heater p roblems. For engi nes eq u i pped being used and are they operational as complete
with air i ntake h eaters, the air i ntake heaters req u i red?
should beg i n to fu nction at 1 9 ° C [66 OF] . NO
Repai r:
I nstall or repai r cold weather start i n g aids.

Refer to Proced u re 008-0 1 1 (Cool ant H eater)
i n Section 8 i n the Service Man ual , I S B e , I S B ,
and a S B (Co m mon Rail Fuel System ) ,
Bul leti n 402 1 271 . Refer t o P roced u re
007-00 1 (Engine Oil Heater) i n Section 7 i n
Section 8 i n t h e Service Man ual , I S B e , I S B ,
a n d a S B (Co m mon Rail Fuel System ) ,
Bul leti n 402 1 271 . F o r a n y OEM i nstal led cold
starting aids (rad iator sh utters , etc . ) , refe r to
the OEM i nstructions.
STEP 3 8 . feat u res an d progra m m a b le parameters.

Ch ec k e i ect romc
Cond ition :
• Keyswitch ON .
Check if the e lectronic featu res and Are electronic featu res and programmable Repai r
programmable parameters are the cause for the parameters the cause for the engine sh utting Complete
engine sh utting d own or the no-start complaint. down or the no-start complai nt?
The electronic featu res and p rog ram mable YES
parameters include: I d l e S h utdown , Engine Repa ir:
Protection S h utdown , and Veh icle Anti-theft
Protection . Prog ram the electronic featu res per the
customer or OEM req u i rements.
Are el ectronic featu res and p rog ram mable Go to Step

parameters the cause for the engine sh utting 3C
down or the no-start complai nt?
NO
Engine Performance Troubleshooting Tree - IS8, IS8e, an [ . . . J IS8, IS8e2 , IS8e3 , IS8e4, QS84 [ . . . J
STEP 3C Mon itor the enaine sDeed durina cranki na .
Cond iti o n :
• Keyswitch O N .
• Con nect I N S ITE™ electronic service tool .
• I N S ITE™ Mon itor
Act i o n S pecification/Repai r N ext Step
Mon itor the engine speed d u ring cranki n g . Is the engine speed g reater than 1 50 rpm Go to 3D
d u ring cran king?
U s e I N S ITETM electronic service too l .
YES
Attem pt t o start t h e e n g i n e ; engage t h e engine
starter for at l east 30 conti n uous seconds. Repair:
Note: Do n o t overheat the starter.

Note : Attempti ng to start the engine for 30 Is the engine speed g reater than 1 50 rpm See the
contin uous seconds also allows the fault code during cran king? Engine Will
logic time to ru n . If any fau lt codes become n o t Cran k or
NO
active , stop using this troubleshooti ng tree and Cranks
Repai r: Slowly
reference the corresponding fau lt code
troubleshooting tree . Find and correct the cause for low cran ki ng (Electric or
speed . Consider the batteries , engine Air Starter)
starting motor, d rive u n its, and accessory troubleshooti
loads. ng sym ptom
(TS) tree.
STEP 3 D M o n itor the ECM Kevswitch I n out.
Cond i t i o n :
• Keyswitch O N .
• E n g i n e not ru n n i n g
Action Specificati on/Re pair N ext Step
Mon itor User Fuel ing State and key switch while Does the User Fuel i ng State i n d i cate Go to Step
cran king the engine. Cran king or is keyswitch voltage eq ual to 3E
battery voltage?
Use I N S ITETM electronic service too l .
YES
Note : If t h e engine is i nterm ittently sh utting
down , User Fuel ing State can also be mon itored
d u ring engine shut down . Does the User Fuel ing State i n d i cate Repai r
"Cranki ng" or is keyswitch voltage eq ual to Com plete
If I N S ITE™ electronic service tool is not avai lable: battery voltage?
Disconnect the OEM harness fro m the ECM . NO
Turn keyswitch O N . Repai r:
Measure the signal voltage from t h e keyswitch Check the keyswitch battery supply circuit.
i n put sig nal wire of the OEM harness to the Refer to P roced u re 0 1 9-064 (Key Switch
engine b l ock g rou n d . Battery Su pply C i rcu it) in Section 1 9 . Repai r
Measure t h e keyswitch voltage with t h e or replace the OEM harness, keyswitch , o r
keyswitch i n t h e ON position a n d also with the check the battery con nections. Refer t o t h e
keyswitch i n the Cranking positio n . OEM troubleshooting a n d repai r m a n u a l for
the proper proced u res.
Consult t h e correspond ing wiring d i ag ram for the
engine being serviced for connector pin
identificatio n .
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J
Engine Performance Troubleshooti ng Tree - ISB, ISBe, an [ . . . J
Page TT-69
STEP 3 E : M o n itor the E C M Batte rv S U D Dlv.
Cond ition:
• Keyswitch O N .
• Engine n o t ru n n i n g
Mon itor Battery Voltage while cran king the

Is the ECM battery supply voltage greater Go to Step
engine.
than + 1 1 -VDC for 1 2-volt systems o r + 22 3F
VDC for 24-volt systems?
Use I N S ITE™ electronic service too l .
YES
If I N S ITE™ electronic service tool is n o t avai lable:
• D isco n nect the ECM power supply connectio n .
Is the ECM battery supply voltage greater Repai r
• T u r n keyswitch ON .
than + 1 1 -VDC for 1 2-volt systems o r + 22 complete
Measu re the voltage from the ECM battery VDC for 24-volt systems?
S U P P LY (-) pines) to the ECM battery S U P P LY NO
( + ) p i n es) i n the ECM con n ector.
Repai r :
Measure the ECM voltage with the keyswitch i n
t h e ON position a n d also with t h e keyswitch i n the Repai r o r replace the ECM power and g round
cran king positio n . connections. Check the battery con n ections
and fuse term i nals.
See t o t h e corresponding wiring d i ag ram for the
engine being serviced for con n ector pin
identificatio n .
S TEP 3 F : C heck the load carrvina caDab i l ities of the ECM Dower and around c i rcu its.
Cond ition:
• Keyswitch OFF.
• Disconnect the ECM power su pply con nector from the E C M .
Connect a head l ight ( 1 2-volt o r 24-volt systems) . Do the head l i g hts i l l u m i nate brig htly? Go to Step
YES 3G
Note: A head l ight m ust be used to make sure
that the wattage rating wi l l put enough of a load
on the c i rcuit. Do the head l i g hts i l l u m i nate brig htly? Repai r
Use the ECM battery S U P P LY ( + ) pin in the NO
complete
ECM power supply connection for the battery
Repai r :
positive ( + ) and the ECM battery S U P P LY (-) pin
i n the ECM power harness con nector for the Repai r o r replace the ECM power and ground
battery negative (-) . con nections. Check the battery con nections
Consult the corresponding wiring d i ag ram for the and fuse term i nals.
engine being serviced for con nector p i n
identificatio n .
STEP 3 G · C h e c k orientation of connecto r
Cond ition :
Action S pecificati on/Repa ir N ext Step
Check for the appropriate orientation of the rai l Is t h e sensor correctly i nstal led? 2C- 1
fuel p ressure sensor con nector. YES
NOTE: Con n ector can be i nstal l ed rotated 1 80
degrees . Is the sensor correctly i nstalled? 4A
NO
Repair:
Reorient connector.
STEP 3 H v e nt
·fv ral· 1 f ue pressu re sensor accu racy.
Conditi o n :
• T u r n keyswitch ON
• Connect I N S ITE™ electronic service tool
• I N S ITE™ Mon itor
• Engine not ru n n i n g .
Mon itor the fuel rail pressure. Is the Fuel Rail P ressure (measu red) less 31
than 30 bar (435 psi)?
Use I N SITE™ electronic service tool to measu re
the fuel rai l pressure. YES
Is the Fuel Rai l Pressure (measu red) less Repai r

than 30 bar (435 psi)? Complete
NO
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISB, ISBe, an [ . . . J
STEP 3 1 M o n itor f u e r a i l press u re w h i l e cran kina the ename.
Cond ition:
• Connect I N SITE™ electronic service tool
• I N S ITE™ Mon itor.
Mon itor Fuel Rail P ressure (measu red) and Fuel Did the Fuel Rail P ressure (measu red) equal SA
Rai l Pressure (co m manded). the Fuel Rail P ressure (co m m anded)?
Use I N S ITE™ electronic service tool . YES
NOTE: Fuel Rail P ressure (co m m anded) can also
be referred to as H PC R fuel setpoint. Did the Fuel Rai l Pressure (measu red) equal 4A
the Fuel Rai l Pressu re (com manded)?
Attem pt to start the engine, engage the engine

starter for at least 30 continuous seconds. NO
NOTE : Do n o t overheat the starter.

NOTE : A m i n i m u m of 1 00 bar [ 1 450 psi] of fuel
rai l pressure is req u i red before the i nj ectors wi l l
open a n d provide fue l .
NOTE : Attem pting t o start the engine f o r 30
contin uos seconds allows the fau lt code logic
time to ru n . I f Fau lt Code 221 5 or 559 becom es
active, adeq u ate fuel rai l p ressure is not being
developed . Discontinue using this
troubleshooti ng tree and troubleshoot Fau lt Code
22 1 5 or 559 .
Engine Performance Troubleshooting Tree - ISB, ISBe, an [ . . . ] ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ]
STEP 4: F u el system tro u b l eshoot i n g p roced u res.

STEP 4A: Check for a i r i n the fuel su I line.
Cond i t i o n :
• Keyswitch OFF.
• Engine OFF.
• Connect req u i red service tools at the gear pump i n l et .
Action S pecification/Repa ir N ext Step
Check for air i n the fuel Is air present i n the fuel supply? Repai r
Refer to P roced u re 006-003 (Ai r i n Fuel) in YES complete
Section 6 i n the Service Manual , I S Be , I S B , and Repai r:
aS B (Com mon Rail Fuel System) Series
Engi nes, B u l letin 402 1 271 . Operate the engine Locate and correct the cause of air i ngestion
at idle and check for air bubbles. If the engine will i n the fuel supply system . Sou rces of air
n o t start , check while cran king the engine. i ngestion i nclude loose fuel fi lters , loose fuel
line fittings, loose or cracked fuel tan k stand
Note: Do n o t overheat the starter. pi pes , o r severe restrictions i n the fuel supply
l i nes and fi lters that cause cavitation at h i g h
fuel flow rates.
Is air p resent in the fuel supply? Go to Step

NO 4B
158, IS8e2 , IS8e3 , IS8e4, QS84 [ . . . J Engine Performance Troubleshooti ng T ree - 158, IS8e, an [ . . . J
STEP 4 8 : M easu re fuel ress u re at the i n l et of the o n e n i n e fuel filter.
Cond ition:
• Keyswitch OFF.
• Engine OFF.
• Connect req u i red service tools at the i n let to the fuel filter, o r if eq u i pped , the fuel fi lter head diagnostic port
(i n l et) .
Check for air i n the fuel Is the pressure measu red with i n Go to Step
specification? N ote: Record t h e m easu red 4C
Refer to Proced u re 006-0 1 5 (Fuel Fi lter Spi n-On
fuel i n let pressure for use in the next step .
Type) in Section 6 in Service Manual , I S B e , I S B ,
a n d aSB (Common Rai l F u e l System) Series YES
Engi nes, B u l l etin 402 1 271 .
Measu re the fuel pressure at low i d l e : Is the pressu re measu red wit h i n Go to Step
specification? 4B-1
• F u e l p ressu re range: 5 to 1 3 b a r [ 7 3 to 1 89 psi ] .
NO
If t h e engine w i l l not start , measu re t h e fuel
pressure d u ri n g engine cran king
• Fuel p ressure range: 3 to 1 1 bar [44 to 1 60 psi ] .
Record t h e fuel fi lter i n l et p ressure m easu red .
OOd00 1 1 3
STEP 4 8- 1 : Measu re the fuel i n let restriction.
Cond i t i o n :
• Keyswitch OFF.
• Engine OFF.
• Connect req u i red service tools at the gear p u m p i n let.
Measu re the fuel i n let restrictio n . Is the fuel i n let restriction greater than the Repai r
specificatio n ? Complete
Refer t o Service Manual , I S 8 e , I S 8 , a n d aS8
(Common Rai l Fuel System) Series Engi nes, YES
8u l l etin 402 1 271 . Operate the engine at h i g h Repair:
idle:
Find and correct cause of high i n let
Maxi m u m i n let restriction - 50 . 8 kPa [ 1 5 i n-Hg] restriction . Look for plugged OEM fuel fi lters
(vacuum) or screens, or a restricted ECM cooler,
If the engine w i l l n o t start , m easu re fuel pi nched OEM fuel l i nes, or restricted stand
restriction wh i l e the engine is cran king. pipe i n the OEM fuel tan k.
Note: Do n o t overheat the starte r.
Is the fuel i n l et restriction g reater than the Repai r
N ot e :If the issue is i nterm ittent (no start or specification? Complete
engine sh uts off u n expected ly) and no issues can
be found w h i l e the engine is being serviced , there NO
can be debris i n the fuel system causing an Repai r:
i nterm ittent restriction . I nstal l a fuel fi lter m i nder,
Fl eetg uard™ Part N u m ber 3892576 , at the Replace the high pressure fuel p u m p . Refer
con nection between the OEM fuel supply l i nes to Proced u re 005-0 1 6 (Fuel P u m p) in the
and the engine. A fuel fi lter m i nder will captu re Service M an ual , IS8e, I S 8 , and aS8
the peak restriction in m i l l i m eters and i nches of (Common Rail Fuel System) Series Engines,
mercu ry. If the issue occu rs agai n , the fuel fi lter 8ulletin 402 1 271 .
m i nder can be checked to see if there is
someth i n g on the OEM side causing an
i nterm ittent high restrictio n .
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooti ng Tree - ISB, ISBe, an [ . . . J
STEP 4C M easure fuel D ressu re at the out et of the on ename fuel filter.
Cond ition:
• Keyswitch OFF.
• Engine OFF.
• Connect req u i red service tools at the outlet of the fuel filter, or if eq u i pped , the fuel fi lter h ead d i agnostic port
(outlet) .
Measure fuel pressu re at the outlet of the fuel Is the p ressu re d rop across the filter g reater Repai r
filter. than the specification? Complete
Refer to Proced u re 006-0 1 5 (Fuel Fi lter Spi n-On YE S
Type) i n Section 6 in Service Manual , I S B e , I S B , Repai r:
a n d aS B (Com mon R a i l F u e l System) Series
Engi nes , B u l letin 402 1 271 . Replace the fuel filter. Refer to P roced ure
006-0 1 5 (Fuel Fi lter Spi n-On Type) in Section
Calculate the p ressure d rop across the fuel fi lter 6 i n Service Manual, ISBe, ISB, and aS B
by subtracting the press u re m easu red h e re from (Common Rail Fuel System) Series Engines,
the p ressu re from Step 4 B . Bul letin 402 1 271 .
Measu re the f u e l press u re a t h i g h idle :
• M axi m u m press u re d rop across the fue l fi lter Is the p ressu re d rop across the fi lter g reater Go to Step
2 bar [29 psi ] . than the specification? 4D
If t h e e n g i n e wi l l not start , m easu re t h e fuel NO
pressure d u ri n g engine cran king
STEP 40: Perfo rm I N S ITE™ e l ectrO n i c service tool s ina l e cvl inder cutout test .
Cond i t i o n :
• Engine ru n n i ng at low i d l e .
If the engine wi l l not start or is d ifficult to start , Can the m i ss or excessive smoke be Repai r
move to the next step. attributed to a single cyl i nder? Complete
• I n the ECM Diagnostic Tests menu of I N S ITE™
YES
electronic service tool , click on the Cyl i nder
C utout Test , and fol low the instructions on the Repa ir:
scree n . Look for a cause of the complaint, i ncluding
• Operate the engine u nder the conditions i n
valve l ash and excessive cran kcase p ressure
w h i c h t h e com plaint occurs. that may i n d icate power cyl i nder damage or
• U se I NS ITE™ electronic service tool to perform
the Cyl inder C utout Test to d isable i n d ividual found , replace the fuel i njector i n the cyl i nder
i njectors. that was identified using the s i n g l e cyl inder
N ote: If this test is performed and there is not a cutout test . Refer to P roced u re 006-026
sign ificant change while cutting out one i nj ector, (I njector) in Section 6 in Service M anual ,
there can be a problem with more than one ISBe, I S B , and aSB (Common Rail Fuel
i nj ector. It may be necessary to cut out m u ltiple System) Series Engi nes , B u l l etin 402 1 271 .
cyl i nders at a time.
Can the m i ss or excessive smoke be Go to Step
attrib uted to a single cyl i nder? 4E
NO
STEP 4 E : Perform a m a n u a l s i n
Conditio n :
- T u r n keyswitch OFF.
- I nstall the i nj ector leakage isolation too l .
- Tu rn keyswitch ON .
Act i o n S pecificat ion/Re pai r N ext Step
Perform a manual cut-out test. Did the engine start after blocki ng off a Repai r
- With the engine not ru n n i n g , d isco n nect the cyl inder(s) or can the m iss or excessive Complete
fuel line ru n n i n g from the fuel rai l to cyl inder smoke be attrib uted to a cyl i nd e r(s)?
n u mber 1 . Refer to P roced u re 006-051 YES
(I njector Su pply Li nes - H ig h P ressu re) in
Section 6 i n Service Man ual , ISBe, ISB, and Repair:
aSB (Common Rail Fuel System) Series Look for a cause of the com plaint, i ncluding
Engines, B u l l eti n 402 1 271 . valve lash and excessive cran kcase pressu re
- I nstal l the i nj ector leakage isolation tool that can i n d icate power cyl i nder damage or
For 3 . 9 L and 5 . 9 L engi nes, i nstall the i nj ector camshaft lobe wear. If no other damage is
leakage isolation too l , Part N u m ber 3 1 64325 , on fou n d , replace the fuel i nj ector i n the cyl inder
the rai l where the n u m ber 1 cyl i nder fuel l i n e that was identified using the man ual single
con n ects . cyl inder cut-out test. Refer to P roced u re
006-026 ( I nj ector) i n Section 6 i n Service
Torq ue Val ue: 30 N - m [22 ft-Ib] Manual , I S B e , I S B , and aSB (Com mon Rail
For 4.5L and 6.7L engi nes, i nstall the leakage Fuel System) Series Engi nes, B u l l etin
isolation too l , Part N u mber 49 1 8298, on the rai l 402 1 271 .
where t h e n u m ber 1 cyl i nder f u e l l i ne connects.
Torq ue Val ue: 35 N - m [26 ft-Ib] Did the engine start after blocki ng off a Go to Step
cyl inder(s) or can the m iss or excessive 4F
Attem pt to start the engine or operate the engine smoke be attrib uted to a cyl i nde r(s)?
at i d l e.
NO
Repeat the above test , a s necessary, with each
cyl inder blocked off.
06d00259
STEP 4 F : M easu re the i njector return fuel d rain flow from the cvl inder head .
Cond i t i o n :
• Keyswitch OFF.
• Connect appropriate service tools to measu re i njector fuel d rain flow from the cyl inder head .
M easu re the i nj ector return fuel d rai n flow from Is i njector fuel d rain flow from the cyl i nder Go to Step
the cyl i nder head . head g reater than specification? 4G- 1
Refer to Proced u re 006-026 ( I nj ector) i n Section YES
6 of the ISBe, ISB, and aSB Service Manual ,
B u l leti n 402 1 271 .

Is i njector fuel d rain flow from the cyl i nder Go t o Step
Flow S pecification : head g reater than specification? 4H
I d l e Cond itions NO
4 cyl inder engi n es - 1 20 m l/m i n ute [4 fl-oz per
m i n ute) maxi m u m
6 cyl inder engi nes - 1 80 m l/m i n ute [ 4 fl-oz per
m i n ute) maxi m u m
Cran king Conditions
NOTE: M ake sure not to overheat the starter.
4 and 6 cyl inder engi nes - 90 m l/ m i n ute [3 fl-oz
per m i n ute) maxi m u m .

STEP 4G : Determ i ne w h i c h cyl inder(s) is causing excessive i njector fuel d rain flow from the cyl inder
head
Cond i t i o n :
• Keyswitch OFF .
• Connect appropriate service tools to measu re i nj ector fuel d rain flow from the cyl inder head .
• I nstall the i njector leakage isolation too l .
Measure the i njector retu rn fuel d rain flow from Did blocki ng off a cyl inder(s) decrease the Repai r
the cyl inder head and isolate a cyl inder one at a flow rate below the m axi m u m specified flow Complete
time using the i nj ector leakage isolation too l . rate?
Refer to Proced u re 006-026 (I njector) in Section YES
6 of the I S B e , I S B , and aSB Service Man ual, Repai r:
B u l letin 402 1 271 .
Remove t h e fuel con nector a n d i nspect for
The flow rate wi l l decrease below the maxi m u m damage. Replace if necessary. Remove the
specified flow when the cyl i nder with the leak is i njector and i nspect the fuel con nector
blocked . contact su rface for damage. Replace if
N ote: If this test is performed and there is n o t a necessary. Refer to Proced u re 006-052 (Fuel
sign ificant change in fuel return flow while cutting Connector (H ead Mou nted» i n Section 6 in
out one i njector, there can be a problem with the ISBe, I S B , and aSB Service Man ual ,
more than one i njector. Com pare the fuel flow Bulleti n 402 1 271 . Refer to Proced u re
d ifference across al l i nj ectors. Is there more than 006-026 ( I nj ector) in Section 6 i n the I S B e ,
one i nj ector that caused a noticeable decrease i n I S B , a n d aSB Service Manual , B u l leti n
fuel flow? If so , these could be the i njectors with 402 1 27 1 .
the prob lems.
Another cause of this problem could be that the Did blocki ng off a cyl inder(s) decrease the Go to Step
customer is operating on fuels l i g hter than flow rate below the maxi m u m specified flow 4H
specified . Fuels with low viSCOSity will result in rate?
h igher i njector leakage and g reater d rai n flow NO
rates.
STEP 4 H ' M easu re fuel d ra i n l i ne restriction
Cond ition:
• Keyswitch off
• Connect appropriate service tools to m easure fuel drain l i n e restriction
Acti o n S pecificat ion/Repair N ext Step
Measure the fuel i n let restriction. Is the d rai n l i n e restriction l ess than Perfo rm next
specification? troubleshooti
Refer to Proced u re 006-0 1 2 (Fuel D rai n Line
YES ng proced u re
Restriction) in Section 6 of the Service Man ual ,
as outl i ned i n
ISBe, I S B , and aSB (Common Rail Fuel System)
Step 2.
Series Engi nes, B u l leti n 402 1 271 .
Operate the engine at high idle: Is the d rain l i n e restriction less than Repai r
Maxi m u m fuel d rain l i n e restrictio n : 0 . 1 9 bar (2 . 7 specification? Complete
psi). NO
Repair:
Check OEM fuel d rai n l i nes to tan k fo r proper

size , l eaks , bends, clogs and fuel tan k vents
for p l u g g i n g .
STEP 5: Ai r hand l i ng t ro u b l eshoot i n g proced u res.

S T EP 5A: Check i ntake man ifold D ress ure sensor accu racv .
Con d i t i o n :
• Keyswitch ON
• E n g i n e OFF.
Mon itor the read i n g for i ntake man ifold pressu re I ntake man ifold pressu re read i n g is less than Go to Step
with the engine OFF. 1 02 mm-Hg [4 in-Hg]? 5B
Start I N S ITE™ electronic service tool data YES
mon itorllogger and monitor the tool read ing for Repa i r :
i ntake man ifold p ress u re with the engine OFF.
I ntake man ifold pressu re read i n g is less than Repai r

1 02 mm-Hg [4 in-Hg]? complete
NO
Repa ir:
Replace the i ntake man ifold pressu re sensor.

If eq u i pped with a com bination I ntake
Man ifold P ressu relTem perature Sensor,
refer to Proce d u re 0 1 9- 1 59 (I ntake Man ifold
Pressu relTem peratu re Sensor) i n Section
1 9.
STEP 5 B : Ch ec k the A"Ir I nta ke Sivstem for Leaks.
Cond ition:
Check the ai r i ntake system for leaks Were any air i ntake system leaks fou n d ? Repai r
YES
complete
Refer t o Proced u re 0 1 0-024 (Ai r Leaks , Ai r I ntake
and Exhaust Systems) in Section 1 0 of the Repai r:
Service Manual , ISBe, ISB, and aSB (Com mon
Rai l Fuel System) Series Engi nes, B u l letin Repai r or replace the damaged com ponent.
402 1 271 . Note: On engi nes eq u i pped with a
tu rbocharged air compressor, one often Were any air i ntake system leaks fou nd? Go to Step
overlooked item as a sou rce for air leaks is the 5C
NO
ai r com p ressor i ntake l i n e . The i ntake l i ne
suppl ies i ntake air fro m the i ntake of the engine
to the air com p ressor.
Engine Performance Troubleshooti ng Tree - ISB, ISBe, an [ . . . J ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
STEP 5 C : C h e c k a i r i ntake restrict i o n .
Conditi o n :
• Engine running a t rated speed a n d full load .
Action Specification/Re pair N ext Step
Check the air i ntake restriction by i nstal l i ng a Is the air i ntake restriction greater than the Repai r
vacuum gauge (Cu m m i ns® Part N u m ber specification? Com plete
ST- 1 1 1 1 -3) i nto the air i ntake system . YES
Refer to P roced ure 0 1 0-03 1 (Ai r I ntake Repa i r :
Restriction) in Section 1 0 of the Service Manual ,
I S B e , I S B , and aSB (Common Rail Fuel System) Correct the cause of h i g h i ntake air
Series Engi nes, B u l leti n 402 1 271 . restrictio n . Check for a plugged air filter o r
restricted air i ntake p i p i n g .
Maxi m u m Air I ntake Restriction :
Di rty Fi lter Is the air i ntake restriction g reater t h a n t h e Step 5D
635 mm-H 20; [25 i n- H 20] specification?
NO
Clean Fi lter
254 mm-H 20 ; [ 1 0 i n-H 20]
OOd00109
Engine Performance Troubleshooting Tree · ISB, ISBe, an [ . . . J
Section TT · Troubleshooting Symptoms (New Format)
Page TT·81
STEP 5 0 : I n s ect t h e tu rboc har
Cond i t i o n :
• Turn engine OFF.
• Remove the i ntake piping from the tu rbocharger.
I nspect the com p ressor blad es for damage or

Damage fou n d on tu rbocharger blad es? Repai r
wear.
YES
Complete
Refer to the Service Manual , I S B e , I S B , and aSB Repa ir:
(Common Rai l Fuel System) Series Engi nes,
Bul leti n 402 1 271 . Replace the tu rbocharger assembly. Refer to
Proced u re 0 1 0·033 (Tu rbocharger) i n Section
1 0 of the Service Manual , ISBe, I S B , and
aS B (Co m m o n Rai l Fuel System) Series
Engines, B u l l eti n 402 1 271 .
Damage found on tu rbocharger blad es? Go to Step

NO
5E
S TE P 5 E : Determ i n e if the tu rbocharaer is a wastea ated tu rbocharaer.
Cond ition:
Determ i n e if the tu rbocharger is a wastegated Is the tu rbocharger a wastegated 5F

tu rbocharger. tu rboch arger?
YES
Repa ir:
Is the tu rbocharger a wastegated Go to Step

tu rboch arger? 5H
NO
STEP SF: I n s ect the waste ate actuator hose.
Cond i t i o n :
• Remove the tu rbocharger if the wastegate actuator is i n accessible.
Action S pecification/Re pair Next Step
I nspect the i ntegral wastegate actuator hose for Holes or cracks found in the wastegate Repai r
cracks or holes. actuator hose? com plete
Refer to P roced ure 0 1 0-050 (Tu rbocharger YES
Wastegate Actu ator) i n Section 1 0 of the Service

Repa ir:
Manual , I S B e , I S B , and aSB (Common Rai l Fuel
System) Series Engi nes, B u l l et i n 402 1 271 . Replace the wastegate actuator h ose . Refer
to Proced u re 0 1 0-050 (Tu rbocharger
Wastegate Actuator) i n Section 1 0 of the
Service M anual , ISBe, I S B , and aS B
(Com mon Rail Fuel System) Series Engi nes,
B u l letin 402 1 271 .
Holes or cracks found in the wastegate 5G

actuator hose?
NO
OOdOO 1 07
STEP 5 G : Ins
Cond ition:
• Engine OFF.
• Remove the wastegate actuator h ose from the wastegate actuator.
Perform a leak test on the wastegate actuator Did the wastegate actuator capsule l eak air? Repai r
caps u l e . YES
com plete
Refer t o Proced u re 0 1 0-050 (Tu rbocharger Repai r:
Wastegate Actuator) i n Section 1 0 of the Service
Manual , ISBe, I S B , and aSB (Co m m o n Rail Fuel Replace the wastegate actu ator. Refer to
System) Series Engi nes, B u l l et i n 402 1 271 . P roced u re 0 1 0-050 (Tu rbocharger
Wastegate Actuator) in Section 1 0 of the
Use C u m m i ns® too l , Part N u m be r 3823799, to Service Man ual , ISBe, I S B , and aSB
apply a reg u l ated air supply of 59 in-Hg (29 psi) (Common Rail Fuel System) Series Engi nes,
to the wastegate actuator caps u l e . N o air should B u l leti n 402 1 271 .
be h eard (L e . , leaking noise) t h rough a fu nctional
wastegate caps u l e .
Did the wastegate actuator capsule leak air? 5G- 1
NO
STEP 5G-1 :
Cond i t i o n :
• Engine OFF.
• Remove the wastegate actuato r hose from the wastegate actuator.
Action S pecification/Repai r N ext Step
Check for wastegate actuator rod for movement. Did the wastegate actuator rod m ove? Go to Step
YES 5H
Refer to Proced u re 0 1 0-050 (Tu rbocharger

Manual , ISBe, I S B , and aSB (Com mon Rail Fuel

Did the wastegate actuator rod move? 5G-2
System) Series Engi nes, B u l letin 402 1 271 .
NO
Use C u m m i ns® too l , Part N u m ber 382379 , to
apply a reg u l ated ai r supply of 59 i n-Hg (29 psi)
to the wastegate actuator capsule. Check for
wastegate actuator rod for movement.
OOd00 1 0 6
STEP 5G-2 :
Cond ition:
• Engine OFF .
• Remove the e-c l i p from the wastegate p i n and d isconnect the actuator rod from the wastegate lever.
Action Specification/Repa i r N ext Step
Check for wastegate actuator rod for m ovement Does the wastegate actuator rod m ove? Repai r
with it disco n nected from the tu rbocharger YES
Complete
wastegate .
Repai r:
Wastegate Actuator) in Section 1 0 of the Service Move the wastegate lever back and forth and
Man u al , I S B e , I S B , and aSB (Co m m o n Rai l Fuel check for smooth operation. If the wastegate
System) Series E n g i n es , B u l l et i n 402 1 271 . lever d oes not m ove freely o r b i nds, spray a
penetrating o i l on the wastegate lever j o i nt
Use C u m m i ns® Too l , Part N u m ber 3823799 , to and try to free the wastegate lever by worki ng
apply a reg u l ated air supply of 59 in-Hg (29 psi) the lever back and fort h . If the l ever does
to the wastegate actuator capsule. Check for not beco m e free, then replace the
wastegate actuator rod for m ovement. turbocharger. Refer to Proced u re 0 1 0-033
(Tu rbocharger) in Section 1 0 of the Service
Manual , I S B e , I S B , and aSB (Co m mon Rai l
Fuel System) Series Engi nes, B u l leti n
402 1 271 .

NO
Complete
Repa ir:

Service Man ual , ISBe, ISB, and aSB
(Common Rail Fuel System) Series Engi nes,
Bulletin 402 1 271 .
OOd00 1 08
Page TT 86
- Section TT - Troubleshooting Symptoms (New Format)
STEP 5 H . I and rad·l a I c I earance .

M easure tu rboch araer aXla
Cond iti o n :
• Engine OFF.
• Disconnect the exhaust and i ntake con nections from the tu rbocharger.
Fol low the proced u re for measuring the axial and Are the axial and rad ial cl earances wit h i n Go t o Step 51
rad ial clearances of the tu rbocharger. specification
Refer to P roced u re 0 1 0-033 (Tu rbocharger) in YES
Section 1 0 of the Service Manual, I S B , ISBe, and
aSB (Co m mon Rail Fuel System) Series Are the axial and rad ial clearances within Repai r
Engines, B u l leti n 402 1 27 1 .

See Clearance S pecifications: NO
Repair:
Replace the tu rbocharger assembly. Refer to

1 0 of the Service Man ual , ISBe, I S B , and
aS B (Co m mon Rail Fuel System) Series
STEP 5 1 : e a i r cooler
Cond ition:
I nspect the charge air cooler for clean l i n ess, Does the charge air cooler pass the visual Perform the
cracks , holes, o r other damage. i nspection as wel l as the pressu re test and next
temperatu re differential test? trou bleshooti
Note: The press u re test and the tem peratu re
YES ng proced u re
differential test i n Proced u re 0 1 0-027 (Charge-Ai r
as outl ined i n
Cooler) i n Section 1 0 of the Service Manual,
Step 2 .
ISBe, ISB, and aSB (Com mon Rai l Fuel System)
Series Engi nes, B u l leti n 402 1 271 , can be used to
verify charge air cooler problems. Does the charge air cooler pass the visual Repai r
inspection as wel l as the p ressu re test and com plete
NO
Repa ir:
Repai r or replace the charge air cooler

asse m b ly. Refer to Proced u re 0 1 0-027
(Charge-Air Cooler) in Section 1 0 of the
Service Manual , ISBe, ISB, and aSB
Bul leti n 402 1 271 .
OOd00 1 1 2
STEP 6: Verify electro n i c featu res are operat i n g correctly

S T E P 6A: Verify accele rator (th rottle) pedal travel .
Condition :
Mon itor accel erator (th rottle) position while fully Does the accelerator (th rottle) position read 0 68
depressing and releasing the th rottle pedal percent when the accelerator (th rottle) is fu l ly
released a n d 1 0 0 percent w h e n t h e
Use I N S ITE™ electronic service too l .
accelerator (th rottle) is fully depressed?
YES
Does the accelerator (th rottle) position read 0 Repai r

percent when the accel erator (th rottle) is fully Complete
released and 1 00 percent when the
accelerator (th rottle) is fully depressed ?
NO
Repair:
Refer to the OEM service manual for

accelerator (th rottle) pedal troubleshooting.
STEP 6 8 M omtor th e ve h ·IC I e SDee d
Cond itio n :
• Keyswitch O N .
Mon itor the vehicle speed while the vehicle is not Does the veh icle speed read zero w h i l e the 6C
moving vehicle is not movi ng?
• Use I N S ITE™ el ectronic service too l .
YES
Does the vehicle speed read zero w h i l e the Repai r

vehicle is not movi ng? complete
NO
Repair:
Verify the VSS parameters are adj usted

correctly in the ECM . Check the VSS and
OEM harness.
STEP 6C : . feat u re setti ngs are correc t .

v e m' fy e ectromc
Cond ition:
• Keyswitch O N .
• Connect I N S ITE™ el ectronic service too l .
Verify the fol l owing adj ustable parameters are Are el ectronic featu res set correctly? 6D
correctly set: YES
Use I N S ITE™ electronic service tool to verify:
• Maxi m u m ve hicle speed Are electronic featu res set correctly? Repai r
• Powertrai n p rotection NO Complete
• Rear axle ratio
• Transm ission tai lshaft teeth Repai r:
• Tire revol utions per m i l e Correct prog rammable features.
• G ear-down p rotection
• Cruise control d roop settings
• Cru ise control m axi m u m vehicle speed
• Accelerato r type
• Road speed governor
• Vehicle acceleration management
• Transm ission type.
STEP 60: C h e c k temDerature sensor accu racy .
Cond itio n :
• Keyswitch O N .
• Conn ect I N S ITE™ electronic service too l .
• T h e e n g i n e m ust be tu rned off l o n g enough for e n g i n e coolant temperatu re t o be eq ual t o amb ient a i r
temperatu re .
Mon itor the following temperatu res: Are al l tem peratu re read ings with i n 5 . 6 ° C 6E
[ 1 0 ° F] o f each other?
Use I N S ITE™ electronic service tool to verify:
YES
• Engine coolant tem perature sensor
• I ntake man ifold air tem perature sensor
• If eq u i pped , the tu rbocharger com p ressor i n let Are all tem perature read ings with i n 5 . 6 ° C Repai r
air tem peratu re sensor [ 1 0 ° F] o f each other? Complete
NO
Repa ir:
Check fo r a short from the sig nal pin of the

temperatu re sensor i n q u estion to all other
pins i n the harness. Refer to P roced u re
0 1 9-360 (Resistance Measurement Using A
M u ltimeter and a Wiring Diag ram) (pi n-to-pin
check) i n Section 1 9 . If no short is found ,
replace the tem peratu re sensor that is
read i n g h i g h e r or lower than the other
sensors . See Section 1 9 for specifications on
each temperatu re sensor.
STE P 6 E : C heck am b·l ent a i r press u re sensor accu racy.
Cond i t i o n :
• Keyswitch ON .
Action S pecification/Repa i r Next Step
Start the I N S ITE™ electronic service tool data I N S ITE™ electronic service tool read ing is Perform the
mon itor/logger. within 50. 8 m m-Hg [2 i n-Hg] of local next
barometric p ressu re? troubleshooti
Start I N S ITE™ electronic service tool data
mon itor/logger and com pare I N S ITE™ electronic ng proced u re
YES as out l i ned i n
service tool read i n g for barometric air pressu re
Step 2.
t o t h e local baro m etric pressure. Refer to
Proced u re 0 1 8-028 (Baro m etric P ressure at
Altitude) i n Section 1 8 . I N S ITE™ electronic service tool read i n g is Repai r
within 50. 8 m m - H g [2 in-Hg] of local complete

barometric p ressu re?
NO
Repa ir:

ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ] Engine Performance Troubleshooti ng Tree - ISB, ISBe, an [ . . . ]
Section TT - Troubleshooting Symptoms (New Format) Page TT 9 1

-
STEP 7 : Perform base e n g i n e mec h a n i cal chec ks .

STEP 7A: Verif overhead ad · ustments are correct.
Cond i t i o n :
• Keyswitch O N .
• Con nect I N S ITETM electronic service too l .
M easu re the overhead settings. Are the overh ead settings with i n the l ash 7B
check l i m its?
Refer to P roced u re 003-004 (Overhead Set) i n
Section 3 o f t h e Service Man ual , I S B e , I S B , and YES
aSB (Common Rai l Fuel System) Series
Engines, B u l leti n 402 1 27 1 . Are the overhead settings with i n the l ash Repai r
check l i m its? complete
NO
Repa ir:
Adj ust the overhead settings agai n . Refer to

Proced u re 003-004 (Overhead Set) i n
Section 3 o f t h e Service Man u a l , I S B e , I S B ,
a n d a S B (Com mon R a i l F u e l System) Series
Engi nes, B u l l etin 402 1 271 .
STEP 7 8 : C h e c k exhaust restrictio n .
Cond i t i o n :
• Engine ru n n i ng at rated speed a n d fu l l load .
Measu re the exhaust system back pressure Is the exhaust back p ressure greater than the Repai r
specificatio n ? Comp lete
Measu re the exhaust system back pressu re by
instal l i n g a pressure gauge, Part N u m ber YES
ST- 1 273, i nto the exhaust system i m med iately Repa ir:
downstream of the tu rbocharger exhaust outlet.
Correct the cause of high back p ress u re ; look
Maxi m u m back pressure measu red at the for col lapsed or plugged exhaust p i pes.
tu rbocharger outlet (exhaust man ifold outlet for
naturally aspi rated engines) is:
Is the exhaust back pressu re greater than the 7C
• 1 0 kPA ( 1 . 5 psi) specification?
• 1 5 kPa (2. 2 psi) .
NO
OOd00 1 1 0
STEP 7C: is with i n s ecification
Cond ition:
• Connect appropriate service tools to measu re blowby.
Measure engine cran kcase pressure (blowby) . Is the engine cran kcase press u re (blowby) 7D
less than specification?
Refer to Proced u re 0 1 4-0 1 0 (Cran kcase Blowby,
M easu re) in Section 1 4 of the Troubleshooting YE S
and Repai r Manual, ISBe, ISB, and aSB
(Common Rai l Fuel System) Series Engi nes, Is the engine cran kcase press u re (blowby) See the
B u l leti n 402 1 271 . l ess than specification? Cran kcase
NO Gases
(Blowby)
Repai r : Excessive
See the C ran kcase (Blowby) Excessive Troubleshoot
Troubleshooting Sym ptom (TS) tree. ing Sym ptom
(TS) tree.
OOd00 1 1 1
Engine Performance Troubleshooting Tree - ISB, ISBe, an [ . . . ] ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ]
STEP 7 0 : C h e c k f o r I nterna engi ne damaae.
Cond ition :
• Keyswitch OFF.
Action Specification/Re pair Next Step
Remove the o i l filter. Did cutting the oil fi lter open reveal evidence Repai r
of i nternal engine damage? Complete
Refer to P roced u re 007-0 1 3 (Lub ricating Oil Fi lter
- Spi n-On) in Section 7 of the Service Manual , YES
ISBe, I S B , and aSB (Com m o n Rail Fuel System) Repair:
Determ i n e the area of p robable damage and
Cut the o i l fi lter open and i nspect for debris and repai r as n ecessary. Remove the l u bricating
area of p robable damage. Refer to P roced u re o i l pan and rocker lever cover, if necessary,
007-083 (Lubricating Oil and Fi lter Analysis) i n to i nspect for damage . Refer to Proced ure
Section 7 o f t h e Service Man ual , I S B e , I S B , and 007-025 (Lubricating Oil Pan) i n Section 7 of
aS B (Com mon Rail Fuel System) Series the Service Manual , I S Be , I S B , and aS B
Engi nes, B u l leti n 402 1 271 . (Common Rail Fuel System), B u l leti n
402 1 271 . Refer to Proced u re 003-0 1 1
(Rocker Lever Cover) i n Section 3 of the
Service Manual , ISBe, ISB, and aSB
Did cutting the oil fi lter open reveal evidence Perform the
of i nternal engine damage? next
NO
troubl eshooti
ng proced u re
as outl i ned i n
Step 2 .
STEP 8: Excessive v i b rati o n checks

STEP SA Ch ec k e n (;u n e I· d le spee d
Cond ition:
• I N S ITE™ Mon ito r.
Monitor the engine speed while the engine is Is the engine idle speed wit h i n specification? 8B
idling. YES
U s e I N S ITE™ electronic service too l .
See t h e e n g i n e dataplate f o r idle speed Is the engine idle speed with i n specification? Repai r
specifications. NO Com plete
Repa ir:
Adj ust or i ncrease the engine idle speed .

ISB, ISBe2 , ISBe3 , ISBe4 , QSB4 [ . . . J Engine Performance Troubleshooti ng Tree - ISB, ISBe, an [ . . . J
Section TT - Troubleshooting Sym ptoms (New Format) Page TT 95

-
.
STEP 88 Ch ec k I·f t he feature Fast I d l e W arm u' P IS aval· 1 a b l e an d ena b led
Cond ition:
Check the featu res and parameters and check if Is the feature Fast Idle Warm Up avai lable Go to Step
the feature Fast I d l e Warm U p is available and and enabled? 88-1
enabled . YES
• I N SITE™ Mon itor.

Is the feature Fast Idle Warm Up avai lable Go to Step
and enabled? 8C
NO
STEP 8 8 1-
M omtor t h e Fast I d l e W arm u' P St at us
Cond ition:
• Connect I N S ITE'M electronic service tool .
Mon itor Fast warm-up status Is the feature Fast Idle Warm Up becoming Repai r
active? Com p lete
Connect I N S ITE™ electronic service too l .
YES
Repa ir:
Adj ust the fast idle warm u p idle speed o r

check w i t h the customer on d isab l i n g t h e
feature.
Note: Disab l i ng the Fast Idle Warm U p
feature can affect warranty.
Is the feature Fast Idle Warm U p becom ing Go to Step

active? 8C
NO
Page TT 96- Section TT - Troubleshooting Symptoms (New Format)
STEP 8C: Check front engine d riven accessorv(s)
Cond ition :
• Keyswitch OFF.
• Isolate front engine d riven accessory(s) .
Isolate front engine d riven accessory(s) one at a Did isolati ng the front engine d riven Repai r
time, i n c l u d i n g : accessory(s) correct the vibration? Complete
• Alternator(s)
YES
• Refrigerant com p ressor(s)
• Fan h u b(s) Repai r:

• Hydrau lic/Power steeri ng p u m p(s)
Repai r or replace the malfunctioning
• Water p u m p
com ponent.
• Coo l i n g fan
• C rankshaft d riven PTO accessories.

Did isolati ng the front engine d riven Go to Step
accessory(s) correct the vibration? 8D
NO
STEP 80: Check the V i bration OamDer/Crankshaft sDeed i n d icator rina .
Cond i t i o n :
• Keyswitch OFF.
Isolate front engine d riven accessory(s) one at a Is the vibration dam per/cran ksh aft speed Repai r
time, including: ind icato r ri ng damaged? Complete
Check the vibration damper/crankshaft speed YES
indicator ring for damage. Repair:
For engines eq u i pped with a rubber vibration Replace the damaged vibration damper/
damper, refer to Proced u re 00 1 -05 1 (Vi bration cran kshaft speed indicator ri n g .
Damper, Rubber) i n Section 1 of the Service
Man ual , ISBe, I S B , and aSB (Common Rai l Fuel
System) Series Engi nes, B u l letin 402 1 271 . Is the vibration damper/cran ksh aft speed Go to Ste p
indicator ring damaged? 8E
For engines eq u i pped with a viscous damper,
NO
refer to P roced u re 00 1 -052 (Vi b ration Damper,
Viscous) i n Section 1 of the Service Manual ,
ISBe, I S B , and aSB (Common Rail Fuel System)
For engines eq u i pped with a cran kshaft speed
indicato r ring only, refer to P roced u re 001 -07 1
(Crankshaft Speed I ndicator R i ng) i n Section 1 of
the Service Manual , ISBe, I S B , and aS B
(Com mon Rail Fuel System) Series Engi nes,
B u l letin 402 1 271 .
STEP 8 E Ch ec k the e n a l n e su pport b rac kets mou nts an d/o r ISO ators .
Cond ition:
• Keyswitch OFF.
Act i o n Specification/Repair N ext Step
Check the engine support b rackets, mou nts and/ Are the engine su pport b rackets , m o u nts , Repai r
or isolators for damage and/or isolators or damaged? Com plete
For front engine supports refer to Proced u re YES
0 1 6-002 (Engine S u pport Bracket , Front) i n Repa ir:
Section 1 6 of the Service Man ual , ISBe, ISB, and
aSB (Com mon Rail Fuel System), B u l leti n Replace the damaged engine support
402 1 271 . b rackets , mou nts and/o r isolators.
For rear engine supports, refer to P roced u re
0 1 6-003 (Eng i n e Su pport B racket, Rear) i n Are the e n g i n e su pport b rackets, mou nts , Go to Step
Section 1 6 o f t h e Service Man ual , I S B e , I S B , and and/or isolators or damaged? 8F
aSB (Common Rail Fuel System) , B u l l etin NO
402 1 271 .
STEP 8 F : C h e c k enaine ae a r d riven accessorv(s}.
Cond ition:
• Keyswitch OFF.
Check if the engine has an engine gear d riven / Does the engine have an engine gear d riven/ Go to Step
air com p ressor d riven hyd rau lic p u m p . ai r com p ressor d riven hydrau l i c p u m p? 8 F- 1
YES
Does the engine have an engine gear d riven/ Go t o Step

air com p ressor d riven hydrau l i c p u m p? 8 F-2
NO
S T E P 8F-1 : Isolate e n a i n e aear driven accessorv(s\ '
Cond ition:
• Keyswitch OFF.
• Isolate/rem ove the gear/air com p ressor d riven hyd rau lic p u m p .
Isolate/remove the gear d riven air compressor Did isolating/removing engine gear d riven/ai r Repai r
d riven hyd rau l i c p u m p and operate the engine. compressor d riven hydrau lic pump correct Complete
t h e vi b ration?
Refer to Proced u re 009-0 1 6 (Hyd rau l i c P u m p
Drive) i n Section 9 of the Service Man ual , ISBe, YES
I S B , and aS B (Com mon Rail Fuel System) Repa ir:
Series Engi nes, B u l let i n 402 1 271 , for general
hyd rau lic p u m p remove and i nstall i nstructions. Repai r or replace the damaged co m ponent.
Note: Some engi nes req u i re an accessory d rive
to d rive the hydrau lic pump. It cou l d be Did isolating/removi ng engine gear d riven/air Go to Step
necessary to isolate this as we l l . Refer to com p ressor d riven hyd rau lic p u m p correct 8 F-2
Proced u re 009-001 (Accessory D rive) i n Section the vi b ration?
9 of the Service Manual , I S B e , ISB, and aS B NO
(Com mon Rai l Fuel System) i n Series Engi nes,
Bul leti n 402 1 271 .
Engine Performance Troubleshooti ng Tree - IS8, IS8e, an [ . . . J IS8, IS8e2 , IS8e3 , IS8e4, QS84 [ . . . J
STEP 8F-2 : .
Check I·f the e n �lI n e IS eQU I DDe d With a n a i r comDressor.
Co nditi o n :
• Keyswitch OFF.
Check if the engine is eq u i pped with an engine Is the engine eq u i pped with an engine gear Go to Step
gear d riven air compressor. d riven ai r compressor? 8F-3
YES
Is the engine eq u i pped with an engine gear Go to Step

d riven air compressor? 8G
NO
STEP 8 F-3 : U n load the a i r comDressor and ODerate .
Condition :
• Keyswitch OFF.
• U n load the ai r com p ressor.
With the air com p ressor u n loaded , operate the Did u n load i n g the air com pressor Go to Step
engine i n the condition i n which the vibration sign ificantly red uce or e l i m i n ate the 8F-4
com plaint occurs . vibration?
T h e air compressor can be u n loaded by: YES
1 . Disconnecting the air governor sig nal l i n e and

connecting reg u l ated shop air, with a pressu re Did u n load i n g the air compresso r Go to Ste p
gauge, to the air compressor governor ai r sig nal sign ificantly red uce or e l i m i nate the 8G
port . vibration?
Note: Typically 621 k P a (90 psi) o f air pressure is NO
the set point for u n load i n g the air com p ressor.
See the OEM Service Man ual .
2. Discon necting the air com p ressor discharge
l i n e and air i ntake hose from the air com p ressor.
Note : On tu rbocharged air com p ressors , m ake
sure to plug the ai r i ntake h ose attached to the
i ntake man ifold .
ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J
Engine Performance Troubleshooti ng Tree - ISB, ISBe, an [ . . . J
Section TT - Troubleshooting Sym ptoms (New Format)
Page TT-99
STEP SF-4: Check the a i r compressor tim I n a .
Cond ition:
• Keyswitch OFF.
• Check the t i m i n g of the air co m p ressor.
Note: 3. 9 L and 5 . 9 L eng i n es d o not req u i re the Was the air com p ressor correctly timed to the Repai r
ai r com p ressor to be timed to the engine. engine? Complete
Check that the air com p ressor is correctly timed YES
to the engine. Repai r:
Refer to P roced u re 0 1 2-0 1 4 (Ai r Com pressor) in Replace the air com p ressor. Refer to
Section 1 2 of the Service Manual , ISBe, ISB, and Proced u re 0 1 2-0 1 4 (Ai r Com p ressor) in
aSB (Common Rai l Fuel System) Series Section 1 2 of the Service Manual , I S B e , I S B ,
Engines, B u l l etin 402 1 271 , i n Section 1 2 . and aSB (Com mon Rai l Fuel System) Series
Note : When troubleshooti ng a vibration issue in Engi nes, B u l letin 402 1 271 .
which it is suspected that the air compressor is
the cause of the vibratio n , it m ay be necessary to Was the air compressor correctly timed to the Repai r
isolate the air com p ressor from the e n g i n e . engi ne? Complete
NO
Repair:
Correctly time the air com p ressor to the

engine. Refer to Proced u re 0 1 2-0 1 4 (Ai r
Compressor) i n Section 1 2 o f the Service
Manual , ISBe, I S B , and aSB (Co m mon Rail
Fuel System) Series Engines, B u l l etin
402 1 271 .
STEP SG : Check/isolate t h e enaine d riven components.
Cond ition:
• Keyswitch OFF.
• Isolate/remove any engine d riven com ponents .
Isolate/remove any engine d riven components Did isolating/removi ng any engine d riven Repai r
and operate the engine. component correct the vibration? Complete
Engine d riven components include: YES
• Transm issions (Torq u e converters/Cl utches) Repai r:

• Hyd raulic p u m ps
Replace the m alfu nction ing component.
• Di rect d rive shafts
Refer to the OEM i nstructions.
• Flywheels. Refer to Proced u re 0 1 6-005
(Flywheel) in Section 1 6 of the Service Manual ,
I S Be , I S B , and aSB (Co m m o n Rail Fuel Did isolating/rem ovi ng any engine d riven Go to Step
System) Series Engi nes, B u l l eti n 402 1 271 . component correct the vib ration? 8H
• Fl explates . Refer t o P roced u re 0 1 6-004 NO
(Flexplate) i n Section 1 6 o f the Service
Manual , ISBe, I S B , and aSB (Common Rail
Fuel System) Series Engi nes, B u l leti n
402 1 271 .
•
Engine Performance Troubleshooti ng Tree - ISB, ISBe, an [ . . . J ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J
Page TT- 1 00 Section TT - Troubleshooting Symptoms (New Format)
STEP 8 H : Check the f Ivwhee I h ousma a rlanment.
Cond i t i o n :
• Keyswitch OFF.
• Engine d rive n components removed .
Action S pecification/Repai r Next Step
Measu re the flywheel housing bore and face Is the flywheel housing bore and face runout See Step 8 1
runout. within specification?
Refer to P roced u re 0 1 6-006 (Flywheel Housi ng) YES
in Section 1 6 of the Service Manual, ISBe, I S B ,
a n d QSB (Com mon Rai l F u e l System) Series Is the flywheel housing bore and face runout Repai r
Engines, B u l l eti n 402 1 271 . with i n specification? Com plete
NO
Repair:
Refer to P roced u re 0 1 6-006 (Flywheel

Housi ng) in Section 1 6 of the Service Man ual ,
ISBe, I S B , and QSB (Co m mon Rai l Fuel
System) Series Engi nes, B u l l et i n 402 1 27 1 ,
for flywheel housing repair options.
STEP 81: .
C heck if e n a i n e is e a u i DDe d With an mterna e n a i ne b alancer.
Cond ition:
• Keyswitch OFF.
Check if engine is eq u i pped with an i nternal Is the engine eq u i pped with an i nternal Go to Step
engine balancer. engine bal ancer? 81-1
Use the engine serial n u m ber to look u p the YES
engine b u i l d history to see if the engine was b u i lt
with an i nternal engine balancer optio n . Is the engine eq u i p ped with an i nternal Go to Step
N ote: O n ly 4 cyl i nder engi nes can be eq u i pped engine bal ancer? 8A
with an i nternal engine balancer. NO
ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . ] Engine Performance Troubleshooti ng Tree - ISB, ISBe, an [ . . . ]
Section TT - Troubleshooting Symptoms (New Format) Page TT- 1 0 1
STEP 8 1 - 1 : Check the i nternal e n a i n e balancer.
Cond i t i o n :
• Keyswitch off
• Lub ricating o i l pan removed
Remove the l u b ricating oil pan and i nspect the Is the i nternal engine balancer ti m i n g Repai r
i nternal engine balancer. i ncorrect or is the balancer damaged? Complete
Refer to Proced u res 007-025 (Lu b ricating Oil YES
Pan) in Section 7 of the Service Man ual , ISBe, Repair:
ISB, and aSB (Com mon Rail Fuel System)
Series Engines, B u l leti n 402 1 271 . Repai r or replace the i nternal e n g i n e
balancer.
Check to make s u re the i nternal engine balancer
is correctly timed to the engine.
Is the i nternal engine balancer timing Go to Step
Check for any damage to the i nternal engine i ncorrect or is the balancer damaged ? 7A
balance r.
NO
Note: O n ly 4 cyl i nder engi nes can be eq u i pped
with an i nternal engine balancer.
Engine Performance Troubleshooting Tree for QSB5 . 9 Mari [ . . . J ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
Page TT-1 02 Section TT - Troubleshooting Symptoms (New Format)
Engine Performance Troubleshooting Tree for QSB5 . 9 Marine Engines with

CM850 Electronic Control System
This tro u bleshoot i n g p roced u re shou ld be fol lowed fo r the fo l low i n g sym pto ms:
• Cran king Fuel P ressu re is Low
• Engine Operating Fuel Pressu re is Low
• Engine D ifficult to Start or Will Not Start (Exhaust Smoke)
• Engine Difficult to Start or Wi l l Not Start (No Exhaust Smoke)
• Engine R u n s Rough at I d l e
• E n g i n e R u ns R o u g h or M i sfi res
• Engine S peed S u rges at Low or H ig h I d l e
• E n g i n e Speed S u rges U nder Load o r i n Operating Range
• Smoke, Black - Excessive
• Engine S h uts Off or Dies U n expectedly or Dies During Deceleration
• Engine Starts But Will Not Keep R u n n i n g
• E n g i n e Wi l l N ot Reach Rated Speed (rpm)
• I ntake M an ifold P ressure (Boost) is Below Normal
• Excessive Vibration i n Marine Applications
How to U se T h i s T ro u b l eshoot ing P roced u re:

This symptom tree can be used to troubleshoot all performance based sym ptoms l i sted above . Start by performing
Step 1 troubleshooti n g . Step 2 wi l l ask a series of questions and wi l l provide a l ist of troubleshooti ng steps to perform ,
depending on the sym pto m . Perform the list of troubleshooting i n the seq uence shown i n the S pecifications/Repai r
section of the tree .
Shop T a l k:
Operational is a term that i n general descri bes vessel performance on the wate r. Operational problems for an engine
can be caused by several different facto rs . Some of the factors are engine-related and som e are n o t . Before
troubleshooting , it is i m portant to determ i n e the exact com p l ai nt and whether the engine h as a real operational
p roblem or if it sim ply does not meet owner expectations.
Low power is a term that is used i n the field to descri be many d ifferent perform ance prob lems. Low power is defi ned
as the inabil ity of the engine to p roduce the power necessary to move the vessel at a speed that can be reason ably
expected u nder the given environ ment.
Poor acceleration or response is described as the inabil ity of the vessel to accele rate satisfactori ly fro m a stop. It can
also be the lag in acceleration at cond itions less than rated speed and load . Poor acceleration or response is d ifficult
to troubleshoot , si nce it can be caused by several factors .
IS8, IS8e2, IS8e3 , IS8e4, QS84 [ . . . J Engine Performance Troubleshooting Tree for QS85 . 9 Mari [ . . . J
Section TT - Troubleshooting Symptoms (New Format) Page TT- 1 03
T RO U B L ES H O OT I N G S U M MARY
STEPS S P EC I F I CATI O N S S RT CO DE
STEP 1 : Perform bas i c tro u b l eshoot i n g proced u res .
STEP 1 A: C h e c k f o r active fau l t codes o r Active fau lt codes or h i g h cou nts
h i g h cou nts of i nactive fau lt of i n active fau lt codes?
codes.
STEP 1 B : Perform basic troubleshoot i n g

Can the problem be verified?
c h ecks.
STEP 1 C: Perform basic troubleshoot i n g

A l l steps have been verified to
c h ecks.
be correct?
STEP 2 : Dete r m i nat i o n of e n g i n e sym pto m .

STEP 2A: Low power , poor acceleration ,
Is the e ng ine symptom low
or poor response.
powe r, poor accelerat i o n , or
poor response?
STEP 2B: Engine m isfi re , engine speed Is the e n g i n e symptom e n g i n e

s u rg e , o r e n g i n e speed
m isfire, e ng ine speed surge, o r
u n stabl e .
e n g i n e speed u nstable?
STEP 2 C : Excessive w h ite o r black smoke. Is the engine sym ptom

excessive white o r black smoke?
STEP 20: Low i ntake man ifold p ressure. Is the e ng ine sym ptom low boost
p ressu re?
STEP 2 E : Engine will not start o r d ifficult

Is the e n g i n e sym ptom e n g i n e
to start , e n g i n e shuts off
w i l l n o t start or d iffic u lt to start ,
u n expected ly.
e ng ine sh uts off u nexpected ly?
STEP 2 F : E n g i n e vi bration excessive . Is the sym ptom e n g i n e vi bration

is excessive occurring when the
engine is i n or out of gear?
STEP 3: E n g i n e start i n g and ru n n i n g trou bleshoot i n g proced u res.

STEP 3A: Verify the fuel s u p p l y a n d return A r e the f u e l s u p p l y and ret u rn
valves are o pe n . valves i n the open position?
S T E P 3A- 1 : Check the fuel cooler for Is the fuel cooler damaged or
damage due to h i g h fuel collapsed i nternal ly?
ret u rn back p ressu re.
STEP 3 B : Verify the l o w p ressu re f u e l l i nes Are the low p ress u re fuel l i nes
are routed correctly. con nected properly to the ECM
coo l i n g plate?
STEP 3C: Check the e n g i n e speed d u ri ng Is the e ng ine cranking speed

cranki n g . g reater than 1 50 rpm?
STEP 3 D : Check t h e E C M keyswitch Is the keyswitch voltage equal to

voltag e . the battery voltage?
STEP 3E: C h e c k the ECM batte ry supply Is the ECM battery supply
voltag e . voltage equal to the battery
voltage?
STEP 3F: Verify the r a i l fuel press u re Is the rai l fuel press u re sensor
sensor accu racy. (m easu red) val ue less than 30
bar [435 psi]?
STEP 3 G : C h e c k f o r fuel rai l p ress u re w h i l e Did Fau lt Code 2 2 1 5 o r Fau lt

c r a n k i n g the e n g i n e . Code 559 beco me active d u ri n g
th e fai l ed start attem pt?
STEP 3 H : Check t h e fuel l ift p u m p I s t h e fuel l ift p u m p press u re

pressure . g reater than the specifications
ou tli ned i n P roced u re 005-045?
STEP 4: Fuel system trou bleshooti ng p roced u res.

S T E P 4A: C h e c k for fau lt codes that Did Fau lt C o d e 2 2 1 5 o r Fault
pertai n to the fuel system . Code 559 become active d u ri n g
the failed start attempt?
STEP 48: Check f o r a i r i n t h e h i g h Is air present in the fuel supply?

pressu re p u m p fuel supply.
STEP 4C: M easure t h e fuel i n let I s the fuel i n l et restriction above

restriction . specification?
STEP 4D: Perform t h e s i n g l e cyl inder Can the m iss or excessive

cutout test. smoke be attributed to a s i n g l e
cyl i nde r?
STEP 4 E : Perform the cyl i n d e r balance Does the cyl i nder performance
d i ag nostic test . test identify any cyl i nd e r that is
contributing to a power
i m balance?
STEP 4F: Measure t h e fuel d ra i n l i n e I s th e fuel d rain l i n e restriction

restrict i o n . with i n specification?
STEP 5 : A i r hand l i ng tro u b l eshoot i n g proced u res.

S T E P 5A: Check the i ntake man ifold I s the read ing wit h i n 5 0 . 8 m m- H g
press u re sensor accu racy . [2 i n-Hg] of local barometric
p ressu re?
STEP 5 8 : C h e c k the a i r i ntake system for Were any a i r intake syste m leaks
leaks. found?
STEP 5 C : C h e c k the a i r i ntake restriction. I s the a ir i ntake restriction

STEP 5D: I nspect the tu rbocharger blades A re the tu rbocharger blades

for damag e . damaged?
STEP 5E: Dete r m i n e if the tu rbocharger is Is the tu rbocharger a wasteg ated

a wastegated tu rbocharger. tu rbocharger?
STEP 5F: I nspect the waste gate actuator Are holes or cracks fo u n d in the
hose . wastegate actu ato r hose?
STEP 5 G : I nspect the tu rboc harger Did the wastegate actuator rod
wastegate capsule for a i r leaks . m ove?
S T E P 5G-1 : I nspect t h e tu rbocharger Did the waste gate actu ator rod
operat i o n .
S T E P 5G-2 : I nspect the tu rboc harg e r Does the wastegate actu ator rod
wastegate for p roper m ove?
operat i o n .
STEP 5 H : M easu re tu rbocharger axial and Are the axial and rad ial
rad ial clearance . c learances with i n specification?
STEP 5 1 : I nspect the aftercooler. Is th e aftercoo ler free of c racks

or other damage?
STEP 6: Electro n i c featu re tro u b l eshoot i n g p roced u res.

STEP 6A: Verify the th rottle travel . Does t h e th rottle pOSition read 0
w h e n the t h rottle is rel eased and
1 00 percent when the th rottle is
actuated?
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree for QSB5 . 9 Mari [ . . . J
Section TT - Troubleshooting Symptoms (New Format) Page TT-1 05
STEP 6 8 : C h e c k the a m b i e n t a i r pressu re Is the read i n g with i n 1 0 1 . 6 m m

sensor accu racy. H g [4 i n-Hg] of local baro m etric
p ressu re?
STEP 6 C : Check the i ntake man ifold Is the read i n g with i n 1 0 1 . 6 m m

p ressu re sensor accu racy. H g [4 i n-Hg] o f local baro m etric
p ressu re?
STEP 7: Base e n g i n e t ro u b l eshoot i n g p roced u res .

STEP 7A: Verify the overhead adj ustments Are the ove rhead sett i ngs with i n
are correct. t h e reset l i m its?
STEP 7 8 : Check the exhaust restriction . Is the exhaust system back

press u re less than 1 27 m m-Hg [5
i n- H g] o r 1 763 mm-H 20 [68 in-H
20] o r 1 7 kPa [2 . 5 psi]?
STEP 7C: Check t h e engine blowby. Are th e e n g i n e blowby

m easu re m ents within
specification?
STEP 7C- 1 : Verify tu rbocharger Has th e total e ng ine bl owby

contribution to e n g i n e d ropped m ore than 30 percent o f
blowby. the total?
STEP 8: Excessive vi brat i o n t ro u b l eshooti ng p roced u res.

S T EP 8A: C h e c k the g e a r rati o and Are th e gear ratio and the
prope l l e r configu ratio n . prope l l e r i ncorrectly m atched to
the e n g i n e power?
STEP 8 8 : Check f o r correct e n g i n e Are the e n g i n e mount iso lators

m o u n t i n g isolators and for correct and i nstalled correctly?
proper i nstal lation
req u i rem ents.
STEP 8 C : Check for damaged e n g i n e Are the e n g i n e mou nts and

mou nts and isolators. isolators i n good condition?
STEP 8 0 : Check the exhaust system . Is the exhaust system deficient?
S T E P 8 E: Check t h e e n g i n e d riven Is an e n g i n e d riven accessory

accessories. malfunct i o n i ng?
STEP 8 F : Check the shaft cou p l i n g to gear Is the shaft cou p l i n g to gear
coupling alignment. cou p l i n g m isalig ned?
STEP 8G: Check the prope l l e r shaft f o r Is the prope l l e r shaft i nstalled
p r o p e r i nstal l at i o n . correctly?
STEP 8H: C h e c k the prope l l e r shaft for Is the prope l l e r shaft

straig htness. stra ig htness with i n th e O E M
specification?
STEP 81: Isolate the e n g i n e . Does the e ng ine vibration

persist?
S T E P 8J : C h e c k for strut/cutlass bearing Is the strut/cutlass beari n g

m isal i g n ment . m isal i g ned o r strut m ou nting not
secu re?
STEP 8K: Check the prope l l e r . Is the prope l l e r out of balance o r

n o t fitted properly to th e shaft?
STEP 8 L : C h e c k the V-angle o n the V Does the V-ang l e on th e V-strut

strut. match the angle of th e blade on
the p rop?
STEP 8 M : Check the prope l l e r t u n nels. Doe s the entry and e x it of the
prope l l e r tunnel match with the
prope l l e r blades?
STEP 8 N : Check the e n g i n e to Is the torsional cou p l i ng

transm ission torsional cou p l i n g . i n co rrect or worn?
STEP 8 0 : Check the rudder. Does the rudder have excessive

in the rudder post?
STEP 8P: Check the engine flywheel I s the flywheel housing

housing to cyl inder block a l i g n m ent incorrect?
al i g n m e n t .
TRO U BLESHOOT I N G STEP
STEP 1 : Perform basic t ro u b l eshoot i n g proced u res .

STEP 1 A : Check for active fau lt codes or h i a h cou nts o f i nactive fau lt codes.
Cond i t i o n :
Check for any active fau lt codes. Active fau lt codes or high cou nts of i n active Repai r
• Use I N S ITE™ electronic service tool to read the fau lt codes? com plete
fau lt codes. YES
Repai r:
Refer to Section TF i n the ISB, I S Be4,

OSB4. 5 , OS B5.9, OSB6 .7, ISC, OSC8 . 3 ,
ISL, I S Le3 a n d OSL9 (Common R a i l Fuel
System) Series Engines, CM850 Electronic
Control System Troubleshooting and Repai r
Manual , B u l l etin 402 1 4 1 6 for fau lt code
troubleshoot i n g .
Active fault codes or h i g h cou nts of i n active 1B

fau lt codes?
NO
STE P 1 B . trou bl es h ootma c h ec ks.

P er f orm b aSlc
Cond i t i o n :
None.
Action Specification/Re pai r N ext Step
Verify the fol lowi ng items. Can the problem be verified? 1C

• Is the engine operating wit h i n the cond itions it
YES
was i ntended to perform? For exam ple, wide
open th rottle rpm , ambient versus engine
room tem peratures, load on the vesse l , sea Can the problem be verified? Repai r
conditions, etc. NO
co mplete
• Are the customer's expectations i n l i n e with
Repai r:
the engine capabi l ity?
• Is the engine perform i n g accord i ng to the OEM The problem can n o t be verified and no
sea trial? repai r is possible.
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . ] Engine Performance Troubleshooting Tree for QSB5 . 9 Mari [ . . . ]
Section TT - Troubleshooti ng Symptoms (New Format) Page TT- 1 07
STEP l C : Perform the basic tro u b l eshootma checks .
Cond ition:
None.
Action Specificati on/Repai r Next Step
The fol lowi ng items m u st be checked or verified All steps h ave been verified to be correct? 2A
before conti n u i n g . YES
• Verify t h e fuel l evel i n t h e tanks.
• Verify there have not been any changes to the
control parts l ist (tu rbocharger, i njectors , All steps h ave been verified to be correct? Repai r
pistons, fuel p u m p , camshaft, etc.) NO
complete
com ponents on the engine.
Repai r:
• Verify the fuel g rade is correct for the
applicati o n . Correct the condition and verify the complaint

• Verify the engine is operating with i n t h e is no longer p resent after the repai r.
reco m mended altitude.
• Verify the engine oil is at the correct level .
• Verify none of the air vents are restricted o r
obstructed .
• Verify the engine parasitics have not changed .
• Verify the engine d uty cycle has not changed .
• Verify the engine cran king speed is g reater
than 1 50 rpm .
• Verify the battery voltage is adeq uate .
• Verify the d rive trai n is correctly matched to the
engine.
• Verify the transm ission is correct and is not
malfu nctio n i n g .
• Verify t h e p ropeller is at t h e correct pitch and
is not damaged .
• Verify the fuel i n l et tem perature to the fuel
pump is with i n specificatio n .

• Verify t h e e n g i n e th rottle a n d th rottle wiring i s
correct for t h e e n g i n e response issues.

• Verify the condition of the h u l l (cl ean and no
damage) .
Engine Performance Troubleshooting Tree for QSB5 . 9 Mari [ . . . J ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J
STEP 2: Dete r m i n at i o n of e n g i ne sym pto m .

STEP 2A: Low powe r, poor acceleration or Door response .
Cond i t i o n :
None.
Acti o n S pecification/Repair Next Step
Determine the engine sym ptom accord i n g to the Is the engine symptom low power, poor Perform the
eng i n e performance. acceleratio n , or poor response? troubleshooti
YES ng steps
suggested i n
Repa ir: t h e repai r
recom mended order listed below.
-
• Step 5 Ai r Hand l i ng Checks

-
• Step 6 Electronics Checks

-
• Step 7 Base Engine Checks

-
Is the engine sym ptom low power, poor 2B

acceleration, or poor response?
NO
STEP 28 E nc:u n e m l· sfI re en�:lIne spee d su rQe or enQme spee d u nsta bl e .
Cond i t i o n :
None.
Acti o n S pecification/Repai r N ext Step
Determine the engine sym ptom accord ing to the Is the engine sym ptom engine m i sfire, engine Perform the
engine performance. speed surge, or engine speed u nstable? troubleshooti
YES ng steps
suggested in
Repair: the repai r
reco m mended order listed below.
• Step 5 - Air Handling Checks
• Step 6 - Electronics Checks
Is the engine sym ptom engine m isfi re , engine 2C

speed surge, or engine speed unstable?
NO
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . ] Engine Performance Troubleshooting Tree for QSB5 .9 Mari [ . . . ]
STEP 2 C · Excessive wh ite or b l a c k smoke
Cond itio n :
None.
Determine the engine sym ptom accord i n g to the Is the engine sym ptom excessive wh ite o r Perform t h e
engine performance. black smoke? troubleshooti
YES ng steps
suggested in
Repai r: the repai r
Perform the troubleshooting steps in the proced u re .
recom mended order listed below.
• Step 5 Air Hand l i ng Checks
-

-
Is the e n g i n e sym ptom excessive wh ite or 2D

black smoke?
NO
STEP 20 Low mta ke m a n !·f 0 Id

pressure.
Cond ition:
None.
Determ i n e the engine sym ptom accord i n g to the Is the engine sym ptom l ow boost p ressu re? Perform the
engine performance. YES troubl eshooti
ng steps
Repa ir: suggested i n
Perform t h e troubleshooting steps i n the the repai r
recom mended order listed below. proced u re .
• Step 5 Ai r Hand l i n g Checks
-

-

-
Is the engine sym ptom low boost pressu re? 2E

NO
Engine Performance Troubleshooti ng Tree for QSB5 . 9 Mari [ . . . J ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
Page TT-1 1 0 Section TT - Troubleshooting Symptoms (New Format)
STEP 2 E : E n a m e w i l l n o t start or d ifficu t t o start engme shuts off unexpectedly.
Cond i t i o n :
None.
Determine the engine sym ptom accord ing to the Is the engine sym ptom engine wi l l n o t start Perform the
engine performance. or d ifficult to start , engine sh uts off troubleshooti
unexpected ly? ng steps
YES suggested in
the repai r
Repair: proced u re .
recommended o rder listed below.
• Step 3 N o Start Checks
-
• Step 4 Fuel System checks

-
• Step 5 Ai r Handling Checks

-

-
Is the e n g i n e sym ptom engine wi l l not start Return to the

or d ifficult to start , engine sh uts off correct
unexpected ly? sym ptom
NO
tree.
STEP 2 F E name VI' b rafIon excessive.
Cond i t i o n :
None.
Determ i ne the e n g i n e sym ptom accord ing to the Is the sym ptom engine vibration is excessive Perform the
engine performance. occurring when the engine is in or out of troubleshooti
gear? ng steps
YES suggested i n
t h e repai r
Repai r: proced ure.
recommended order listed below.
-
• Step 5 Ai r H and l i n g Checks

-
• Step 6 Electron ics Checks

-

-
• Step 8 Excessive Vibration Checks

-
Is the symptom engine vibration is excessive Retu rn to the

occu rri ng when the engine is in or out of correct
gear? sym ptom
NO
tree.
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree for QSB5. 9 Mari [ . . . J
Section TT - Troubleshooting Symptoms (New Format) Page TT-1 1 1
STEP 3: E n g i ne start i n g and ru n n i ng tro u b l eshoot i n g proced u res .

STEP 3A:
Verify t h e fuel SUDDlv and return valves are ope n .
Cond i t i o n :
Verify the fuel supply and return valves are in the Is the fuel supply and return valves in the 3B
open position . open position?
If the vessel is new or work h as been com p l eted YES
on the vessel , the fuel valves cou l d h ave been l eft
i n the OFF positi o n . Is t h e f u e l s u p p l y a n d return valves i n t h e 3A- 1
open position?
NO
Repai r:
Turn the fuel su pply and return valve to the

OPEN position and verify that no e n g i n e
damage has occu rred .
STEP 3A 1 -
Ch ec k t he f ue I coo er fo r d amaae d ue to h ·la h
l f ue I ret u rn b ac k Dressure.
Cond ition:
None.
Remove and i nspect the fuel cooler. Is the fuel cooler damaged or collapsed Repai r
i nternal ly? complete
Check the fuel cooler for i nternal damage, o r
col lapse . Refer to P roced u re 006-062 (Fuel YES
Cooler) i n Section 6 i n the I S B , ISBe, I S Be4, Repa ir:
OSB4 . 5 , OS B5.9, and OSB6.7 (Com m o n Rail
Fuel System) Series Engi n es Service Manual , Remove and replace the fuel cooler.
B u l letin 402 1 271 . Refer to P roced u re 006-062 (Fuel Cooler) i n
Section 6 i n t h e I S B , I S B e , I S Be4 , OSB4 . 5 ,
OSB5.9 , a n d OSB6 . 7 (Com mon R a i l Fuel
System) Series Engi nes Service Man ual ,
Bul leti n 402 1 271 .
Is the fuel cooler damaged or col lapsed 3B

i nternal ly?
NO
Engine Performance Troubleshooting Tree for OSB5 . 9 Mari [ . . . J ISB, ISBe2, ISBe3 , ISBe4, OSB4 [ . . . J
Page TT -1 1 2 Section TT - Troubleshooting Symptoms (New Format)
STEP 3 8 v eru'fv the I ow D ress u re fue i r mes are rou t e d correctlIV.
Cond ition:
None.
It is sometimes possible to get the low pressure Are the low pressure fuel l i nes con n ected 3C
fuel l i nes con nected to the ECM cool ing plate properly to the ECM cool ing plate?
i nstalled i m p roperly. YES
The top connection to the ECM coo l i n g plate is
the i n l et and the bottom con n ection is the outlet. Are the low pressu re fuel l i nes connected Repai r
Verify these con n ections are correct if the low properly to the ECM coo l i n g plate? com plete
pressure fuel l i nes have been removed and NO
reinstalled on the engine.
Repair:
P roperly connect the low pressure fuel l i n es

to the ECM coo l i n g plate. The fuel i n let is the
top con nection .
ST E P 3 C Check the enaine SDee d d u rina cran ki n a .
Cond i t i o n :
• Connect I N S ITETM electronic service tool .
Use I N S ITE™ electronic service tool to mon itor Is the engine cran king speed g reater than 3D
Engine Speed w h i l e cran king the engine. 1 50 rpm?
If the engine does n o t cran k at al l , see the YES
troubleshooting sym ptom tree Engine W i l l Not
Cran k or Cran ks Slowly. Is the engine cran king speed g reater than Repai r
1 50 rpm? complete
NO
Repair:
Find and correct the cause for low cran king

speed . Check the batteries , engine starting
motor and accessory loads. See the
troubleshooti ng sym ptom tree Engine Wi l l
Not Crank or Cran ks Slowly.
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree for QSB5. 9 Mari [ . . . J
Section TT - Troubleshooting Sym ptoms (New Format) Page TT-1 1 3
STEP 3 D : Check t h e electro n i c control mod u l e tECM) kevswitch voltage .
Cond ition:
• Disconnect the OEM harness from the EC M .
Measu re the signal voltage. Is the keyswitch voltage eq ual to the battery 3E
M easu re the signal voltage from the keyswitch
• voltage?
i n put S I G NAL wire of the OEM harness to the YES
engine block g ro u n d .
Measu re t h e keyswitch voltage with the Is the keyswitch voltage eq ual to the battery Repai r
keyswitch i n the "ON" position and also with the voltage? complete
keyswitch in the "Cran ki ng" positio n .
NO
Refer t o t h e wiring d i ag ram for connector p i n
Repai r:
identificatio n .
Repai r o r replace t h e keyswitch h arness ,
keyswitch , or check the battery con nections.
The keyswitch harness can be suppl ied by
the OEM .
STEP 3 E : Check the ECM b atterv SUDDIV vo taae.
Cond ition:
• Turn the keyswitch OFF.
• Disconnect the ECM power harness from the ECM .
Measure the voltage. Is the ECM battery supply voltage eq ual to 3F

•M easu re the voltage from the ECM battery the battery voltage?
supply ( ) to the ECM battery supply ( + ) pins
-
YES
in the ECM power harness connector.
M easu re the ECM voltage with the keyswitch in Is the ECM battery supply voltage equal to Repai r
the "ON" position and also with the keyswitch i n t h e battery voltage? complete
the "Cran ki ng" positio n .
NO
Refer to the wiring d i ag ram for con nector pin
Repa i r :
identificatio n .
Repai r or replace t h e E C M power harness.
Check the battery con n ections and fuse
term i n als.
Eng i ne Performance Troubleshooting Tree for QSB5. 9 Mari [ . . . J ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J
STEP 3 F : Verify the rai l fue press u re sensor accu rac .
Cond ition:
• Connect I N S ITpM electronic service tool .
Mon itor the rai l fuel p ressu re sensor. Is the rai l fuel pressu re sensor (m easu red) 3G
val ue less than 30 bar [435 psi] ?
Use I N S ITE™ electronic service too l , to mon itor
the rai l fuel p ressure sensor (measu red) with the YES
keyswitch ON and the engine OFF ( not ru n n i ng).
Is the rai l fuel p ressure sensor (measu red) Repai r
val ue less than 30 bar [435 psi ] ? com plete
NO
Repai r:
Replace the rai l fuel pressure sensor.

Refer to P roced u re 0 1 9- 1 1 5 (Rail Fuel
Pressure Sensor) i n Section 1 9 i n the I S B ,
I S Be4, OSB4 . 5 , OSB5 . 9 , OSB6 . 7 , ISC,
OSC8 . 3 , I S L , I S Le3 and OSL9 (Co m mon Rail
Fuel System) Series Engi nes, CM850
Electronic Control System Troubleshooti ng
and Repai r Manual , B u l letin 402 1 4 1 6 .
STEP 3 G Check f o r f u e rai l pressu re w h i l e cran ki l1� the engi ne.
Cond ition:
• Connect I N S ITETM el ectronic service too l .
Check for fuel rai l p ressure . Did Fau lt Code 221 5 or Fau lt Code 559 Repai r
• Attem pt t o start the engine b y engag i n g t h e become active d u ring the fai led start complete
engine starter f o r a t lease 3 0 conti nuous attem pt?
seconds. YES
• Use I N S ITETM electronic service tool to mon itor
the Fuel Rail p ressure (M easu red) and Fuel Repair:

Rai l P ressu re (Com manded). Follow troubleshooti ng Fau lt Codes 22 1 5 or
• Use I N S ITETM electronic service tool to read the
559 Fuel P u m p Del ivery P ressure Low
fau lt codes. Choice.
Attem pting to start the engine for 30 contin uous
seconds allows the fau lt code logiC time to ru n . If Did Fault Code 221 5 o r Fau lt Code 559 4A
Fau lt Code 221 5 or Fau lt Code 559 becom es becom e active d u ring the fai l ed start
active, then fuel rai l pressu re is not being attem pt?
developed .
NO
If the engine starts d u ring this attem pt , it is
possible that fuel prime to the high pressure
p u m p has been l ost . Look for l oose fuel l i nes or
fi lters that allow for loss of fuel pri me.
IS8, IS8e2 , IS8e3 , IS8e4, QS84 [ . . . J Engine Performance Troubleshooting Tree for QS85 .9 Mari [ . . . J
STEP 3 H : Check t h e fuel l ift pump pressure.
Cond i t i o n :
I nstall a p ressure gauge at the i n let port of the Is the fuel l ift p u m p pressure g reater than the Repai r
fuel p u m p . specifications? com pl ete
• M easu re t h e fuel lift p u m p output pressure.
YES
Refer to Proced u re 005-045 (Fuel Lift P u m p) in
Section 5 i n the ISB, ISBe, I S Be4, OSB4.5, Repair:
OSB5 . 9 , and OSB6.7 (Co m m o n Rail Fuel Replace the fuel p u m p .
B u l letin 402 1 271 . Refer t o P roce d u re 005-0 1 6 ( F u e l P u m p) i n
Section 5 i n t h e I S B , I S B e , I S Be4, OSB4 . 5 ,
At i n itial key-on , the l ift p u m p wi l l run for 60 OSB5 . 9 , and OSB6 . 7 (Com m o n Rail Fuel
seconds then stop if the engine is not started and System) Series Engi nes Service Man ual ,
not operat i ng . The l ift p u m p wi l l o pe rate Bul let i n 402 1 271 .
conti nuously once the engine is operat i n g .
Is the fuel l ift p u m p pressure g reater than the Repai r
specifications? complete
NO
Repai r :
Replace the fuel lift pump. Refer to

Proced u re 005-045 (Fuel Lift P u m p) i n
Section 5 i n the I S B , ISBe, I S Be4, OSB4.5,
OSB5 . 9 , and OSB6 . 7 (Com mon Rail Fuel
Bul leti n 402 1 271 .
STEP 4: Fuel system t ro u b l eshoot i n g p roced u res.

S T E P 4A ' t0
Ch ec k f or fau I t co d es th at 3lert am the f ue I st e m .
Cond ition:
• Conn ect I N S ITE™ electronic service tool .
Check for fault codes. Did Fau lt Code 22 1 5 or Fault Code 559 Repai r
• Attem pt to start the engine by engaging the become active d u ring the fai led start complete
starter for at least 30 contin uous seconds. attem pt?
• Use I N S ITE™ electronic service too! to mon itor
YES
Fuel Rail P ress u re (M easu red) and Fuel Rai l
Pressu re (Co m manded). Repa i r :
• Use I N S ITE™ electronic service tool to read the
Fol low troubleshooting Fau lt Code 559 Fuel
fau lt codes . P u m p Del ivery Pressu re Low choice.
Attem pting to start the engine for 30 conti nuous
seconds allows the fau lt code logic time to ru n . If Did Fau lt Code 22 1 5 or Fault Code 559 4B
Fault Code 22 1 5 or Fault Code 559 becomes becom e active d u ring the fai led start
active, then fuel rai l press u re is not being attem pt?
developed .
NO
Engine Performance Troubleshooti ng Tree for OS85 .9 Mari [ . . . J IS8, IS8e2, IS8e3 , IS8e4, OS84 [ . . . J
Page TT 1 1 6
- Section TT - Troubleshooti ng Symptoms (New Format)
STEP 4 8 : Check for a i r i n the h i a h D ress u re D u m D fu e SU D D l v .
Conditio n :
None.
Act i o n Specifi cation/Repai r N ext Step
Check fo r air in the fuel . Is air p resent i n the fuel supply? Repai r
YES com plete
Refer to P roce d u re 006-003 (Ai r i n Fuel) i n
Section 6 in the I S B , ISBe, I S Be4, OSB4 . 5 , Repair:
OSB5 . 9 , and OSB6 . 7 (Co m mon Rail Fuel
System) Series Engi nes Service Manual , Bul letin Locate and correct the cause of air i ngestion
402 1 271 . i n the fuel supply system . Sou rces of air
ingestion i nclude loose fuel filters , loose fuel
l i ne fittings, loose or cracked fuel tan k stand
pipes , o r severe restrictions i n the fuel supply
Is ai r p resent i n the fuel su pply? 4C

NO
S T E P 4C ' M easure the fuel i n let restriction
Cond i t i o n :
None.
Measure the fuel i n let restriction at the customer Is the fuel i n let restriction above Repai r
connectio n . specification? complete
Refer to Proced u re 006-020 (Fuel I n l et YES
Restriction) in Section 6 in the I S B , ISBe, I S Be4, Repair:
OSB4. 5 , OSB5 . 9 , and OSB6 . 7 (Common Rai l
Fuel System) Series Engi nes Service Man ual , Find and correct the cause of h i g h fuel i n l et
B u l l etin 402 1 271 . restriction . Look for p l ugged OEM fuel fi lters
or screens, a restricted ECM cooler, pi nched
Maxi m u m fuel i n let restriction at the customer OEM fuel l i nes, o r a restricted stand pipe in
con n ection the OEM fuel tan k.
• N ew Fi lter: 63. 5 m m- H g [2.5 i n-Hg]
• D i rty Fi lter: 1 0 1 . 6 m m - H g [4.0 i n-Hg] Is the fuel i n let restriction above 4D
specification?
NO
IS8, IS8e2 , IS8e3, IS8e4, QS84 [ . . . J Engine Performance Troubleshooting Tree for QS85 . 9 Mari [ . . . J
STEP 4 0 : Pe rform t h e S l n a e CV Ir In d er cutout test .
Cond ition:
• Connect I N S ITE™ electronic service tool.
• Start the engine and ru n at low idle.
Perform the single cyl inder cutout test. Can the m i ss or excessive smoke be Repai r
• Operate the engine at load . attributed to a single cyl i nder? com plete
• Use I N S ITE™ electronic service tool to perform YES
the Cyl inder Cutout test. Disable ind ividual
i nj ectors. Repai r:
Look for a cause of the com plaint, i n c l u d i n g

valve l ash a n d excessive cran kcase p ressure
that can i n d icate power cyl inder damage, or
found , replace the fuel i njector in the cyl i nd e r
that was identified u s i n g the single cyl i nder
cutout test.
Refer to P roced u re 006-026 ( I nj ector) i n
Section 6 i n the I S B , ISBe, I S Be4, OSB4 . 5 ,
OSB5 . 9 , a n d OS B6. 7 (Com mon Rail F u e l
Can the m i ss or excessive smoke be 4E

attributed to a single cyl i nder?
NO
Engine Performance Trou bleshooting Tree for OSB5. 9 Mari [ . . . ] ISB, ISBe2, ISBe3, ISBe4, OSB4 [ . . . ]
STEP 4 E Perform the cyl i nder balance d i agnostic test .
Cond ition:
Perform the cyl inder balance diagnostic test. Does the Cyl inder Performance Test identify Repai r
• Use I N S ITE™ electronic service tool to perform any cyl i nder that is contri buting to a power complete
the Cyl i nder Performance Test . Determine if a i mbalance?
single cyl inder is contri buting to the engine YES
sym ptom .
Repai r:
Look for a cause of the power i m balance ,

including valve l ash and excessive
cran kcase p ressure that may i n d icate power
cyl inder damage or camshaft lobe wear. If no
other damage is fou nd , replace the fuel
i nj ector in the cyl inder contri buting to the
power i m balance .
Section 6 i n t h e I S B , ISBe, I S Be4, QSB4.5,
QSB5 . 9 , and QSB6 . 7 (Com m o n Rail Fuel
System) Series Engi nes Service Manual ,
B u l l etin 402 1 27 1 .
Does the Cyl inder Performance Test identify 4F

any cyl inder that is contri buti ng to a power
i m balance?
NO
STEP 4F" M easu re the fuel d rain l i ne restriction
Cond ition:
None.
Acti o n Specification/Re pai r N ext Step
Measu re the fuel d rai n l i n e restrictio n . Is t h e f u e l d rain l i n e restriction wit h i n 2A

specification?
Refer to P roced u re 006-0 1 2 (Fuel D rai n Line
Restriction) i n Section 6 i n the ISB, ISBe, I S Be4, YES
QSB4. 5, QSB5 . 9 , and QSB6.7 (Com mon Rai l
Fuel System) Series Engi nes Service Manual, Is the fuel d rain line restriction wit h i n Repai r
B u l l etin 402 1 271 . specification? complete
NO
Repair:
Look fo r causes of high d rain line restriction,

such as kin ked or blocked fuel l i nes.
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooti ng Tree for QSB5 . 9 Mari [ . . . J
STEP 5 : A i r hand l i ng tro u b l eshoot i n g proced u res .

STEP 5A: Check t h e i ntake man ifo l d press u re sensor accu racy.
Cond i t i o n :
• Connect I N SITE™ electronic service too l .
Act i o n Specification/Repair Next Step
Mon itor the read i n g for i ntake man ifold pressure Is the i ntake man ifold pressure read i n g less 5B
with the engine off. than 50 . 8 m m - H g [2 i n-Hg] of local barometric
• Start I N S ITE™ electronic service tool datal pressure?
logger and monitor the I N S ITE™ electronic

YES
service tool read ing for i ntake man ifold
pressure with the eng i n e off. Com pare the
pressu re read ings i n I N S ITE™ to the local Is the i ntake man ifold pressure read i n g l ess Repai r
barometric p ressure . Refer to P roced u re
than 50 . 8 m m- H g [2 i n-Hg] of local barometric complete
0 1 8-028 (Barometric P ress u re at Altitude) i n
pressu re?
Section V. NO
Repa ir:
Replace the i ntake man ifold pressu re sensor.

Refer to P roced u re 0 1 9- 1 59 (I ntake Man ifold
Pressu re/Temperatu re Sensor) i n Section 1 9
i n Troubleshooting and Repai r Manual , I S B ,
I S Be4, OSB4.5, OSB5 . 9 , OSB6 . 7 , I SC ,
OSC8 . 3 , I S L , and OS L9 Engines, CM850
Electronic Control System , B u l l eti n 402 1 4 1 6 .
STEP 5 8 : Ch ec k the ai r mta ke system fo r Ieaks.
Cond i t i o n :
None.
Check the ai r i ntake system for leaks. Were any air i ntake system leaks fou n d ? Repai r
Refer t o P roced u re 0 1 0-024 (Ai r Leaks, Air I ntake YES
complete
and Exhaust Systems) in Section 1 0 in the I S B ,
Repa i r :
ISBe, I S Be4, OSB4.5, OSB5 . 9 , and OSB6 . 7
(Common Rai l F u e l System) Series Engi n es Repai r or replace the damaged component.
Service Manual , B u l leti n 402 1 271 .
Were any air i ntake system leaks fou nd? 5C
NO
Engine Performance Troubleshooting Tree for QSB5 . 9 Mari [ . . . J ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J
STEP 5C ' Check the a i r i ntake restriction
Cond ition:
• I nstal l vac u u m gauge Part N u m ber ST- 1 1 1 1 -3 i nto the ai r i ntake system .
• Engine operating at rated speed and f u l l load .
Measu re the i ntake system restriction. Is the air i ntake restriction g reater than the Repai r
Refer to P roced u re 0 1 0-031 (Ai r I ntake
Restriction) in Section 1 0 in the I S B , I S B e , I S Be4 , YES
OSB4 . 5 , OSB5. 9 , and OSB6 . 7 (Com mon Rai l Repai r:
Fuel System) Series Engi n es Service Man ual ,
B u l leti n 402 1 27 1 . Correct the cause of h i g h i ntake ai r
restrictio n . Check for plugged air fi lter o r
Maxi m u m air i ntake restrictio n : restricted air i ntake p i p i n g .
Clean filter: 38 1 m m- H 2 0 [ 1 5 in-H 20)
Di rty filter: 635 m m-H 20 [25 in-H 20) Is the air i ntake restriction g reater than the 5C
specification?
NO
STE P 5 0 : I n sDect the tu rboc h araer b lades f or d amaae.
Cond itio n :
• Remove the i ntake and exhaust pi pes from the tu rbocharger.
Inspect the tu rbocharger. Are the tu rbocharger blades damaged? Repai r

• I nspect the com p ressor blades for damage or YES complete
wear.
Repair:
Refer to Proced u re 0 1 0-033 (Tu rbocharger) in
Section 1 0 i n the I S B , ISBe, I S Be4, OSB4 . 5 , Replace the tu rbocharger assem bly.
OSB5. 9 , and OSB6.7 (Com mon Rail Fuel Refer to P roced u re 0 1 0-033 (Tu rbocharger)
System) Series Engi nes Service Manual , B u l leti n i n Section 1 0 i n the I S B , ISBe, I S Be4,
402 1 271 . OSB4 . 5 , OSB5 . 9 , and OSB6 . 7 (Common Rail
Fuel System) Series Engi nes Service
Manual , B u l l etin 402 1 271 .
Are the tu rbocharger blades damaged? 5E

NO
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . J
. . Engine Performance Troubleshooting Tree for QSB5 . 9 Mari [ J . . .
STEP S E : Dete r m i n e if the tu rboc h araer IS a wasteaated tu rbocharaer.
Cond ition:
None.
Determ i ne if the tu rbocharger is a wastegated Is the tu rbocharger a wastegated 5F
tu rboch arger. tu rbocharger?
YES
Is the tu rbocharger a wastegated 5H

tu rbocharger?
NO
STEP SF: nSDect the wasteaate actuator hose .
Cond ition:
• Remove the tu rbocharger if the wastegate actuator is i n accessi ble.
I nspect the i nteg ral wastegate actuator hose for Are holes or cracks found in the wastegate Repai r
cracks o r holes. actuator h ose? complete
Refer to Proced u re 0 1 0-050 (Tu rbocharger YES
Wastegate Actuator) i n Section 1 0 i n the I S B ,

Repa ir:
I S B e , I S Be4, OSB4 . 5 , OSB5 . 9 , a n d OSB6 . 7
(Com mo n Rai l F u e l System) Series Engines Replace the wastegate actuator h ose .
Service Manual , B u l letin 402 1 271 . Refer to P roced u re 0 1 0-050 (Tu rbocharger
I S B e , I S Be4, OSB4.5, OSB5 . 9 , a n d OS B6 . 7
(Common Rai l Fuel System) Series Engi nes
Service Manual , B u l l etin 402 1 271 .
Are holes or cracks found i n the wastegate 5G

actuator hose?
NO
Engine Performance Troubleshooting Tree for QSB5 .9 Mari [ . . . J ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J
STEP 5G : . Ieaks
nspect the tur boch arQer wasteQate capsu Ie fo r air
Cond ition:
• Engine OFF.
• Remove the wastegate actuator hose from the wastegate actuator.
Action S pecificati on/Repai r Next Step
Perform a l eak test on the wastegate actuator Did the wastegate actuator capsule leak air? Repai r
capsule. YES com plete
U se Wastegate P ressure Test Kit, Part N u m ber Repai r:
3823799, to apply a reg u l ated air supply of 59 in-
Hg to the wastegate actuator capsu l e . No air Replace the wastegate actuator. Refer to
should be heard (a leaking noise) t h rough a Proced u re 0 1 0-050 (Tu rbocharger
fu nctional wastegate capsule. Wastegate Actuator) i n Section 1 0 i n the IS8,
I S 8e , I S 8e4, OS84 . 5 , OS85 . 9 , and OS86 . 7
Refer to P roced u re 0 1 0-050 (Tu rbocharger (Common Rai l F u e l System) Series Engi nes
Wastegate Actuator) i n Section 1 0 i n the I S 8 , Service Manual , 8ul leti n 402 1 271 .
IS8e, I S 8e4, OS84 . 5 , OS85 . 9 , and OS86 . 7
(Common Rai l Fuel System) Series Engi nes
Service Manual, 8 u l l etin 402 1 271 . Did the wastegate actuator capsule leak air? 5G-1
NO
STEP 5G 1
-
nspec t t he t u r b oc h arger wast egate for proper operat i o n .
Cond itio n :
Check for wastegate actuator rod for movement. Did the wastegate actuator rod move? 5H
Use Wastegate P ressure Test Kit, Part N u m ber YES
3823799, to apply a reg u l ated air supply of [29
psi) to the wastegate actu ator capsu l e . Check for Did the wastegate actuator rod move? 5G-2
wastegate actu ator rod for movement.
NO
Refer to P roced u re 0 1 0-050 (Tu rbocharger
Wastegate Actu ator) i n Section 1 0 i n the I S 8 ,
I S 8 e , I S 8e4, OS84 . 5 , OS85 . 9 , a n d OS86 . 7
(Common Rai l F u e l System) Series Engi nes
Service Manual, 8ul leti n 402 1 271 .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J Engine Performance Troubleshooti ng Tree for QSB5 . 9 Mari [ . . . J
Section TT - Troublesho oting Symptoms (New Format) Page TT-1 23
STEP 5G-2 : I nsoect the tu rbocharaer wasteaate for orooer ooerat i o n .
Condition :
• E n g i n e O F F.
• Remove the e-c l i p from the wastegate p i n and discon nect the actuator rod from the wastegate lever.
Check for wastegate actu ator rod movement with Does the wastegate actuator rod m ove? Repai r
it d isconnected from the tu rbocharger wastegate . YES
complete
Use Wastegate P ressu re Test Kit, Part N u mber Repa ir:
psi] to the wastegate actu ator capsu l e . Check for Move the wastegate l ever back and forth and
wastegate actuator rod for movement. check for smooth operatio n . If the wastegate
lever d oes not move freely o r binds, spray a
Refer to Proced u re 0 1 0-050 (Tu rbocharger penetrating o i l on the wastegate l ever joint
Wastegate Actuator) i n Section 1 0 i n the I S B , and try to free the wastegate l ever by worki ng
I S B e , I SBe4, OSB4 . 5 , OSB5 . 9 , a n d OSBS . 7 the lever back and fort h . If the lever does
(Com m o n R a i l F u e l System) Series Engi n es not become free , then replace the
Service Man u a l , B u l letin 402 1 271 . tu rbocharger.
Refer to P roce d u re 0 1 0-033 (Tu rbocharger)
i n Section 1 0 i n the I S B , I S B e , I S Be4,
OSB4 . 5 , OSB5 . 9 , and OSBS . 7 (Co m mon Rail
Manual , B u l let i n 402 1 271 .

NO
complete
Repa ir:

I S B e , I S Be4, OSB4.5, OSB5 . 9 , a n d OSBS . 7
(Co m m o n R a i l F u e l System) Series Engi nes
STEP 5 H M easure t u r boch araer aXl. a I an d ra d·l a I c I earance .
Cond i t i o n :
• Engine OFF.
Action Specification/Re pai r Next Step
Follow the proced ure for measuring the axial and Are the axial and rad ial clearances with i n 51
rad ial clearances of the tu rbocharger. specification?
Section 1 0 i n the ISB, ISBe, I S Be4, OSB4.5,
OSB5 . 9 , and OSB6 . 7 (Com m o n Rail Fuel Are the axial and rad ial cl earances wit h i n Repai r
System) Series Engi nes Service Manual , Bul l eti n specification? com plete
402 1 271 .
NO
Repai r:
Replace the tu rbocharger assembly.

Refer to P roced u re 0 1 0-033 (Tu rbocharge r)
in Section 1 0 i n the I S B , ISBe, I S Be4,
OSB4 . 5 , OSB5 . 9 , and OSB6 . 7 (Com mon Rail
Manual , B u l letin 402 1 271 .
STEP 5 1 nspect t h e a fte rcoo er.
Cond ition:
None.
Action S pecificati on/Repa i r Next Step
I nspect the aftercooler. Is the aftercooler free of cracks or other 2A

damage?
YES
Is the aftercooler free of cracks or other Repai r

damage? com plete
NO
Repair:
Repai r or replace the aftercooler assem bly.

Refer to P roced u re 0 1 0-005 (Aftercooler
Assembly (Sea Water» i n Section 1 0 i n the
I S B , ISBe, I S Be4, OSB4. 5 , OSB5 . 9 , and
OSB6 . 7 (Com mon Rail Fuel System) Series
Engi nes Service Manual , B u l l et i n 402 1 271 .
STEP 6 : El ectro n ic feat u re tro u b l eshoot i n g p roced u res.

S T EP 6A : v e m'f v th e th ro ttl e trave I .
Cond ition :
• Connect I N S ITE™ el ectronic service tool .
Verify the th rottle trave l . Does t h e th rottle position read 0 w h e n t h e 2A

• Use I N SITE™ electronic service tool to mon itor th rottl e is released and 1 00 percent when the
th rottle position while fully depressing and th rottle is actuated ?
releasing the th rottle l ever. YES
Does the th rottle position read 0 when the Repai r

th rottle is released and 1 00 percent when the com p l ete
th rottle is actuated?
NO
Repai r:
Determ i n e and correct the cause of the

th rottle l ever restrictio n .
STEP 7: Base e n g i n e tro u bleshoot i n g proced u res

STEP 7A : v e m'f v t he over head a dIJUS
' tment S are correct.
Cond i t i o n :
Action Specificatio n/Repair Next Step
Measu re the overhead setti ngs. Are the overhead settings with i n the reset 7B
• Remove the rocker lever cover. Refer to l i m its?
P roce d u re 003-0 1 1 (Rocker Lever Cover) i n YES
Section 3 in the I S B , I S B e , I S Be4, OSB4 . 5 ,
OSB5 . 9 , a n d OSB6.7 (Co m m o n R a i l Fuel
System) Series Engi nes Service Manual , Are the overhead settings with i n the reset Repai r
B u l let i n 402 1 271 . l i m its? complete
• M easu re the overhead settings. Refer to NO
P rocedure 003-004 (Overhead Set) in Section
Repa ir:
3 i n the ISB, ISBe, I S Be4, OSB4 . 5 , OSB5 . 9 ,
a n d OSB6 . 7 (Common R a i l F u e l System) Adj ust the overhead settings. Refer to
Series Engi nes Service Man ual , Bul letin P roced u re 003-004 (Overhead Set) i n
402 1 271 . Section 3 i n the I S B , ISBe, I S Be4, OSB4.5,
OSB5 . 9 , and OSB6 . 7 (Common Rail Fuel
Bullet i n 402 1 271 .
Engine Performance Troubleshooting Tree for QSB5 .9 Mari [ . . . J ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J
STEP 7 8· C h e c k the exhaust restriction
Condition :
None.
I nstal l a pressure gauge i nto the exhaust system Is the exhaust system back pressure less 7C
j ust past the tu rbocharger outlet to check the than 1 27 m m-Hg [5 i n-Hg] or 1 763 m m-H 20
exhaust system back pressure . [68 in-H 20] or 1 7 kPa [2.5 psi]?
Refer t o P roced u re 0 1 1 -009 (Exhaust Restriction) YES
i n Section 1 1 i n the I S B , ISBe, I S Be4, OSB4 . 5 ,
OSB5.9, a n d OSB6 . 7 (Common R a i l Fuel
System) Series Engi nes Service Man ual , B u l leti n Is the exhaust system back pressu re l ess Repai r
402 1 27 1 . than 1 27 m m-Hg [5 i n-Hg] or 1 763 m m-H 20 com plete
[68 in-H 20] or 1 7 kPa [2.5 psi]?
NO
Repai r:
Fix or clear the sou rce of high exhaust

system restrictio n .
STEP 7C : Check t he e n a i n e bl OW b)v .
Cond i t i o n :
None.
Action Specificati on/Repai r Next Step
Measu re the engine blowby. Are the engine blowby measurements with i n Return to
specification? step 2 , or
Refer to P roced u re 0 1 4-005 (Engine Testing
(Engine Dynamometer) i n Section 14 i n the I S B , YES contact a
I S Be , I S Be4, OSB4 . 5 , OS B5.9, a n d OSB6 . 7 local
C u m m i ns®
Service Man ual , B u l l etin 402 1 271 . Authorized
Repai r
Location for
further
diagnostic
and
troubleshooti
ng
i nstructions.
Are the engine blowby measurements with i n 7C-1

specification?
NO
IS8, IS8e2 , IS8e3 , IS8e4, QS84 [ . . . J Engine Performance Troubleshooting Tree for QS85 . 9 Mari [ . . . J
STEP 7C- 1 : Verifv the tu rbocharaer co ntribution to th e en�lIne blowbv.
Cond i t i o n :
Verify the tu rbocharger contri bution . H as the total engine blowby d ropped more Repai r
• Connect the appropriate orifice to the end of than 30 percent of the total? complete
the blowby d raft tube. YES
• Remove the tu rbocharger o i l d rain line from
the block and d rain i nto a b ucket. Repa i r :

• Load the engine to rated rpm .
Replace the tu rbocharger asse m b ly. Refer to
• M easu re the engine blowby. Refer to
P roced u re 0 1 4-005 (Engine Testing (Engine 1 0 i n the ISB, ISBe, I S Be4, OSB4 . 5 , OS B5.9,
Dynamometer» i n Section 1 4 i n the ISB, ISBe, and OS B6.7 (Common Rail Fuel System)
I S Be4 , OSB4 . 5 , OSB5 . 9 , and OSB6 . 7 Series Engi nes Service Manual , B u l l eti n
(Common R a i l F u e l System) Series Engi nes 402 1 271 .
Has the total engine blowby d ropped more Repai r
than 30 percent of the total? complete
NO
Repa i r :
The engine m ay need to be rebuilt. Refer to

Proced u re 000-00 1 (Engine Removal) i n
OSB5 . 9 , a n d OSB6 . 7 (Common Rai l Fuel
Bul letin 402 1 271 and the engine reb u i l d
specifications.
STEP 8: Excessive vibration t rou bleshoot i n g p roced u res .

STEP 8A : Ch ec k the Qear rati o an d DrODe II er con fI Q u ratl o n .
Cond ition:
Check for an i ncorrect matching of the gear ratio Are the gear ratio and the propeller Repai r
and p ropeller to the engine power. incorrectly matched to the engine power? complete
YES
Repa ir:
Contact a C u m m i ns® Distri butor o r Marine

District Field Service Manager.
Are the gear ratio and the propeller 8B

incorrectly m atched to the engine power?
NO
Engine Performance Troubleshooti ng Tree for QSB5 . 9 Mari [ . . . J ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
Page TT- 1 2 8 Section T T - Troubleshooting Symptoms (New Format)
STEP 8 8 : C h e c k f o r the correct en�:lIne mou ntma ISO ators and for proper I nsta l l ation reQ U i rem ents.
Cond i t i o n :
None.
Check for the correct engine mount isolators and Are the engine m o u nt isolators correct and 8C
for p ropeller instal lation req u i rements . i nstalled correctly?
YES
Are the engine mount isolators correct and Repai r

i nstal led correctly? com plete
NO
Repai r:
Check for proper isolator instal lation

req u i rements . Replace and repai r vibration
isolators as needed. Refer to P roced u re
0 1 6-026 (Marine Vibration Isolator) i n Section
1 6 i n the I S B , ISBe, I S Be4, OSB4 . 5 , OSB5 . 9 ,
a n d OSB6 . 7 (Common Rai l F u e l System)
Series Engi nes Service Manual , B u l l eti n
402 1 271 and Engine Mounting/Drive
Systems section in the Marine Recreational
I n stal lation D i rections, B u l l etin 3884649 . If
the isolators are not man ufactu red by
C u m m i ns I n c . , refer to the OEM service
manual .
STEP 8C Ch ec k f or d am aae d engme m o u n t s an d ISO

· I at ors.
Cond i t i o n :
None.
I nspect the engine mount and isolators for Are the engine mou nts and isolators i n good 8D
fai l u re . condition?
YES
Are the engine mou nts and isolators in good Repai r

condition? complete
NO
Repair:
Remove and replace the engine mount

isolators . Refer to P roced u re 0 1 6-026
(Mari ne Vibration Isolator) in Section 1 6 in the
ISB, ISBe, I S Be4, OSB4. 5, OSB5 . 9 , and
OSB6 . 7 (Common Rail Fuel System) Series
Engi nes Service Manual , B u l letin 402 1 27 1
a n d Engine Mounting/Drive Systems section
i n the M ari ne Recreational I nstallation
Di rections, B u l letin 3884649 . If the isolators
are not man ufactu red by C u m m i ns I nc. , refer
to the O E M service manual .
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . ] Engine Performance Troubleshooting Tree for QSB5 . 9 Mari [ . . . ]
STEP 80 Ch ec k the ex haust s s te m .
Cond i t i o n :
None.
Action Specificatio n/Repai r N ext Step
Check for exhaust system d eficiencies. Is the exhaust system deficient? Repai r
YES com p l ete
Repa i r :
Repai r or replace as needed . See the

Exhaust System section i n the M ari n e
Recreational I nstal lation D i rections, B u l letin
3884649 and the OEM service lite ratu re and
i nstructions.
Is the exhaust system deficient? 8E

NO
STEP 8E C h e c k the e n un e d riven accessories.
A CAUTI O N A
Some sea wate r p u m ps are belt driven. O perating the e n g i n e when the sea water p u m p is d isconnected
can res u l t in e n g i n e damage due to overheat i n g .
Cond ition:
Check for engine d riven accessories Is an engine d riven accessory Repai r
malfunctions. malfu nction i ng? complete
Isolate o r d isconnect the accessories and check YES
for vibration .
Repa i r :
Do not operate the engine if the sea water p u m p

Determ i n e the cause of the m alfu nctioning
is d isconnected . accessories and correct the prob l e m . See the
Engine D riven Accessories section i n the
Mari n e Recreational I nstal lation Di rections,
Bul leti n 3884649 . If the accessory is not
i nstalled by C u m m i ns I nc. , refer to the OEM
service manual .
Is an engine d riven accessory 8F

malfu nctioning?
NO
Engine Performance Troubleshooting Tree for OS85 . 9 Mari [ . . . J IS8, IS8e2 , IS8e3, IS8e4, OS84 [ . . . J
STEP 8 F
f t COU P r
Ch ec k th e s h a I InQ a rIQnment.
I InQ to Qear COUP r
Cond ition:
Check the shaft cou pl ing to gear cou p l i ng

Is the shaft cou p l i n g to gear cou p l i n g Repai r
al ignment.
m isal igned? com plete
YES
Repair:
Repai r o r replace as needed . Refer to

Proced u re 0 1 6-025 (Propeller S haft) in
Section 1 6 i n the ISB, ISBe, I S Be4, OSB4 . 5 ,
OSB5 . 9 , and OSB6 . 7 (Com mon Rail Fuel
B u l leti n 402 1 271 and Engine M o u nting/Drive
I nstallation D i rections, B u l leti n 3884649 , and
the gear manufacturer's reco m m e ndations.
Is the shaft cou p l i ng to gear co u p l i ng 8G

m isal igned?
NO
STEP 8 G Ch ec k th e prope I I e r S haf t fo r proper inS t a i l atl' o n .
Cond ition:
None.
Act i o n Specification/Repa i r Next Step
Check the propel l e r shaft for proper instal latio n . Is t h e p ropeller shaft i nstalled correctly? 8H
YES
Is the p ro pe l ler shaft instal led correctly? Repai r

NO complete
Repair:
Repai r o r replace as needed . Refer to

Proced u re 0 1 6-025 (Propeller S haft) in
Section 1 6 i n the ISB, ISBe, I S Be4, OSB4 . 5 ,
OSB5 . 9 , and OSB6 . 7 (Com mon Rai l Fuel
B u l leti n 402 1 271 and Engine M o u nting/D rive
Instal lation D i rections, Bul letin 3884649 , and
the gear man ufacturer's reco m m e ndations.
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
Engine Performance Troubleshooti ng Tree for QSB5 . 9 Mari [ . . . J
Page TT- 1 3 1
STEP 8 H : Check the proDe l i e r shaft for

straia htness.
Cond ition:
None.
Check the propeller shaft for straig htness. Is the propeller shaft straightness wit h i n the 81
OEM specification?
YES
Is the p ro peller shaft straightness with i n the Repai r

OEM specification? com plete
NO
Repair:
Repai r or replace the propel l e r shaft as

needed . Refer to an authorized OEM Service
Locatio n .
STEP 8 1 : so I at e the
e n a m e .
Cond i t i o n :
Run the engine without the d rive sh aft attached Does the engine vibration persist? Repai r
at the coupler. YES complete
Repai r:
Check the engine vibration damper for

damage. Repair or replace as needed . Refer
to Proced u re 001 -052 (Vi b ration Damper,
Viscous) i n Section 1 i n the ISB, ISBe, I S Be4,
aSB4 . 5 , aSB5 . 9 , and aSBS . 7 (Co m mon Rail
Manual , B u l l et i n 402 1 271 .
Does the engine vibration persist? 8J

NO
Engine Performance Troubleshooti ng Tree for QSB5 .9 Mari [ . . . J ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
STEP 8J : Check for strut/cutlass bearina m .lsa rla nm e nt.
Cond i t i o n :
Check for strut/cutlass beari n g m isal ign ment or Is the strut/cutlass beari ng m isal igned or Repai r
strut mounting is not secu re. strut mounting not secure? com plete
YES
Repair:
Check the strut for mounting stiffness . Repai r

or replace as needed . Refer to an authorized
OEM Service Locatio n .
Is t h e strut/cutlass beari ng m isal igned o r 8K

strut mounting n o t secure?
NO
STEP 8K: Che ck the prope I I er.
Cond iti o n :
None.
Check for p ropeller out-of-balance o r prope l le r Is the propeller out of balance o r n o t fitted Repai r
not fitted properly to shaft . properly to the shaft? complete
YES
Repai r:
Check the p ropeller for accu racy. Repai r or

replace as needed . Refer to an authorized
OEM Service Locatio n .
Is the p ro pe l l e r out o f balance or not fitted 8L

properly to the shaft?
NO
STEP 8 L : Ch e ck the V -ana l e on th e V -st ru t .
Con d i t i o n :
None.
Check to see if the V-angle on the V-strut does Does the V-ang l e on the V-strut m atch the 8M
not match the angle of the blad e on the prop. angle of the blade on the prop?
YES
Does the V-angle on the V-strut match the Repai r

angle of the blade on the prop? complete
NO
Repair:
Repai r o r replace as needed . Refer to an

authorized OEM Service Location .
STEP 8 M : Check t h e DroDe l l e r t u n n e l s .
Cond ition:
None.
Check if the propell e r tunnels are properly Does the entry and exit of the p ropeller t u n nel 8N
matched with the p ropel l e rs . match w i t h the p ropeller blades?
YES
Does the entry and exit of the propeller tunnel Repai r

match with the propeller blades? complete
NO
Repai r:
Repai r or replace as needed . Refer to an

STEP 8 N : Check the e n a i n e to transmission torslona couDl i na .
Cond ition:
None.
Check for i n correct or worn torsional coupl i n g . Is t h e torsional coup l i ng incorrect or worn? Repai r
YES complete
Repai r:
Replace the coupl i n g . Refer to the OEM

service l iterature.
Is the torsional cou p l i ng i n co rrect or worn? 80

NO
Engine Performance Troubleshooti ng Tree for QSB5 .9 Mari [ . . . J ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . J
.
STEP 8 0 ·. Check the rudder
Cond ition:
None.
Check the rudder for excessive play in the rudder Does the rudder have excessive play in the Repai r
post. rudder post? com plete
YES
Repai r:
Repai r o r replace as needed . Refer to an

Does the rudder have excessive play i n the 8P

rudder post?
NO
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree for QSB5 . 9 Mari [ . . . J
STEP 8 P : Check the enaine flvwheel housina to cvl i nd e r block a

lianment.
Cond ition:
None.
Check the engine flywheel housing to cyl i nder Is the flywheel housi ng align ment i n correct? Repai r
block al ign ment. YES com p l ete
Repa i r :
Real ign the flywheel housing to cyl inder

block. Refer to P roced u re 0 1 6-006 (Flywheel
Housi ng) in Section 1 6 i n the I S B , ISBe,
I S Be4, OSB4 . 5 , OSB5 . 9 , and OSB6 . 7
Service Manual , B u l let i n 402 1 271 .
Is the flywheel housing alignment i ncorrect? Repai r

NO
complete
Repa i r :
The engine m i g ht have i nternal d am age that

has not been detected . Analyze the o i l and
i nspect the fi lters to l ocate an area of
probable damage. Refer to Proce d u re
007-083 (Lub ricating Oil and Fi lter Analysis)
in Section 7 in the I S B , ISBe, I S Be4, OSB4. 5 ,
OSB5 . 9 , a n d OSB6 . 7 (Com mon R a i l Fuel
System) Series Engi nes Service M an u al ,
B u l l etin 402 1 271 .
The engine m i g ht need to be reb u i lt . Refer to
Proced u re 000-00 1 (Engine Removal) i n
OSB5 . 9 , a n d OSB6 . 7 (Com mon Rail F u e l
Bul letin 402 1 271 and the engine reb u i l d
specifications. If t h e e n g i n e is n o t damaged ,
the problem m i g ht be the vessel desi g n .
Refer t o an authorized OEM Service
Location .
Engine Performance Troubleshooting Tree for QSC and QSL [ . . . J ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J
Engine Performance Troubleshooting Tree for QSC and QSL Marine Engines
with CM850 ECM
T h i s tro u bleshoot i n g proced u re s h o u l d be fo l l owed fo r the fo l lowi n g sym pto ms:

• Cran king Fuel P ressu re is Low
• Engine Operati ng Fuel Pressu re is Low
• Engine D iffic u lt to Start or W i l l Not Start (Exhaust Smoke)
• Engine Difficult to Start or W i l l Not Start (No Exhaust Smoke)
• Engine R u n s Rough at I d l e
• Engine Runs R o u g h or M i sfi res
• E n g i n e Speed S u rges U nder Load or i n Operating Range
• Engine S h uts Off or Dies U n expectedly or Dies D u ring Deceleration
• Engine Starts But Will Not Keep R u n n i n g

• E n g i n e Wi l l N ot Reach Rated S peed (rpm)
• I ntake Man ifold Pressu re (Boost) is Below Normal
• Excessive Vibration i n Mari n e Applications
How to Use This T ro u b l eshooti ng P roced u re:

This sym ptom tree can be used to troubleshoot all performance based sym ptoms l i sted above . Start by perform i n g
Step 1 troubleshoot i n g . Step 2 wi l l ask a series o f q u estions a n d wi l l provide a l ist o f troubleshooti ng steps t o perform
depend i n g on the sym pto m . Perform the l ist of troubleshooting in the seq uence shown in the S pecifications/Repai r
section of the tree.
Shop T a l k:
Operational is a term that i n general descri bes vessel performance on the water. Operational p roblems for an engine
can be caused by several d i fferent factors . Some of the factors are engine-related and som e are n o t . Before
troubleshoot i n g , it is i m portant to determ i n e the exact com plaint and whether the engine has a real operational
problem or if it s i m p ly does not meet owner expectations.
Low power is a term that is used i n the field to describe many d ifferent performance p roblems. Low power is defi n ed
as the inabil ity of the engine to prod uce the power necessary to move the vessel at a speed that can be reasonably
expected under the g iven environ ment.
Poor acceleration or response is described as the inabil ity of the vessel to accelerate satisfactorily from a stop. It can
also be the lag in acceleration at cond itions less than rated speed and load . Poor acceleration or response is d iffic u lt
to troubleshoot, si nce it can be caused by several factors.
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree for QSC and QSL [ . . . J
TROU BLESHOOT I N G S U M MARY
STEPS S P EC I F I CATI O N S S RT CO D E
STEP 1 : Perform basic trou bleshooti ng proced u res.
S T E P 1 A: C h e c k f o r active fau l t codes or Active fau lt codes o r high cou nts
high cou nts of i n active fau lt of i n active fau l t codes?
codes.
STEP 1 8 : Perform basic troubleshooting

Can the problem be verified?
checks.
STEP 1 C : Perform basic troubleshoot i n g

All steps h ave been verified to
checks.
be correct?
STEP 2 : Deter m i nat i o n of e n g i n e sym pto m .

STEP 2A: Low power , poor acce leration ,
Is the e n g i n e sym ptom low
or poor response.
powe r, poor acce leration , or
poor response?
STEP 2 8 : Engine m isfire, engine speed Is the e n g i n e sym ptom e n g i n e

surge, o r e n g i n e speed m isfi re , e n g i n e speed surge, o r
u nsta b l e . e n g i n e speed u nstable?
STEP 2 C : Excessive white o r b l a c k smoke. Is th e engine sym ptom

excessive wh ite or black smoke?
STEP 2 0 : Low intake man ifold p ressure. Is the e n g i n e sym ptom low boost
press u re
STEP 2 E : Engine will not start o r d ifficult

Is the e n g i n e symptom e n g i n e
to start , e n g i n e shuts off
w i l l n o t start or diffi c u l t to start
u n expected ly.
o r e n g i n e sh uts off
u n expected ly?
STEP 2 F : En g i n e vibrati o n excessive. Is the e n g i n e sym ptom E ng ine

Vi bration Excessive occurring
when the e ng ine is i n or out of
gear?
STEP 3: E n g i n e start i n g and ru n n i ng trou bleshoot i n g proced u res.

STEP 3A: Verify the f u e l supply and return Are th e fuel supply and return
valves are open. valves i n the open position?
STEP 3A- 1 : Check the fuel coo l e r for Is the fuel cooler damaged o r
damage due to h i g h fuel coll apsed i nternal ly?
ret u rn back pressure.
STEP 38: Verify the low p ressu re fuel l i nes Are the low p ress u re fuel l i nes
are routed correctly. con nected properly to the ECM
coo l i n g plate?
STEP 3C: Check the e n g i n e speed d u ri n g Is the e ng ine cran king speed
cranki n g . g reate r than 1 50 rpm?
STEP 3D: Check the e lectro n i c control Is the keyswitch voltage equal to
m od u l e (ECM) keyswitch battery voltage?
voltag e .
STEP 3E: C h e c k the E C M battery supply Is the ECM battery supply

voltag e . voltage equal to the battery
voltage?
STEP 3F: Verify the rail fuel press u re Is the rai l fuel press u re sensor
sensor accu racy . (measu red) val ue l ess than 30
bar [435 psi]?
Engine Performance Troubleshooting Tree for QSC and QSL [ . . . J ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J
STEP 3 G : C h e c k f o r fuel rai l press u re w h i l e Did Fau l t Code 22 1 5 or 559

cran king the e n g i n e . become active d u r i n g the failed
start attem pt?
S T E P 3G- 1 : Check the fuel gear p u m p Is the fuel gear p u m p pressure

p ress u re . g reater than 69 kPa [ 1 0 psi]?
STEP 3G-2 : Check the fuel l i ft p u m p Is the fuel l ift pump press u re
p ressure. g reate r than the specifications?
STEP 4: F u el system tro u b l eshoot i n g proced u res.

STEP 4A: Check f o r a i r i n the h i g h I s a i r present i n t h e f u e l s u pply?
press u re p u m p fuel supply
STEP 48: Measure the fuel i n let restriction Is the fuel i n let restriction above
specification?
STEP 4 C : Perform the s i n g l e cyl i nder Can th e m iss o r excessive

cutout test . s m o ke be attri buted to a S i n g l e
cyl i nder?
STEP 4 0 : Perform t h e cyl i nder balance Does the Cyl i nder Performance
d i ag nostic test . Test identify any cyl i nder that is
contri buting to a power
i m balance?
STEP 4 E : M easu re the fuel d rain l i ne Is the d ra i n l i ne restriction w i t h i n

restrictio n . specification?
STEP 5 : A i r hand l i ng tro u b l eshoot i ng proced u res .

STEP 5A: Check the i ntake manifold Is the read i ng with i n 1 0 1 . 6 mm
p ress u re sensor accu racy . H g [4 i n- H g] of local barom etric
p ressu re?
STEP 5 8 : Check t h e a i r i ntake syste m for Were any air i ntake system leaks
leaks . found?
STEP 5C: C h e c k the a i r i ntake restrictio n . Is the a ir i ntake restriction

STEP 50: I nspect t h e tu rbocharger b l ades Are the tu rbocharger b l ades

for damage. damaged?
STEP 5E: Dete r m i n e if the tu rbocharger is Is the tu rbocharger a waste

a waste g ated tu rbocharger. gated tu rbocharger?
STEP 5F: I nspect the wasteg ate actuator Are h ol es or cracks fou n d in the
hose . waste g ate actu ato r hose?
STEP 5 G : I nspect the tu rbocharger Did the wastegate actuator rod

wastegate caps u l e for a i r leaks. m ove?
STEP 5G-1 : I nspect the tu rbocharger Did the wastegate actuator rod
operat i o n .
S T E P 5G-2 : I nspect t h e tu rbocharger Does the wastegate actuator rod

operat i o n .
STEP 5 H : M easu re tu rbocharger axial and A re the axial and rad ial
rad ial cl earance. c learances with i n specification?
STEP 5 1 : I nspect t h e afte rcooler. Is the afte rcoo ler free of c racks
or damage?
STEP 6: E l ectro n ic featu re tro u b l eshoot i n g p roced u res.

STEP 6A: Verify the th rottl e travel . Does the t h rottle position read 0
when the t h rottle is rel eased and
IS8, IS8e2 , IS8e3 , IS8e4, QS84 [ . . . J Engine Performance Troubleshooting Tree for QSC and QSL [ . . . J
1 00 percent when the th rott l e is

actuated?
STEP 7 : Base e n g i n e tro u b l eshoot i n g p roced u res _
STEP 7A : Verify the ove rhead adj ustments A r e the overhead settings with i n
are correct. t h e reset l i m its?
STEP 7 B : Check the exhaust restrictio n . Is the exhaust back p ress u re

l ess than 75 m m - H g [3 in-Hg] o r
1 0 1 6 m m-H 20 [ 4 0 i n-H 20]?
STEP 7C: Check the engine b l owby. Are the e ng ine b lowby
m easu re m e nts w i t h i n
specification?
STEP 7C- 1 : Verify tu rbocharger Has the total e n g i n e b l owby

contribution to e n g i n e d ro pped m ore than 30% of the
blowby. total?
STEP 8: Excessive v i b rati o n t ro u b l eshoot i n g p roced u res .

STEP 8A: Check the gear rati o and Are the gear ratio and the
prope l l e r confi g u rati o n . prope l l e r i ncorrectly m atched to
the e n g i n e power?
STEP 8 B : C h e c k for correct e n g i n e m o u n t Are the e ng ine mount isolators

isolators and f o r proper correct and i nstal led correctly?
i nstal lation req u i rements.
STEP 8 C : Check for damaged e n g i n e Are the e n g i n e mou nts and

m o u nts and isolators. iso l ators i n good condition?
STEP 8 0 : Check the exhaust system . Is th e exhaust system deficie nt?
STEP 8 E : Check t h e e n g i n e d riven Is an e n g i n e driven accesso ry

accessories. malfunctioni ng?
STEP 8F: Check the shaft cou p l i ng to gear I s the shaft cou p l i n g to gear
cou p l i n g a l i g n ment. cou p l i n g m isal ig ned?
STEP 8G: Check t h e prope l l e r shaft for Is the prope l l e r shaft i nsta l l ed
proper i n stal l at i o n . correctly?
STEP 8H: C h e c k the prope l l e r shaft for Is the prope l l e r shaft

strai ghtness. straig htness with i n th e O E M
specification?
STEP 8 1 : Isolate t h e e n g i n e . Does the e ng ine v i b ration

pe rsist?
STEP 8J : C h e c k for strut/cutlass beari ng Is the strut/cutlass beari ng

m isal i g n m e n t . m isal ig ned o r strut m ou nting not
secu re?
STEP 8 K : C h e c k the prope l l e r . Is the prope l l e r out of balance o r

prope l l e r n o t fitted properly t o
shaft?
S T EP 8 L : C h e c k the V-angle o n the V Does the V-angle on th e V-strut

strut. match the angle of the blade on
the propel l e r?
STEP 8M: Check the prope l l e r t u n nels. Does the entry and exit of the
prope l l e r t u n n e l match with the
prope l l e r blades?
STEP 8 N : Check the e n g i n e to Is the torsional cou p l i n g

transmission torsional cou p l i n g . i ncorrect o r worn?
STEP 80: C h e c k the rudder. Does the rudder have excessive

p l ay in the rudder post?
STEP 8 P : Check the e n g i n e flywheel Is the flywheel housing

housing to cyl inder block a l i g n ment incorrect?
a l i g n ment.
STEP 1 : Perform basic t ro u b l eshoot i n g proced u res.

STEP 1 A: .
Ch ec k f or acrIve fau It codes or h'Igih cou n t s 0 f macrIve fau It codes.
Cond ition:
Check for any active fau lt codes. Active fau lt codes or high cou nts of i n active Repai r
• Use I N S ITE™ electronic service tool to read the fau lt codes? com plete
fau lt codes. YES
Repai r:
Reference Section TF i n the Troubleshooting

and Repair Man ual , I S B , I S Be 4 , OSB4 . 5 ,
OSB5 . 9 , OSB6 . 7 , ISC, OSC8 . 3 , I S L , and
OS L9 Engi nes, CM850 Electronic Control
System , B u l letin 402 1 4 1 6 for fau lt code
troubleshooti ng .
Active fau lt codes or h i g h cou nts o f i n active 1B

fau lt codes?
NO
STEP 1 8 . t rou blesh 00 r ma checks .

P er f orm baSlc
Cond ition:
None.
Verify the fol lowi ng items. Can the problem be verified? 1C

• Is the engine operating with i n the con d itions it
YES
was i ntended to perform? For exam p l e , wide
open th rottle rpm , ambient versus engine
room tem peratu res, load on the vessel , sea Can the problem be verified? Repai r
cond itions, etc. NO complete
• Are the customer's expectations i n line with
Repair:
the engine capab i l ity?
• Is the engine performing accord i n g to the OEM The problem can n o t be verified and no
sea trial? repai r is possible.
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ] Engine Performance Troubleshooting Tree for QSe and QSL [ . . . ]
STEP 1 C: Perform the basic tro u bleshootina checks.
Cond ition:
None.
The fol lowi ng items m ust be checked or verified All steps have been verified to be correct? 2A
before conti n u i n g .
YES
• Verify the fuel level i n the tanks.
• Verify there h ave not been any changes to the
C P L (tu rbocharger, i njectors , pistons, fuel All steps have been verified to be correct? Repai r
p u m p , camshaft , etc. ) com ponents on the NO com p l ete
engine.
Repa ir:
• Verify the fuel g rade is correct for the
app l i catio n . Correct the condition a n d ve rify the com plaint

• Verify the engine is operating with i n the is no longer present after the repai r.
reco m mended altitud e .
• Verify the engine o i l is at the correct leve l .
• Verify none of the air vents are restricted or
obstructed .
• Verify the engine parasitics have not changed .
• Verify the engine d uty cycl e has not changed .
• Verify the engine cran king speed is g reater
than 1 50 rpm .
• Verify the battery voltage is adeq u ate .
• Verify the d rive trai n is correctly matched to the
engine.
• Verify the transm ission is correct and is not
malfuncti o n i n g .
• Verify the propeller is at the correct p itch and
is not damaged .
• Verify the fuel i n l et temperatu re to the fuel
pump is with i n specification .

• Verify the engine th rottle and th rottle wiring is
correct for the engine response issues.

• Verify the condition of the h u l l (clean and no
damage).
Engine Performance Troubleshooting Tree for ase and aSL [ . . . J ISB, ISBe2 , ISBe3 , ISBe4, aSB4 [ . . . J
STEP 2: Determi nat i o n of e n g i n e sym pto m .

STEP 2A L ow powe r poor acce I e rarl o n , or poor reSDonse.
Cond i t i o n :
None.
Act i o n S pecification/Repa i r Next Step
Determ i n e the engine sym ptom accord i n g to the Is the engine symptom low powe r, poor Perform the
engine performance. acceleration , or poor response? troubleshooti
YES ng steps
suggested i n
Repa ir: t h e repair
Perform the troubleshooting steps in the proced u re .
recom m ended order l i sted below.
• Step 4 - Fuel System Ch ecks
• Step 5 - Air Hand l i n g Checks
• Step 6 - E lectronics C hecks
• Step 7 - Base Engine Checks
Is the engine sym ptom low power, poor 2B

acceleration, o r poor response?
NO
STEP 2 B E naine m i s fI re ename spee d s u rae or e n a i n e spee d u nstab l e .
Cond i t i o n :
None.
Determ i n e the engine sym ptom accord i n g to the Is the engine sym ptom engine m i sfire, engine Perform the
engine performance. speed s u rge, or engine speed u nstable? troubleshooti
YES ng steps
suggested i n
Repai r: t h e repair
Perform the trou bleshooti ng steps i n the proced u re .
recommended order l i sted below.
-
• Step 5 Air H and l i ng Checks

-

-
Is the engine symptom engine m i sfire, engine 2C

speed surge, or engine speed u nstab le?
NO
STEP 2 C ' Excessive white or black smoke
Cond i t i o n :
None.
Determ i n e the engine sym ptom accord i n g to the Is the e n g i n e sym pto m excessive wh ite or Perform the
engine performance. black smoke? troubleshooti
YES ng steps
suggested in
Repa i r : the repai r
Perform the troubleshooting steps i n the proced u re.
reco m m ended order l i sted below.
• Step 5 Air Hand l i ng Checks
-

-
Is the e n g i n e sym ptom excessive wh ite or 20

black smoke?
NO
S T E P 2 0 .. Low mta ke m a n !'f 0 Id pressu re .
Cond ition:
None.
Determ i ne the engine sym ptom accord ing to the Is the engine sym ptom low boost p ressu re? Perform the
engine performance. YES troubleshooti
ng steps
Repai r: suggested i n
Perform t h e troubleshooting steps i n the the repai r
reco m mended order l i sted below. proced u re.
• Step 5 Air H and l i ng Checks
-

-

-
Is the engine sym ptom low boost p ressu re? 2E

NO
Engine Performance Troubleshooting Tree for QSC and QSL [" ,J ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [" ,J
STEP 2 E E n a m e W 'I I I n o t start o r d 'I ffICU t to start, ename s h uts 0 ff u nexpecte d lIV.
Conditio n :
None.
Determine the engine sym ptom accord i n g to the Is the engine sym ptom engine wi l l not start Perform the
engine performance. or d ifficult to start, engine sh uts off troubleshooti
unexpectedly? ng steps
YES
suggested in
the repair
Repair: proced u re .
Perform the troubleshooti ng steps in the
recom mended order l isted below.
• Step 3 N o Start Checks
-
• Step 4 Fuel System checks

-
• Step 5 Ai r H and l i ng Checks

-

-
Is the e n g i n e sym ptom engine wi l l not start Return t o the

or d ifficult to start , engine sh uts off correct
unexpected ly? sym ptom
NO
tree .
STEP 2F E ngme VI· brarIon excessive.
Cond i t i o n :
None.
Determ i n e the engine sym ptom accord i n g to the Is the sym ptom Engine Vibration is Excessive Perform the
engine perfo rmance. occu rri ng when the engine is i n or out of troubleshooti
gear? ng steps
YES suggested i n
t h e repai r
Repair: proced ure.
Perform the troubleshooti ng steps i n the
reco m mended order l isted below.
-

-
• Step 6 Electron ics Checks

-

-
• Step 8 Excessive Vibration Checks

-
Is the sym ptom Engine Vibration is Excessive Return to the

occu rri ng when the engine is in or out of correct
gear? sym ptom
NO tree.
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ] Engine Performance Troubleshooting Tree for QSC and QSL [ . . . ]
STEP 3: E n g i n e start i n g and ru n n i ng troubleshoot i n g p roced u res.

S T E P 3A: Verify t h e fuel su pplv and return valves are open.
Cond ition:
Verify the fuel supply and return valves are i n the Are the fuel supply and return valves i n the 3B
open position . open position?
If the vessel is new or work has been com pleted YES
on the vessel , the fuel valves cou l d have been left
i n the closed position . Are the fuel supply and return valves i n the 3A- 1
open position?
NO
Repai r:
Turn the fuel supply and return valve to the

open position and verify that no engine
damage h as occu rred .
STEP 3A-1 : Check the fue coo er for damaae du e to h i a h fue return back pressure.
Condition:
None.
Remove and inspect the fuel cooler. Is the fuel cooler damaged or col lapsed Repai r
i nternal ly? complete
Check for i nternal damage, or col l apsed
i nternal ly. YES
For QSL9 engi nes, refer to P roced u re 006-062 Repa i r :

(Fuel Cooler) in Section 6 in the ISC, I SCe , Remove and replace the fuel cooler.
QSC8 . 3 , I S L , I S Le3 and QSL9 Troub leshooting
and Repai r Manual , B u l let i n 402 1 4 1 8 . For QS L9 engines , refer to P roced u re
006-062 (Fuel Cooler) i n Section 6 i n the I SC ,
For QSC8 . 3 engi nes, refer t o P roced u re 008- 1 29 ISCe, QSC8 . 3 , I S L , I S Le3 and QSL9
(M ari ne Gear O i l and Fuel Coo ler Assem bly) i n Troubleshooting and Repai r Man ual , B u l l et i n
Section 8 i n t h e I S C , I S C e , QSC8 . 3 , I S L , I S Le3 402 1 4 1 8 .
and QS L9 Tro u bleshooting and Repai r Manual ,
Bul letin 402 1 4 1 8 . For QSC8 . 3 engi nes, refer t o P roced u re
008- 1 29 (Mari n e Gear O i l and Fuel Cooler
Assem bly) i n Section 8 i n the I S C , ISCe,
QSC8 . 3 , I S L , I S Le3 and QSL9
Troubleshoot i n g and Repai r Manual , B u l l et i n
402 1 4 1 8 .
Is the fuel cooler damaged or col lapsed 3B

i nternal ly?
NO
STEP 3 8 : Verify the low D ress u re fuel l i nes are routed correctly.
Cond i t i o n :
None.
Act i o n S pecification/Repai r Next Step
It is som etimes possible to get the low pressure Are the l ow p ressure fuel l i nes con nected 3C
fuel l i nes con nected to the ECM coo l i n g plate properly to the ECM coo l i n g plate?
i nstalled i m p roperly. YES
The top connection to the ECM cool i n g plate is
the i n l et and the bottom con nection is the outlet. Are the l ow pressure fuel l i nes connected Repai r
Verify these con n ections are correct if the l ow properly to the ECM coo l i n g plate? complete
pressure fuel l i nes h ave been removed and NO
i nstalled on the engine.
Repair:
Properly con nect the low pressure fuel l i nes

to the ECM coo l i n g plate. The fuel i n let is the
top con nection .
STEP 3C : .
Ch ec k the e n a l n e SDee d d u rma cran k·I na .
Cond ition :
• Connect I N S ITElM electronic service too l .
Use I N S ITElM el ectronic service tool to mon itor Is the engine cran ki ng speed g reater than 3D
Engine S peed while cran king the engine. 1 50 rpm?
If the engine does n o t cran k at al l , reference the YES
Engine W i l l Not Crank o r C ran ks Slowly
troubleshooting sym ptom tree in the Is the engine cran king speed g reater than Repai r
Troubleshooting and Repai r Manual , I S B , I S Be4, 1 50 rpm? complete
OSB4.5, OSB5 . 9 , OSB6 .7, I SC , OSC8 . 3 , I S L ,
NO
and OSL9 Engi nes, CM850 E lectronic Control
System , B u l letin 402 1 41 6 . Repai r:
Find and correct the cause for low cran king

speed . C h eck the batteries, engine starting
motor and accessory loads. Reference the
Engine Will Not Cran k or Cran ks Slowly
troubleshooti ng sym ptom tree .
ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J
Engine Performance Troubleshooting Tree for QSC and QSL [ . . . J
Page TT-1 47
STEP 3 D : . h vo It aae .
Ch e ck the ECM k evswltc
Cond ition:
• D isconnect the OEM harness from the EC M .
Measu re the sig nal voltage. Is the keyswitch voltage eq ual to the battery 3E
•M easure the signal voltage from the keyswitch voltage?
i n put S I G NAL wire of the OEM harness to the YES
engine block g rou nd .
Measu re the keyswitch voltage with the Is the keyswitch voltage eq ual to the battery Repai r
keyswitch in the "ON" position and also with the voltage? com p l ete
keyswitch in the "Cran king" pOSition .
NO
Refer to the wiring d i ag ram for con nector pin
Repai r:
identification .
Repai r or replace the keyswitch harness and/
or keyswitch . Check the battery connections.
The keyswitch harness can be supplied by
the OEM .
STEP 3E Check th e ECM b att e rv SU--'Hmf voItCHle .
Cond i t i o n :
• Turn the keyswitch OFF.
• Disconnect the ECM power harness from the ECM .
Act i o n Specification/Repair Next Step
Measu re the voltage. Is the ECM battery supply voltage eq ual to 3F

•M easu re the voltage fro m the ECM battery the battery voltage?
supply ( ) to the ECM battery supply ( + ) pins
-
YES
in the ECM power harness con n ector.
Measu re the ECM voltage with the keyswitch i n Is t h e E C M battery supply voltage eq ual to Repai r
the ON position and also with the keyswitch in the the battery voltage? com plete
"Cran king" position .
NO
Refer to the wiring d iagram for con nector pin
Repai r:
identification .
Repai r or replace the ECM power harness.
Check the battery connections and fuse
term i n als.
Engine Performance Troubleshooting Tree for QSC and QSL [ . . . J ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J
STEP 3 F : Verify the rai l fuel press u re sensor accu racy.
Cond ition :
Act i o n S pecification/Repair N ext Step
Mon itor the rai l fuel pressu re sensor. Is the rai l fuel pressu re sensor (m easu red) 3G
val ue less than 30 bar [435 psi]?
Use I N SITE™ electronic service tool to mon itor
the rai l fuel press u re sensor (measu red) with the YES
keyswitch ON and the engine not r u n n i n g .
Is t h e rai l f u e l p ressure sensor (measu red) Repai r
val ue less than 30 bar [435 psi ] ? com plete
NO
Repai r:
Replace the rai l fuel pressure sensor.

Refer to P roced u re 0 1 9- 1 1 5 (Ra i l Fuel
Pressure Sensor) i n Section 1 9 in the
Troubleshooti ng and Repai r Manual , I S B ,
I S Be4, OSB4 . 5 , OSB5.9, OSB6 . 7 , I S C ,
OSC8 . 3 , I S L , a n d OSL9 Engi nes, CM850
Electronic Control System , B u l letin 402 1 4 1 6 .
STEP 3 G Check f o r f u e rai l press u re w h i l e cran kina the enalne.
Cond ition:
Check for fuel rai l pressure . Did either Fau lt Code 22 1 5 or 559 becom e 3G- 1
• Attem pt t o start the engine b y engaging t h e active d u ri n g t h e fai led start attem pt?
engine starter f o r at lease 3 0 cont i n uous

YES
seconds.
• Use I N S ITE™ electronic service tool to mon itor
the Fuel Rail p ressure (M easu red) and Fuel Did either Fau lt Code 221 5 or 559 become 4A
Rail P ressure (Com manded). active d u ri n g the fai led start attem pt?
• Use I N S ITE™ electronic service tool to read the NO
fau lt codes.
Attem pting to start the engine for 30 cont i n uous
seconds allows the fault code logic t i m e to ru n . If
either Fau lt Code 221 5 or 559 becomes active ,
then fuel rai l pressure is not being developed .
Refer to B u l l etin 402 1 4 1 6 Troubleshooti ng and
Repai r Manual , I S B , I S Be4, OSB4 . 5 , OSB5 . 9 ,
OSB6 . 7 , ISC, OSC8 . 3 , I S L , a n d OSL9 Engi nes,
CM850 E lectronic Control System .
If the engine starts d u ri n g this attempt, i t i s
possible that fuel prime t o t h e h i g h pressure
p u m p has been l ost. Look for loose fuel l i nes or
fi lters that allow for loss of fuel pri me.
STEP 3 G- 1 : Ch ec k t h e f ue I aear D u mJtjH"eSSure.
Cond i t i o n :
Action Specificati o n/Repai r N ext Step
I nstall a pressure gauge at the press u re side fuel Is the fuel gear pump p ressure g reater than Repai r
filter head . 69 kPa [ 1 0 psi] while cran king? complete
• Measu re the fuel gear pump output p ressu re
YES
while cran king the eng i n e . Refer to P rocedure
005-025 (Fuel Pump G ear P u m p) i n Section 5 Repa ir:
i n the ISC, ISCe, OSC8 . 3 , I S L , I S Le3 and Fol l ow Fault Code 221 5 troubleshooting tree.
OS L9 Troubleshooti ng and Repai r Man ual , Refer to B u l l et i n 402 1 41 6 Tro u bleshooting
B u l leti n 402 1 4 1 8 . a n d Repai r Manual , 1 9 B , I S Be4, OSB4 . 5 ,
Cran king speed m ust be g reater t h a n 1 50 rpm . OS B5 . 9 , OSB6.7, ISC, OSC8 . 3 , ISL, and
OSL9 E n g i nes, CM850 Electronic Control
System .
I s the fuel gear p u m p p ressure g reater than 3G-2

69 kPa [ 1 0 psi] while cran king?
NO
S T E P 3G-2 : Check t h e fuel l ift D u m D pressure.
Cond ition:
Action Specificati o n/Repair Next Step
I nstall a p ressure gauge at the i n let port of the Is the fuel l ift pump pressure g reater than the Repai r
fuel p u m p . specifications? complete
• M easu re the f u e l lift p u m p output pressure.
YES
Refer to Proced u re 005-045 (Fuel Lift P u m p) in
Section 5 i n the ISC, ISCe, OSC8 . 3 , ISL, I S Le3 Repai r:
and OSL9 Tro ub l eshooting and Repai r Replace the fuel p u m p .
Man u a l , B u l l eti n 402 1 4 1 8 .
Refer to P roced u re 005-025 (Fuel P u m p G ear
At i n itial key-on , the l i ft p u m p w i l l run for 60 Pump) i n Section 5 i n the ISC, ISCe, OSC8 . 3 ,
seconds then stop. The l ift p u m p w i l l run for 30 ISL, I S Le3 a n d OS L9 Tro u bleshooti ng and
seconds at key-on and 30 seconds after starting Repai r Manual , Bul leti n 402 1 4 1 8 .
the eng i n e .
Is t h e f u e l lift p u m p pressure g reater than the Repai r
specifications? complete
NO
Repa ir:
Replace the fuel lift p u m p . Refer to

Proced u re 005-045 (Fuel Lift P u m p) i n
Section 5 i n t h e ISC, I SCe, OSC8 . 3 , I S L ,
I S Le3 a n d OS L9 Troubleshooti ng a n d Repai r
Manual , B u l letin 402 1 41 8 .
Engine Performance Troubleshooting Tree for ase and aSL [ . . . J ISB, ISBe2 , ISBe3, ISBe4, aSB4 [ . . . J
Page TT-1 S0 Section TT - Troubleshooting Symptoms (New Format)
STEP 4: Fuel system tro u b l eshoot i n g proced u res .

STEP 4A: Check for a i r i n the h i a h D ressu re D u m D fu e l S U D D l v .
Condition :
None.
Check fo r air i n the fuel . Is ai r present i n the fuel supply? Repai r

YES com plete
Refer to P roced u re 006-003 (Ai r i n Fuel) i n
Section 6 i n t h e I S C , I SCe, QSC8 . 3 , I S L , I S Le3 Repair:
and QSL9 Troubleshooting and Repai r Manual ,
Bul letin 402 1 41 8 . Locate and correct the cause of air i ngestion
i n the fuel supply system . Sou rces of ai r
i ngestion i nclude loose fuel fi lters , l oose fuel
l i ne fittings, l oose or cracked fuel tan k stand
pi pes , o r severe restrictions i n the fuel supply
Is ai r present i n the fuel supply? 4B

NO
STEP 48 ' M easu re the fuel i n let restriction
Cond ition:
None.
Measu re the fuel i n let restriction at the customer Is the fuel i n let restriction above Repai r
connectio n . specification? com plete
Refer t o Proced u re 006-020 (Fuel I n let YES
Restriction) i n Section 6 i n the ISC, I SCe , Repair:
QSC8 . 3 , I S L , I S Le3 and QSL9 Troubleshooti ng
and Repai r Manual , B u l letin 402 1 41 8 . Find and correct the cause of high fuel i n let
restriction . Look for plugged OEM fuel fi lters
Maxi m u m f u e l i n let restriction a t the customer or screens, a restricted ECM cooler,
con nection. restricted l i ft p u m p bypass check valve (in the
• N ew fi lter: 63 . 5 m m-Hg [2.5 i n-Hg] ECM coole r) , p i nched OEM fuel l i nes, or a
• D i rty Fi lter: 1 0 1 . 6 m m - H g [4.0 i n-Hg] restricted stand p i pe i n the O E M fuel tan k.
Is the fuel i n let restriction above Repai r

NO
Repair:
Replace the fuel gear p u m p . Refer to

Proced u re 005-025 (Fuel Pump G ear P u m p)
i n Section 5 i n the ISC, ISCe, QSC8 . 3 , I S L ,
I S Le3 and QS L9 Troubleshooting a n d Repai r
Manual , B u l l etin 402 1 41 8 .
STEP 4 C : P er f orm t h e smale cv r

l lnder cutout test .
Cond i t i o n :
• Start the e n g i n e a n d ru n at low i d l e .
Perform the single cyl inder cutout test . Can the m iss or excessive smoke be Repai r
• Operate the engine at load . attributed to a single cyl i nder? com p l ete
• U se I N S ITE™ electronic service tool to perform
YES
the Cyl inder Cutout test . D isable i n d ividual
i njecto rs . Repa ir:
Look f o r a cause o f the complaint i n c l u d i n g

that can i n d i cate power cyl inder damage, or
fou nd , rep l ace the fuel i nj ector i n the cyl i nder
that was identified using the s i n g l e cyl inder
cutout test.
Section 6 i n t h e I S C , I SCe, QSC8 . 3 , I S L ,
I S Le3 a n d QSL9 Troub leshooti ng a n d Repai r
Manual , B u l l et i n 402 1 41 8 .
C a n the m i ss or excessive smoke b e 4D

attrib uted t o a single cyl i nder?
NO
Engine Performance Troubleshooting Tree for ase and aSL [ . . . J ISB, ISBe2 , ISBe3, ISBe4, aSB4 [ . . . J
STEP 4 0 : Perform the cyl i nder balance d'laQnostlc test .
Cond i t i o n :
• Connect I N S ITpM electronic service too l .
Perform the cyl i nder balance d i agnostic test . Does the Cyl inder Performance Test identify Repai r
• Use I N S ITE™ electronic service tool to perform any cyl inder that is contri buting to a power complete
the Cyl inder Performance Test . Determ i n e if a i m balance?
single cyl inder is contri buti ng to the engine YES
sym ptom .
Repair:
Look for a cause of the power i m balance

incl u d i n g valve lash and excessive
cran kcase p ressu re that can i n d i cate power
cyl i nder damage or camshaft lobe wear. If no
other damage is found , replace the fuel
i nj ector i n the cyl i nder contri buting to the
power i m balance .
Refer t o P roced u re 006-026 ( I nj ector) i n
Section 6 i n t h e I S C , I SCe, OSC8 . 3 , I S L,
I S Le3 and OS L9 Troubleshooting and Repai r
Manual , B u l letin 402 1 41 8 .
Does the Cyl inder Performance Test identify 4E

any cyl inder that is contri buti ng to a power
i m balance?
NO
S T E P 4E ' Measure the fuel drain l i ne restriction
Cond ition:
None.
Measure the fuel d rain l i n e restrictio n . Is t h e fuel d rain l i n e restriction wit h i n 2A

specification?
Refer to Proced u re 006-0 1 2 (Fuel Drain Line
Restriction) i n Section 6 i n the ISC, ISCe, YES
OSC8.3, ISL, I S Le3 and OSL9 Troubleshooting
and Repai r Manual , B u l letin 402 1 41 8 . Is the fuel d rain l i n e restriction wit h i n Repai r
specification? co mplete
NO
Repair:
Look for causes of high d rain line restriction ,

such as k i n ked or blocked fuel l i nes.
Section TT · Troubleshooting Symptoms (New Format) Page TT·1 53
STEP 5: A i r hand l i ng tro u b l eshoot i n g proced u res.

S T EP 5A: C h e c k the i ntake man ifo l d D ress u re sensor accu racy .
Cond i t i o n :
Mon itor the read i n g for i ntake man ifold pressure Is the i ntake man ifold pressure read i n g less 5B
with the engine off. than 50 . 8 m m - H g [2 i n-Hg] of local barometric
• Start I N S ITE™ electronic service tool datal pressu re?
logger and mon itor the I N S ITE™ electronic YES
service tool read i n g for i ntake man ifold
p ress u re with the engine off.
• Com pare the pressu re read ings observed in

Is the i ntake man ifold pressu re read i n g less Repai r
I NS ITE™ electronic service tool to the local
than 50 . 8 m m- H g [2 i n-Hg] of local baro m etric complete
barometric p ress u re . Refer to P roced u re
press u re?
0 1 8-028 (Barometric Press u re at Altitude) i n NO
Section V .
Repa ir:
Replace the i ntake man ifold p ressure sensor.

Refer to P roced u re 0 1 9-06 1 (I ntake Man ifold
P ressure Sensor) i n Section 1 9 i n the
Troubleshooting and Repai r Manual , I S B ,
I S Be4, OSB4 . 5 , OSB5 . 9 , OSB6 . 7 , ISC,
OSC8 . 3 , I S L , and OSL9 Engi nes, C M850
Electro n i c Control System , B u l l etin 402 1 4 1 6 .
STEP 5 B : Check the a i r mta ke sYstem for leaks.
Cond ition:
None.
Check the ai r i ntake system for leaks. Were any ai r i ntake system leaks fou nd? Repai r
YES
complete
Refer to P roced u re 0 1 0-024 (Ai r Leaks , Air I ntake
and Exhaust Systems) in Section 1 0 in the ISC, Repai r :
ISCe, OSC8 . 3 , I S L , I S Le3 and OSL9
Troubleshooti ng and Repai r Man ual , B u l letin Repai r or replace the damaged com ponent.
402 1 4 1 8 .
Were any a i r i ntake syste m l eaks fou n d ? 5C

NO
Engine Performance Troubleshooting Tree for QSe and QSL [ . . . ] ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ]
STEP 5 C ' C h e c k the a i r intake restriction
Cond i t i o n :
• I nstal l vacu u m gauge Part N u m ber ST- 1 1 1 1 -3 i nto the air i ntake system .
• Engine operating at rated speed and full l oad .
Measure the i ntake system restriction . Is the ai r i ntake restriction g reater than the Repai r
specification? com pl ete
Refer to Proced u re 0 1 0-03 1 (I ntake Air
Restriction) in Section 1 0 in the ISC, ISCe, YES
QSC8 . 3 , I S L , I S Le3 and QSL9 Troubleshooting Repair:
and Repai r Man ual , B u l l et i n 402 1 41 8 .
Correct the cause of h i g h i ntake ai r
Maxi m u m ai r i ntake restriction : restrictio n . Check for plugged air fi lter or
Clean filter: 381 m m- H 20 [ 1 5 i n-H 20] restricted air i ntake p i p i n g .
D i rty fi lter: 6 3 5 m m-H 2 0 [ 2 5 in-H 20]

Is the air i ntake restriction g reater than the 5C
specification?
NO
STEP 50 nspect t he t u r boch arQer b lades f o r d amaQe.
Cond i t i o n :
• Tu rn keyswitch OFF.
• Remove the i ntake and exhaust pi pes from the tu rbocharger.
Action S pecificati on/Re pair N ext Step
I nspect the tu rbocharger. Are the tu rbocharger blades damaged? Repai r

• I nspect the com p ressor b l ades and turb i n e for YES com plete
damage or wear.
Repa ir:
Refer to Proced u re 0 1 0-033 (Tu rbocharger) in
Section 1 0 i n the ISC, I SCe , QSC8 . 3 , ISL, I S Le3 Replace the tu rbocharger assem b ly.
and QS L9 Troubleshooting and Repai r Manual , Refer to P roced u re 0 1 0-033 (Tu rbocharger)
B u l leti n 402 1 4 1 8 . i n Section 1 0 i n t h e I S C , I SCe, QSC8 . 3 , I S L ,
I S Le3 a n d QS L9 Troubleshooti ng a n d Repai r
Manual , B u l letin 402 1 4 1 8 .
Are t h e tu rbocharger blades damaged? 5E

NO
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ] Engine Performance Troubleshooting Tree for QSC and QSL [ . . . ]
STEP 5 E : D ete r m i n e I·f the t u r boc h araer I S a wasteaate d t u rb ocharaer.

Cond ition:
None.
Determ i n e if the tu rbocharger is a wastegated Is the tu rbocharger a wastegated 5F

tu rbocharger. tu rboch arger?
YES
Is the tu rbocharger a wastegated 5H

tu rbocharger?
NO
STEP 5F: nspect the wasteaate actuator hose .
Cond i t i o n :
• Remove the tu rbocharger if the wastegate actuator is i n accessible.
I nspect the i nteg ral wastegate actu ator hose for Are holes or cracks found i n the wastegate Repai r
cracks o r holes. actuator hose? complete
Refer to Proced u re 0 1 0-050 (Tu rbocharger YES
Wastegate Actuator) in Section 1 0 in the ISC, Repa ir:
I SCe, OSC8 . 3 , I S L , I S Le3 and OSL9
Troub leshooting and Repai r Manual , B u l letin Replace the wastegate actuator hose .
402 1 4 1 8 . Refer to P roced u re 0 1 0-050 (Tu rbocharger
Wastegate Actuator) i n Section 1 0 i n the ISC,
Troubleshooting and Repai r Manual , B u l let i n
402 1 4 1 8 .
Are holes or cracks fou nd in the wastegate 5G

actuator hose?
NO
Engine Performance Troubleshooting Tree for ase and aSL [ . . . J ISB, ISBe2, ISBe3 , ISBe4, aSB4 [ . . . J
STEP 5 G : I nsDect the tu rbocharaer wasteaate caDs u l e f o r a i r l eaks
Cond i t i o n :
• Engine OFF.
Perform a leak test on the wastegate actuator Did the wastegate actuator capsule leak air? Repai r
capsu l e . YES complete
Use Wastegate Pressure Test Kit , Part N u m ber Repai r:
3823799 , to apply a reg u l ated air supply of 59 in-
Hg to the wastegate actu ator capsule. N o air Replace the wastegate actuator. Refer to
should be heard (a l eaki ng noise) t h rough a Proced u re 0 1 0-050 (Tu rbocharger
fu nctional wastegate capsule . Wastegate Actuator) i n Section 1 0 i n the ISC,
ISCe, OSC8. 3 , I S L , I S Le3 and OSL9
Refer to Proced u re 0 1 0-050 (Tu rbocharger Troubleshooti ng and Repai r Manual , B u l l etin
Waste gate Actuator) i n Section 1 0 i n the ISC, 402 1 41 8 .
I SCe, OSC8 . 3 , I S L , I S Le3 a n d OSL9
Troubleshooting and Repai r Manual , B u l let i n
402 1 4 1 8 . Did the wastegate actuator capsule l e a k air? 5G- 1
NO
ST E P 5 G- 1 : I nsDect the tu rbocharaer wasteaate for DrODer oDerat i o n .
Cond i t i o n :
• Engine OFF.
• Remove the waste gate actuator hose from the wastegate actuator .
Check for wastegate actuator rod for movement. Did the wastegate actuator rod move? 5H
U se Wastegate Pressure Test Kit, Part N u m ber YES
psi] to the wastegate actu ator capsul e . Check for Did the wastegate actuator rod move? 5G-2
NO
Refer t o Proced u re 0 1 0-050 (Tu rbocharger
Wastegate Actuator) i n Section 1 0 in the ISC,
Troubleshooti ng and Repai r Manual , B u l letin
402 1 4 1 8 .
STEP 5G-2 : nSDect the tu rbocharaer wasteaate for

D rODer ODerat l o n .
Cond i t i o n :
• Engine OFF .
• Remove the e-c l i p from the wastegate p i n and d i scon nect the actuator rod from the wastegate lever.
Check for wastegate actuator rod movem ent with Does the wastegate actuator rod m ove? Repai r
it d i scon n ected from the tu rbocharger wastegate . YES complete
Use Wastegate P ressure Test Kit, Part N u m ber Repa i r :
psi] to the wastegate actu ator capsul e . Check for Move the wastegate lever back and forth and
wastegate actuator rod for m ovement. check for s mooth operation . If the wastegate
lever does not m ove freely or binds, spray a
Refer to Proced u re 0 1 0-050 (Tu rbocharger penetrating o i l on the wastegate lever j o i nt
Wastegate Actuator) in Section 1 0 in the ISC, and try to free the wastegate lever by worki ng
I SCe, OSC8 . 3 , I S L , I S Le3 and OSL9 the lever back and forth . If the lever does
Troub leshooting and Repai r Man ual , B u l letin not becom e free , then replace the
402 1 4 1 8 . tu rbocharger.
Refer to P roce d u re 0 1 0-033 (Tu rbocharger)
i n Section 1 0 i n the ISC, ISCe, OSC8 . 3 , I S L ,
I S Le3 a n d OSL9 Troubleshooting a n d Repai r
Manual , B u l l et i n 402 1 4 1 8 .

NO
complete
Repa ir:

Wastegate Actuator) i n Section 1 0 i n the ISC,
Troubl eshooting and Repai r Manual , B u l letin
402 1 4 1 8 .
STEP 5 H : .
Measu re t u r b och araer aXlaI and rad·l a I c I earance.
Cond ition:
• Engine OFF.
• Disconnect the exhaust and i ntake con n ections from the tu rbocharger.
Follow the p roced u re for measuring the axial and Are the axial and rad ial clearances with i n 51
rad ial clearances o f t h e tu rbocharger. specification?
Refer to Proced u re 0 1 0-033 (Tu rbocharger) in YES
Section 1 0 in the ISC, I SCe , OSC8 . 3 , I S L , I S Le3
and OSL9 Troubleshooting and Repai r Manual , Are the axial and rad ial clearances with i n Repai r
Bul leti n 402 1 4 1 8 . specification? complete
NO
Repa i r :
Replace the tu rbocharger assembly.

Refer to P roced u re 0 1 0-033 (Tu rbocharger)
i n Section 1 0 i n the ISC, I SCe, OSC8 . 3 , I S L ,
I S Le3 a n d OSL9 Troubleshooting a n d Repair
Manual , B u l leti n 402 1 41 8 .
Engine Performance Troubleshooting Tree for QSC and QSL [ . . . ] ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . ]
STEP 5 1 nspec t th e a fte rcoo er.
Cond i t i o n :
None.
Action S pecificat ion/Re pair N ext Step
I nspect the aftercooler. Is the aftercooler free of cracks or damage? 2A

YES
Is the aftercooler free of cracks o r damage? Repai r

NO com pl ete
Repai r:
Repai r or replace the aftercooler assembly.

Refer to Proced u re 0 1 0-005 (Aftercooler
Assembly (Sea Water) i n Section 1 0 i n the
ISC, ISCe, QSC8 . 3 , ISL, I S Le3 and QSL9
402 1 41 8 .
S T E P 6: E l ectro n i c feat u re tro u b l eshoot i n g p roced u res.

STEP 6A v en·frv the t h ro t t i e trave I .
Cond i t i o n :
Verify the th rottl e trave l . Does t h e th rottle position read 0 w h e n the 2A

• Use I N SITE™ electronic service tool to mon itor th rottle is released and 1 00 percent when the
the th rottle position wh i l e fully depressing and th rottle is actuated ?
releasing the th rottle l ever. YES
Does the th rottle position read 0 when the Repai r

th rottle is released and 1 00 percent when the com pl ete
th rottle is actuated?
NO
Repair:
Determ i n e and correct the cause of the

th rottle lever restriction.
Section TT - Troubleshooti ng Symptoms (New Format) Page TT-1 59
STEP 7 : Base e n g i n e tro u b l eshoot i n g p roced u res

STEP 7 A : v erlf·f v t h e over h ead a d ·Jlustments are correct.
Cond i t i o n :
Measu re the overhead settings. Are the overhead settings wit h i n the reset 7B
• M easu re the overhead setti ngs. Refer to l i m its?
Proced u re 003-004 (Overhead Set) in Section YES
3 i n the ISC, ISCe, OSC8 . 3 , ISL, I S Le3 and
OS L9 Trou bleshooti ng and Repair Manual ,
B u l let i n 402 1 4 1 8 . Are the overhead settings with i n the reset Repai r
l i m its? complete
NO
Repa i r :

Proced u re 003-004 (Overhead Set) in
Section 3 i n the ISC, I SCe, OSC8 . 3 , I S L ,
I S Le3 a n d OSL9 Troubleshooting a n d Repai r
Manual , B u l l et i n 402 1 4 1 8 .
STEP 7 8 .· Check the exhaust restriction
Cond ition:
None.
I nstal l a p ress u re gauge i nto the exhaust system Is the exhaust back pressure l ess than 75 7C
just past the tu rbocharger outlet to check the mm-Hg [3 in-Hg] or 1 0 1 6 mm-H 20 [40 i n-H
exhaust system back press u re . 20] ?
Refer to Proce d u re 0 1 1 -009 (Exhaust Restriction) YES
i n Section 1 1 in the ISC, ISCe, OSC8 . 3 , I S L ,
I S Le3 and OSL9 Troubleshooting a n d Repai r
Is the exhaust back pressu re less than 75 Repai r
Manual , Bul let i n 402 1 41 8 .
m m - H g [3 i n-Hg] o r 1 0 1 6 m m- H 2 0 [40 i n-H com p l ete
20]?
NO
Repa i r :
Fix or clear the sou rce of high exhaust

restriction .
Engine Performance Troubleshooting Tree for QSe and QSL [ . . . J IS8, IS8e2, IS8e3, IS8e4, QS84 [ . . . J
STEP 7C: Check the ename blowby.
Cond i t i o n :
None.
Measu re the engine blowby. Are the engine blowby m easu rements with i n Return to
specification? Step 2, or
Refer to P roced u re 0 1 4-0 1 0 (Crancase Blowby,
YES
contact an
Measu re) in Section 1 4 in the ISC, I SCe, OSC8 . 3 ,
authorized
I S L , I S Le3 a n d OSL9 Troubleshooting and
C u m m i ns®
Repai r Manual , B u l leti n 402 1 4 1 8 .
service
representativ
e for further
diagnostic
and
troub leshooti
ng
i nstructions.
Are the engine blowby measurements wit h i n 7C- 1

specification?
NO
STEP 7C-1 : Verify the tu rbocharaer contribution to the e na m e b l owby.
Cond ition:
Verify the tu rbocharger contri b ution. Has the total engine blowby d ropped more Repai r
• Connect the appropriate o rifice to the end of than 30 percent of the total? complete
the blowby d raft tube. YES
• Remove the tu rboch arger oil d rain line from
the block and d rai n i nto a b ucket . Repair:

• Load the engine to rated rpm .
Replace the tu rbocharger assem bly. Refer to
• Meas u re the engine blowby. Refer to
P roced u re 0 1 4-01 0 (C rancase Blowby, 10 i n the I S C , ISCe, OSC8 . 3 , ISL, I S Le3 and
Measu re) in Section 1 4 in the ISC, ISCe, OSL9 Troubleshooting and Repai r Manual ,
OSC8 . 3 , ISL, I S Le3 and OSL9 Bul leti n 402 1 4 1 8 .
Troubleshooting and Repai r M anual , B u l letin
402 1 4 1 8 .
H as t h e total e n g i n e blowby d ro pped more Repai r
than 30 percent of the total? complete
NO
Repair:
The engine may need to be reb u i lt .

Refer t o P roced u re 000-00 1 ( E n g i n e
Removal) i n Section 0 i n the ISC, I SCe ,
OSC8 . 3 , I S L , I S Le3 and OS L9
Troubleshooting and Repai r Manual , B u l l etin
402 1 4 1 8 and the engine reb u i ld
specifications.
Section TT - Troubleshooting Sym ptoms (New Format) Page TT-1 61
STEP 8: Excessive vi brat i o n t rou bleshoot i n g p roced u res .

STEP 8A: Check the aear rat .i o an d orooe l l e r c o nfl a u ratio n .
Cond ition:
Check for an i n correct matc h i n g of the gear ratio Are the gear ratio and the propeller Repai r
a n d p ro peller t o the engine power. incorrectly matched to the engine power? complete
YES
Repai r:
Contact a C u m m i ns® Distributor o r M ari n e

District F i e l d Service Manager.
Are the gear ratio and the prope l l e r 8B

incorrectly matched t o the engine power?
NO
STEP 8 B · C h e c k f o r the co rrect engine mounting ISO ators and for orooer I nsta l l ation reQ u i rements.
Con d i t i o n :
None.
Check for the correct eng i n e mount isolators and Are the engine mount isolators correct and 8C
for propel ler i nstal l ation req u i rem ents. i nstalled correctly?
YES
Are the engine mount isolators correct and Repai r

i nstal led correctly? com plete
NO
Repa ir:
Check for proper isolator i nstal lation

req u i rements. Replace and repai r as needed .
Refer to P roced u re 0 1 6-026 (Mari ne
Vibration Isolator) i n Section 1 6 i n the ISC,
ISCe, QSC8 . 3 , I S L , I S Le3 and QSL9
Trou b l eshooting and Repai r Manual , B u l l etin
402 1 4 1 8 .
Reference t h e E n g i n e Mounting Drive
I nstal lation D i rections, B u l letin 3884649 .
If isolators are non-C u m m i ns®, refer to the
OEM service manual .
STEP 8C : Ch ec k f o r d amaae d engine m o u nt S and 'ISO I at ors.
Cond ition:
None.
I nspect the engine mou nts and isolators for Are the engine mou nts and isolators i n good 8D
fai l u re . condition?
YES
Are the engine mou nts and isolators in good Repai r

condition? complete
NO
Repair:
Remove and replace the engine mount

isolators.
Refer to P roced u re 0 1 6-026 (Mari ne
Vibration Isolator) i n Section 1 6 i n the ISC,
ISCe, OSC8 . 3 , ISL, I S Le3 and OS L9
402 1 41 8 .
Reference t h e E n g i n e Mounting D rive
I nstal lation D i rections, B u l letin 3884649 .
If the isolators are non-C u m m i ns®, refer to
the OEM service manual .
STEP 80 : Check th e ex haust svste m .
Cond ition:
None.
Action S pecificati on/Re pair Next Step
Check fo r exhaust system deficiencies. Is the exh aust system deficient? Repai r
YES complete
Repair:
Repai r or rep l ace as needed . Reference the

OEM service literature and i nstructions.
Is the exhaust system deficient? 8E

NO
STEP 8 E : C heck t h e e n a i n e d riven

· accessories.
CAUT I O N
Some sea wate r p u m ps are belt drive n . O perating the e n g i n e when the sea wate r p u m p is d isco nnected
can res u l t in en g i n e damage due to ove rheat i n g .
Cond ition:
Check for engine d riven accessories Is an engine d riven accessory Repai r

malfunctions. malfu nctioni ng? com p l ete
Isolate or d isconnect the accessories and check YES
for vibration . Repa i r :
Do n o t operate the engine if the sea water p u m p Determ i n e the cause o f the malfu nctioning
is d isconnected . accessories and correct the prob l e m . If the
accessory is not i nstal led by C u m m i n s I nc. ,
refer to the OEM service manual .
Is an engine d riven accessory 8F

malfu nctioning?
NO
S T E P 8 F: I m a to aear COU D r
Ch ec k th e s h af t CO U D r l ma alianment.
Cond ition:
Check the shaft cou p l i n g to gear cou p l i n g Is t h e shaft cou p l i n g t o gear cou p l i n g Repai r
al i g n m ent. m isal igned? com plete
YES
Repai r:
Repair or replace as needed .

Refer to P roced u re 0 1 6-025 (Prope l l e r S haft)
i n Section 1 6 i n the ISC, ISCe, QSC8 . 3 , I S L ,
I S Le3 and QSL9 Troub leshooting a n d Repair
Manual , B u l leti n 402 1 41 8 .
Reference the Engine M o u n t i n g D rive
I nstal l ation D i rections, B u l l etin 3884649 .
Reference the gear man ufacturer's
reco m m endations.
Is the shaft cou p l i n g to gear cou p l i n g 8G

m isal i g ned?
NO
Engine Performance Troubleshooting Tree for QSe and QSL [ . . . ] ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . ]
STEP 8G : Ch eck the D rODe I I er s haf t f or DrODer .inS t a II arI o n .
Cond ition:
None.
Check the propel l e r shaft for proper i nstal lation . Is the propeller shaft i nstal led correctly? 8H
YES
Is the p ropeller shaft i nstalled correctly? Repai r

NO complete
Repa ir:
Repai r o r rep l ace as needed .

Refer to P roced u re 0 1 6-025 (Pro peller S haft)
i n Section 1 6 i n the ISC, I SCe, QSC8 . 3 , I S L ,
I S Le3 and QS L9 Troubleshooting a n d Repai r
Manual , B u l l etin 402 1 4 1 8 .
Reference the Engine Mounting D rive
I nstallation D i rections, B u l letin 3884649 .
Reference the OEM service l iterature.
S T E P 8H . h tness.
Ch ec k the prope I I er s h a ft
fo r stralQI
Cond ition:
None.
Action Specificati on/Repai r N ext Step
Check the propeller shaft for straightness. Is the propeller shaft straig htness with i n the 81
OEM specification?
YES
Is the p ropel ler shaft straightness wit h i n the Repai r

OEM specification? complete
NO
Repa ir:
Repai r o r replace the propeller shaft as

needed . Refer to an authorized OEM Service
Location .
Page TT-1 65
STEP 8 I : so ate t he ename.
Cond ition:
Run the engine without the drive shaft attached Does the engine vibration persist? Repai r
at the coupler. YES
complete
Repa ir:
Check the engine vibration damper for

damage. Repair or replace as needed . Refer
to Proced u re 001 -052 (Vi b ration Damper,
Viscou s) i n Section 1 i n the ISC , ISCe,
QSC8 . 3 , ISL, I S Le3 and QSL9
Troubleshoot i n g and Repai r Manual , B u l letin
402 1 4 1 8 .
Does the e n g i n e vibration persist? 8J

NO
STEP 8 J : Ch ec k f or strut/ cut ass b earma m l. sa rl a n ment.
Cond ition:
Check for strut/cutlass beari ng m isal i g n ment or Is the strut/cutl ass beari ng m isal i g ned or Repai r
strut mounti ng is not sec u re . strut m o u nting not secu re? com plete
YES
Repa i r :
Check the strut for mounting stiffness . Repai r

or replace as n eeded .
Refer to an authorized OEM Service
Location .
Is the strut/cutlass beari ng m isal i g ned or 8K

strut m o u nting n o t secu re?
NO
STEP 8K : Che ck the DrODe I I er.
Cond i t i o n :
None.
Check for propeller out-of-balance or propeller Is the propeller out of balance or n o t fitted Repai r
not fitted properly to shaft. properly to the shaft? complete
YES
Repair:
Check the propeller for accu racy. Repair or

replace as needed .
Location .
Is the propeller out of balance or not fitted 8L

properly to the shaft?
NO
STEP 8L Ch ec k t h e V -anQ l e o n t h e V -strut.
Conditio n :
None.
Check to see if the V-ang l e on the V-strut does Does the V-angle on the V-strut m atch the 8M
not match the angle of the blad e on the propeller. angle of the blade on the p ropel ler?
YES
Does the V-angle on the V-strut m atch the Repai r

ang l e of the blade on the propel ler? com plete
NO
Repai r:
Repai r o r replace as needed .

Location .
Page TT-1 67
STEP 8M : Ch eck th e D rODe I Ie r tu n ne s.
Cond ition:
None.
Check to see if the propeller t u n nels are p roperly Does the entry and exit of the propeller tunnel 8N
matched with the p rope l l ers . match with t h e propeller blades?
YES
Does the entry and exit of the propeller t u n n e l Repai r

match with the propeller blades? com plete
NO
Repa ir:
Repai r or replace as needed .

Location.
STEP 8 N Ch ec k t h e ename to transmission torslona couP r

l ma.
Cond ition:
None.
Check for an i ncorrect o r worn torsional cou p l i n g . Is t h e torsional cou p l i ng i n co rrect or worn? Repai r
YES com plete
Repai r:
Replace the cou p l i n g .

Refer t o the OEM service l iterature .
Is t h e torsional cou p l i n g incorrect or wo rn? 80

NO
STEP 80- Check the rudder
Cond itio n :
None.
Check the rudder for excessive play in the rudder Does the rudder have excessive play in the Repai r
post. rudder post? complete
YES
Repai r:
Repai r o r replace as needed .

Location .
Does the rudder have excessive play i n the 8P

rudder post?
NO
Repair:
If the eng i n e is not damaged , refer to an

STEP 8 p · Check the enaine flvwheel housina to cvl i nder block

a lia nm e nt.
Cond ition:
None.
Check the engine flywheel housing to cyl i nder Is the flywheel housing al i g n m ent i ncorrect? Repai r
block al ign ment. YES com p l ete.
Repa ir:
Real ign the flywheel housing to cyl inder

block. Refer to Proced u re 0 1 6-006 (Flywheel
Housing) i n Section 1 6 i n the ISC, ISCe,
QSC8 . 3 , ISL, I S Le3 and QSL9
Troubleshooting and Repai r Manual , B u l l etin
402 1 4 1 8 .
Is t h e flywheel housing al ign ment i ncorrect? Repai r

NO
com p l ete.
Repai r :
The e n g i n e m ig ht have i nternal damage that

has not been detected . Analyze the o i l and
i nspect the fi lters to locate an area of
probab le damage. Refer to Proced ure
007-083 (Lubricating Oil Fi lter and Analysis)
i n the I S C , I SCe, QSC8 . 3 , I S L , I S Le3 and
QS L9 Troub leshooting and Repai r Manual ,
Bul leti n 402 1 41 8 .
T h e e n g i n e m i g ht need t o b e rebuilt. Refer to
Proced u re 000-001 (Eng i n e Removal) i n
Section 0 i n t h e I S C , I SCe , QSC8 . 3 , I S L ,
I S Le3 a n d QS L9 Troubleshooting a n d Repai r
Manual , B u l letin 402 1 4 1 8 . Refer to the
engine reb u i l d specifications. If the engine is
not damaged , the p roblem m i g ht be the
vessel d esi g n . Refer to an authorized OEM
service l ocatio n .
Engine Performance Troubleshooting Tree - ISB Engines E [ . . . J ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J
Engine Performance Troubleshooting Tree - ISB Engines Equip ped with EGR
(CM850 Electronic Control System)
T h is tro u bleshoot i n g p roced u re s h o u l d be fo l l owed for the fo l lowi n g sym pto m s :

• Engine D ifficult to Start or W i l l Not Start (Exhaust Smoke)
• Engine Difficult to Start or W i l l N ot Start (No Exhaust Smoke)
• Engine Runs Rough at I d l e
• E n g i n e Runs Roug h or M i sfi res
• Engine Speed S u rges under Load or i n Operating Range
• S moke , Wh ite - Excessive
• Engine S h uts Off or Dies U n expectedly or Dies d u ring Deceleration

• Engine Starts but W i l l N ot Keep R u n n i ng
• Engine W i l l N ot Reach Rated S peed (RPM)
• I ntake Man ifold Pressure (Boost) is Below Normal
• Engine Vibration Excessive
How to U se T h i s T rou bleshoot i ng P roced u re:

This sym ptom tree can be used to troubleshoot all performance based sym ptoms l i sted above . Start by performing
Step 1 troub leshooti n g . Step 2 wi l l ask a series of questions and wi l l provide a l ist of troubleshooti ng steps to perform ,
depend i n g on the sym pto m . Perform the l ist of troubleshooting i n the seq uence shown i n the S pecifications/Repai r
section of the tree.
M any steps wi l l reference using the electronic service to I N S ITE™ electronic service tool to check for fau lt codes,
perform tests , mon itor data, and check featu res and parameters. It is recom mended that I N S ITE™ electronic service
tool remai n con nected while using this trou b l eshooti ng tree to periodically check for fault codes. If any fault codes
become active d u ri n g use of the tro u bleshooting tree , disconti nue using this troubleshooting tree and troubl eshoot
the active fau lt cod e .
This sym ptom tree often references other proced u res a n d symptom trees . T h e procedures a n d sym ptom trees
referenced may not be located in the same service l iterature as this sym ptom tree. Refer to P roce d u re 205-00 1
(Add itional Service Literatu re) i n Section L for a l isti ng of the service l iterature avai lable for the engine bei ng serviced .
Shop Talk:
D riveabi l ity is a term that i n general descri bes veh icle performance on the road . Driveab i l ity problems for an engine
can be caused by several d i fferent factors . Some of the factors are engine-related and some are not. Before
troubleshooti ng, it is i m portant to d eterm i n e the exact complaint and whether the engine has a real d riveab i l ity prob lem
or if it sim ply does not meet d river expectations.
Low powe r is a term that is used i n the field to describe many d ifferent perform ance p roblems. Low power is defi n ed
as the inab i l ity of the engine to prod uce the power necessary to m ove the veh icle at a speed that can be reasonably
expected u nder the g iven cond itions of load , g rade, wind, and so on. With i n d ustrial eq u i pment, low power m i g ht
reference the inabil ity of the eq u i pment to pick u p or mai ntai n l oad .
Poor acceleration or response is described as the inabil ity of the veh icle to accelerate satisfactorily from a stop or
from the bottom of a g rade . It can also be the lag i n acceleration d u ring an attem pt to pass o r overtake another ve hicle
at conditions less than rated speed and load . Poor acceleration o r response is d ifficult to troubleshoot si nce it can be
caused by several factors .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISB Engi nes E [ . . . J
T RO U B LESHOOT I N G S U M MARY
STEPS S P EC I F I CATI O N S S RT CODE

STEP 1 : Perfo rm bas i c trou bleshoot i n g proced u res.
S T EP 1 A : Check for active fau l t codes o r Active fau l t codes o r h i g h cou nts
h i g h cou nts of i n active fau lt of inactive fau l t codes?
codes.
STEP 1 B : Perform basic troubleshooti ng

A l l steps have been verified to
checks.
be correct?
STEP 2 : Dete r m i nat i o n of eng i ne sym ptom .

STEP 2A: Engine Diffi c u l t to Start o r W i l l Is the e ng ine sym ptom Eng i n e
N ot Start (With or Without D iffic u l t to Start o r W i l l N ot Start
Exhaust S m o ke) , Engine S h u ts (With o r Without Exhaust
Off or D i es U nexpected ly or D ies S mo ke) , Engine S huts Off o r
d u ri n g Dece l e rat i o n , or Engine D i es U n expectedly or Dies
Starts but Will Not Keep d u r i n g Decel e rat i o n , or E n g i n e
Running. Starts but W i l l Not Keep
R u n n i ng?
STEP 2 B : E n g i n e R u n s Rough a t I d l e ,
Is the engine symptom E n g i n e
E n g i n e Runs Rough o r M i sfi res ,
R u ns Rough a t I d l e , E ng ine R u ns
E n g i n e Speed S u rges at Low or
Rou g h or M i sfi res , E n g i n e Speed
High Idle, E n g i n e Speed S u rges
S u rges at Low or H i g h I d l e ,
u nder Load o r in O pe rat i n g
E ng ine S peed Su rges u nde r
Range.
Load or i n O perat i n g Range?
STEP 2C: Excessive white smoke . Is the engine sym ptom S m oke , .
Black - Excessive?
STEP 2D: Excessive wh ite smoke. Is the e ng ine sym ptom Smoke,
W h ite - Excessive?
STEP 2D-1 : Excessive wh ite smoke . Is the e ng ine using coolant?
S T E P 2D-2 : Excessive wh ite smoke . Is the w h ite smoke excessive

complaint o n ly occu rring when
the e n g i n e is cold and d u ri n g
c o l d a m b i e n t conditions?
STEP 2E: E n g i n e Accel e ration o r Is the e n g i n e sym ptom Eng i n e

Response Poo r , Engine Power Accel e ration o r Response Poo r ,
Output Low , E n g i n e Decel erates E ng ine Power O u t p u t Low,
S lowly, or E n g i n e W i l l N ot Reach E ng ine Dece l erates Slowly,
Rated Speed (RPM) . I ntake Manifold Pressu re (Boost)
is Below Normal or E n g i n e W i l l
N o t Reach Rated Speed (RP M)?
STEP 2 F : I ntake Man ifold P ressu re (Boost) Is the e ng ine sym ptom E ng ine
is Below Normal V i b ration Excessive?
STEP 3: E n g i n e w i l l N ot Start or Stalls Trou b l eshoot i n g P roced u res .

STEP 3A: Verify t h e o peration of cold A r e the necessary c o l d weather
weather start i n g aids. start i n g aids are being used and
are operatio nal as req u i red?
STEP 3B: Check e l ectro n i c featu res and Are e lectronic featu res and
p rogram mable parameters. program mable parameters the
cause for the e ng ine s h utting
down o r the no-start c o m p l a i nt?
STEP 3 C : M o n itor the e n g i n e speed d u ring Is the e ng ine speed g reater than
cranki n g . 1 50 rpm d u r i n g cran king?
Engine Performance Troubleshooting Tree - ISB Engines E [ . . . ] ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . ]
STEP 3 D : Mon itor the E C M Keyswitch Does the User F u e l i n g State

I n pu t . i n di cate "Cranki n g " or is the
keyswitch voltage equal to
battery voltage?
STEP 3 E : Mon itor the ECM Battery S u pply. Is the ECM battery supply
voltage g reater than + 1 1 -VDC
for 1 2-volt systems o r + 22-VDC
for 24-volt systems?
STEP 3F: Check the Load Carry i n g Do the head l i g hts i l l u m i nate
Capab i l ities of the ECM Power brig htly?
and Ground C i rcu its.
STEP 3G: Check orientation of connector. Is th e sensor correctly i nsta l l ed?
STEP 3H: Verify rai l fuel p ressu re sensor Is the Fuel Rail P ressu re
accu racy. (measu red) less than 30 bar
[435]?
STEP 3 1 : M o n itor fuel rai l p ressu re w h i l e Did the F u e l Rai l Press u re

cran king the e n g i n e . (measu red) e q u a l the Fuel Rai l
Press u re (co m manded)?
STEP 4: Fuel system tro u b l eshoot i n g proced u res.

S T E P 4A: C h ec k for a i r i n the fuel supply I s a i r p resent i n the f u e l supply?
line.
STEP 4B: M easu re f u e l fl ow/press u re at Was the pressu re/flow measu red
the i n let of the on e n g i n e fuel with i n the specification?
filter.
STEP 4C: Measu re the fuel i n l et I s th e fuel in let restriction

restricti o n . g reate r than the specification?
STEP 4D: C h e c k if the e n g i n e is e q u i pped Is the engine eq u i p ped with a l i ft

with a l ift pu m p voltage p u m p voltage reg u l ator?
reg u l ator
STEP 4 E : M easu re fuel p ress u re at the Is the p ressure d rop across the
outlet of the o n e n g i n e fuel filter. filter g reater than the
specification?
STEP 4F: Perform I N SITE™ e l ectro n i c Can the m iss o r excessive

service t o o l s i n g l e cyl inder cut smoke be att ributed to a s ing l e
out test . cyl inder?
S T E P 4G : Perform a manual single Did the engine start afte r

cyl i nder cut-out test . blocking off a cyl i nder(s) or can
the m iss or excessive smoke be
attributed to a cyl i nde r(s)?
S T E P 4H : Measu re the i njector return fuel Is i njector fuel d rain flow from
d rai n flow from the cyl i nd e r the cyl inder head g reater than
head . specification?
S T E P 41 : Deter m i n e w h i c h cyl inder(s) is

causi n g excessive i njector fuel
d rain flow from the cyl inder
head .
STEP 4J : Measure fuel d ra i n l i ne I s the d rain line restriction l ess

restrictio n . than specification?
STEP 5: A i r hand l i ng tro u b l eshoot i n g p roced u res

STEP S A : Check i ntake man ifold press u re I ntake man ifold pressu re read i n g
sensor accu racy. is less t h a n 1 02 mm-Hg [4 i n -
Hg]?
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . ] Engine Performance Troubleshooting Tree - ISB Engi nes E [ . . . ]
STEP S B : Check the A i r i ntake System for Were a n y air i ntake syste m leaks
Leaks . found?
STEP SC: C h e c k a i r i ntake restriction . Is the a i r i ntake restriction

g reate r than the specification?
STEP S D : I nspect t h e tu rbocharger blades Damage fou n d on the

for damag e . tu rbocharger b l ades?
STEP SE: Dete r m i n e if the tu rbocharger i s Is the tu rboc harger a variable

a variable geometry geometry tu rbocharger?
tu rbocharg e r .
STEP SF: Perform I NSITE™ e lectro n i c

Does the tu rbocharger pass th e
service t o o l tu rbocharger
tu rbocharger actuator test?
actu ator test.
STEP S G : I nspect the wastegate actuator Holes o r cracks fou n d in the

hose . wastegate actuator h ose?
STEP S H : I nspect t h e tu rbocharg e r Did the wastegate actu ator

waste gate caps u l e for a i r l eaks . caps u l e leak a i r?
STEP SH-1 : I nspect the tu rbocharger Does the wastegate actuator rod
wastegate actuator for m ove?
proper o pe ration .
STEP SH-2: I nspect the tu rbocharger Does the wastegate actuator rod
wastegate for proper move?
operatio n .
STEP S I : M easure tu rbocharger axial and Are the axial and rad ial
rad ial c learance . c l earances within specification?
STEP SJ : I nspect the charge a i r coo l e r . Does the charge a ir cooler pass
the visual i nspection as we l l as
the p ressu re test and
STEP 6: E G R Syste m c hecks .

STEP SA: Check for a i r leaks i n the EGR Air leaks fou n d in the EGR
system . connection tu b i ng?
STEP S B : C h e c k the EGR temperatu re Are al l tem perat u re read i ngs

sensor accu racy. w i t h i n S . S o C [ 1 0 ° F] of each
other?
STEP SC: Check d ifferential pressure Is the EGR d iffe rential pressu re
sensor for proper operat i o n . g reater than S mm-Hg (O . 2 i n- H g)
when the EGR valve is open
g reater than SO percent?
STEP SD: C h e c k exhaust g a s press u re There is l ess than a 1 02 m m- H g

sensor accu racy. [4 i n -Hg] difference between the
exhaust p ress u re sensor read i n g
a n d th e barometric ai r pressu re
sensor read ing?
STEP S E : Perform the I N S ITE™ e l ectronic Does the EGR Valve pass the
service tool EGR valve actuato r I N S I TE™ EGR Valve Actuator
test . Test?
STEP SF: Isolate EGR System . Was the Performance or

Excessive S moke (Black)
complaint corrected by
discon necting the EGR valve
d ifferential p ress u re sensor?
STEP SF-1 : Check the EGR System for

Was bl ockage or excessive
Blockag e .
carbon b u i l d up found in the EGR
Engine Performance Troubleshooting Tree - ISB Engi nes E [ . . . J ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J
valve d iffere ntial p ress u re

sensor and!or i ntake connection
passages?
STEP 6F-2 : Check the EGR system for Was the air i ntake connection
correct o r damaged assembled properly with no
components. damage to any components?
STEP 7: Verify electro n i c featu res are operat i n g correctly.

S T E P 7A: Verify accel e rato r (th rottle) Does the th rottle position read 0
pedal t ravel . percent when the accel e rator
(th rottle) is released and 1 00
percent when the accel erator
(th rottle) is f u l ly depressed?
STEP 7B: M o n itor the veh ic l e speed . Does the vehicle speed read zero
when the veh i c l e is not moving?
STEP 7C: Verify the e lectro n i c feat u re Are the electronic featu res set
settings are correct . correctly?
STEP 70: Check the tem perat u re sensor Are all tem perat u re read ings
accu racy. with i n S . 6 ° C [ 1 0 ° F] of each
other?
STEP 7E: Check ambient a i r p ress u re I N S ITE™ e lectronic service tool

sensor accu racy read i n g is with i n 1 02 m m- H g [4
i n- H g] of local barometric
p ressu re?
STEP 8: Perform base e n g i n e mechanical checks .

STEP 8A: Verify the overhead adj ustments Are the overhead settings w i t h i n
are correct. th e reset l i m its?
STEP 8B: Check the exhaust restrict i o n . Is the exhaust back p ressu re
STEP 8C: Verify the eng i n e cran kcase Is th e e ng ine cran kcase p ressu re
press u re (bl owby) is with i n (blow by) l ess than specification?
specification .
STEP 80: Check for i nternal e n g i n e

Did cutt i n g the oil filter open
damag e .
reveal evidence of i nternal
e n g i n e damage?
STEP 9 : Excessive vibrat i o n checks .

STEP 9A: Check engine i d l e speed . Is the e ng ine idl e speed with i n
specification?
STEP 9 B : C h e c k if the feat u re Fast I d l e Is the feat u re Fast Idle Warm U p

W a r m U p is available and avai lable and enabled?
enabled .
STEP 9B-1 : Monitor if the Fast Idle Is the featu re Fast I d l e Warm U p
Warm U p Status. beco m i n g active?
STEP 9C: Check front engine d riven Did isolating the front e n g i n e
accessory(s) . d riven accessory(s) correct t h e
v i b ration?
STEP 9 0 : C h e c k the V i b ration Damper! Is the vibration damper!

Crankshaft speed i n d i cato r ring . crankshaft speed i n d i cato r ring
damaged?
STEP 9 E : Check the E n g i n e Su pport A re th e e ng ine su pport brackets ,

Brackets , M o u nts and!o r m ou nts and!or isolators o r
Isolators. damaged?
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISB Engi nes E [ . J . .
STEP 9F: Check e n g i n e gear d riven Does the e ng ine have an engine
accessory(s) . gear d riven/ai r compressor
d riven hydrau l i c p u m p?
STEP 9F-1 : Isolate e n g i n e gear d riven Did isolati ng/remov ing e n g i n e

accesso ry(s) g e a r d riven/a i r compressor
driven hyd ra u l i c p u m p correct
the vibration?
STEP 9 F- 2 : C h e c k if the e n g i n e i s Is the e n g i n e e q u i pped with an
eq u i p ped w i t h an a i r e n g i n e gear d riven a i r
co m p resso r. compressor?
STEP 9 F-3 : U n l oad the Ai r Compressor Did u n load i n g the a ir
and Operate . compressor sign ificantly red uce
o r e l i m i nate the vi bration?
STEP 9 F-4 : Check A i r Compressor Was the air compressor
Timing. correctly timed to the e n g i ne?
STEP 9 G : Check/Isolate e n g i n e d riven Did iso lati ng/re mov ing any
com ponents. e n g i n e d riven component
correct the vi b ration?
STEP 9 H : Check t h e Flywheel Housing Is the flywheel housing bo re and
A l i g n ment. face runout with i n specification?
STEP 1 : Perform basic tro u b l eshoot i n g proced u res .

STEP 1 A or h'lalh cou nts 0 f .inactive fau t co des.
Ch ec k f o r active fau I t co d es
Cond ition:
Check for an active fau lt cod e . Active fau lt codes or h i g h cou nts o f i n active Repai r
• Use I NS ITE™ electronic service tool to read the fau lt codes? complete .
fau lt codes.
YES
Reference the corresponding Electronics Repa ir:
Troubleshooting and Repai r Man ual for the
engine being serviced . Fol l ow the electronic fault code trees for the
appropriate troubleshooting p roced u res.
For engi nes eq u i pped with a C M850 Electronic
Control Mod u l e , refer to B u l l etin 402 1 41 6 .
Active fau lt codes or h i g h cou nts o f i n active 1B
fau lt codes?
NO
Engine Performance Troubleshooting Tree - ISB Engines E [ . . . J ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J
STEP 1 8 Perform basIc troubleshootlnQ checks.
Cond i t i o n :
The fol lowi ng items m ust be checked or verified All steps have been verified to be correct? 2A
before conti n u i ng : YES
• Verify t h e fuel level i n t h e tanks.
• Verify the veh i cl e is i n good worki ng order
• Check if any recent mai ntenance or service

All steps h ave been verified to be correct? Repai r
work has been performed NO complete.
• Verify there h ave not been any changes to
Repair:
CPL components on the eng i n e .
• Verify f u e l g rade is correct for the appl ication. Correct the cond ition and verify com plaint is
• Verify the engine is operating with i n the no longer p resent after repair.
recom mended altitude .
• Verify engine o i l is i n good con d ition a n d a t the
correct leve l .
• Verify engine parasitics have not changed .
• Verify engine d uty cycle h as not changed .
• Verify the air fi lter is not excessively pl ugged ,
by checki ng the fi lter m i nder.

• Listen for air and exhaust leaks.
• Verify there are no visi ble external fuel leaks.
• Verify there are no visi ble coolant leaks.
• Verify there are no visible signs (soot streaks)
of an external EG R leak.
• Verify the crankshaft position and the
camshaft position sensors are correctly
con nected to the engine harness.
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISB Engi nes E [ . . . J
STEP 2: Deter m i nat i o n of e n g i n e sym ptom .

STEP 2A : Engine D iffic u l t to Start o r W i l l Not Start (With o r Without Exhaust S m o ke) , Engine Sh uts Off
or Dies U n expected ly or Dies d u r i n g Decel e rat i o n , or Engine Starts but W i l l Not Keep
R u n m. ng .
Condition :
I nterview the d river and verify the com plaint. Is the engine sym ptom Engine Difficult to Perform the
Start o r Will Not Start (With o r Without troubleshooti
Exhaust Smoke) , Engine S h uts Off or Dies ng steps
U n expectedly or Dies d u ring Deceleratio n , o r suggested i n
Engine Starts b u t Wi l l N o t Keep R u n n i ng? the repai r
YES
proced u re .
Repai r:

Step 3 E n g i n e wi l l Not Start o r Stal ls
-
Troubleshooting Proced u res

Step 5 - Air Hand l i n g Checks
Step 7 - E lectron ics Checks.
Is the engine sym ptom Engine Difficult to 28

Start or Wi l l Not Start (With or Without
Exhaust Smoke) , Engine Sh uts Off o r Dies
U n expected ly or Dies d u ring Deceleration , o r
Engine Starts b u t Wi l l N o t Keep R u n n ing?
NO
Engine Performance Troubleshooting Tree - ISB Engines E [ . . . ] ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . ]
STEP 2 B : E n g i n e R u n s R o u g h a t I d l e , E n g i n e R u ns R o u g h or M isfires, E n g i n e S peed S u rges a t Low or

HiQh I d l e E n a i n e Saeed S u raes under Load or in OaeratinQ Ranae.
Cond ition:
I nterview the d river and verify the com plaint. Is the engine sym ptom Engine R u n s Rough Perform the
at Idle, Engine R u ns Rough or M isfi res, troubleshooti
Engine S peed Su rges at Low or H i g h I d l e , ng steps
E n g i n e S peed S u rges u n d e r Load or i n suggested in
Operating Range? the repair
YES proced u re .
Repair:

Step 7 - E lectronic Checks
Is the engine sym ptom Engine Runs Rough 2C

at Idle, Engine R u ns Rough or M isfi res ,
Engine S peed S u rges at Low or H i g h I d l e ,
E n g i n e S peed S u rges u nder Load or i n
Operating Range?
NO
STEP 2C ' S m o ke Blac k -

Excessive
Cond ition:
I nterview the d river and verify the com plaint . Is the engine sym ptom Smoke , B l ack - Perform the
YES ng steps
suggested i n
Repa ir: the repai r
Step 6 - EG R System Checks
Step 5 Ai r H and l i ng Checks
-

Is the engine sym ptom S moke , Black - 2D

Excessive?
NO
ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISB Engi nes E [ . . . J
STEP 2 0 '
S m o ke0' W h ite - Excessive
Cond i t i o n :
I nterview the d river and verify the com plaint. Is the engine sym ptom Smoke, Wh ite - Step 2D- 1
Excessive?
YES
Is the e n g i n e sym ptom S moke, White - Step 2E

Excessive?
NO
S T E P 2 0- 1 ' S m o ke W h ite
..
-
Excessive
Cond ition:
I nterview the d river and verify the complaint.

Is the engine using coolant? Refer to the
YES Coolant Loss
Verify if, along with the wh ite smoke com plaint,
- I nternal
cool ant is bei ng used .
Troubleshoot
Check the coolant leve l .
ing Sym ptom
(TS) Tree.
Is the engine using coolant? Step 2D-2

NO
Engine Performance Troubleshooting Tree - ISB Engines E [ . . . J ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
Page TT-1 80 Section TT - Troubleshooti ng Symptoms (New Format)
STEP 20 2 ·
-
S m o ke W h ite -
Excessive
Cond ition :
I nterview the d river and verify the com plaint. Is the wh ite smoke excessive com plaint o n ly Perform the
occurring when the engine is cold and d u ring troubleshooti
Check if the wh ite smoke excessive com plaint is
cold am b ient cond itions? ng steps
o n ly occu rri ng when the eng i n e is cold and
YES
suggested i n
d u ring cold ambient cond itions?
the repair
NOTE: Some wh ite smoke after a cold start in Repai r: proced u re .
cold ambient cond itions is not u ncom mon . Perform t h e Checks i n Step 3 A only
If wh ite smoke persists once the engine has Step 4 - Fuel System Checks
reached the m i n i m u m operati n g coolant
temperature, trou b l eshoot the wh ite smoke Step 7 - Electronics Checks
com plaint.
M i n i m u m Operating Coolant Tem peratu re: 60°C Is the wh ite smoke excessive com plaint o n ly Perform the
[ 1 40 ° F] occu rri ng when the engine is cold and d u r i n g troubleshooti
cold ambient cond itions? ng steps
NO
suggested in
the repai r
Repair: p roced u re .
reco m mended order listed below:
Step 7 - Electronics Checks
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J. . . Engine Performance Troubleshooting Tree - ISB Engi nes E [ J
. . .
STEP 2E: Engine Accel e ration o r Response Poor, E n g i n e Power Output Low, E ng ine Dece l erates
S l owly, I ntake Man ifold P ressure (Boost) is Below Normal or E n g i n e W i l l Not Reach Rated
S Deed (RPM)
Cond ition:
I nterview the d river and verity the com plaint. Is the engine sym ptom Engine Acceleration Perform the
or Response Poor, Engine Power Output troubleshooti
Low, E n g i n e Decel erates Slowly, I ntake ng steps
Manifold P ressure (Boost) is Below Normal or suggested i n
Engine Wi l l Not Reach Rated S peed (RPM)? t h e repai r
YES
proced u re .
Repa ir:

recom mended order l i sted below:
Step 5 Ai r H and l i n g Checks
-
Step 4 - Fuel Systems Checks

Is the engine sym ptom Engine Acceleration Step 2 F

or Response Poor, Engine Power Output
Low, E n g i n e Decelerates Slowly, I ntake
Manifold Pressure (Boost) is Below Normal or
Engine Wi l l Not Reach Rated Speed (RPM)?
NO
Engine Performance Troubleshooting Tree - ISB Engines E [ . . . J ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J
Page TT-1 82 Section TT - Troubleshooti ng Symptoms (New Format)
S T EP 2 F : E n a l n e v i b ration Excessive
Cond i t i o n :
Acti o n S pecification/Re pai r N ext Step
I nterview the d river and verify the com plaint. Is the engine sym ptom Engine Vibration Perform the
YES
ng steps
suggested i n
Repai r: t h e repai r
Perform the troubleshooti ng steps i n the proced u re .
Perform Step 4G and 4H of the Fuel System
Checks Only
Step 9 - Excessive Vibration Checks
Is the e n g i n e sym ptom Engine Vibration Fo r engine

Excessive? related
NO
sym ptoms,
refer to the
correct
troubleshooti
ng sym ptom
(TS) tree .
IS8, IS8e2 , IS8e3 , IS8e4, QS84 [ . . . J Engine Performance Troubleshooting Tree - IS8 Engi nes E [ . . . J
STEP 3: E ng i ne w i l l N ot Start or Stal l s T rou bleshoot i n g P roced u res .

STEP 3A: Verify t h e operation of cold weather aids.
Cond ition:
• Engine and Amb ient Conditions Cold .
Make s u re the necessary cold weather aids are Are the n ecessary cold weather starting aids 3B
bei ng used and are operational as req u i red . are being used and are operational as
req u i red?
NOTE: M i n i m u m Ambient Ai r Tem peratu re for
U naided Cold Start is - 1 2 . 2 ° C (1 0 ° F) YES
NOTE : The I N S ITElM electronic service tool

I ntake Air H eate r Override test can be used to Are the n ecessary cold weather starting aids Repai r
d i agnose i ntake air heater prob lems. For engi nes are being used and are operational as com plete
eq u i pped with air i ntake heaters, the ai r i ntake req u i red?
heaters should beg i n to fu nction at 1 9 ° C [66 ° F] . NO
Repai r:
I nstall o r repai r cold weather starting aids.

• Refer to P roce d u re 008-0 1 1 (Cool ant
H eater) in Section 8 of the Service Manual ,
I S B e , I S B , aSB (Common Rai l Fuel
System ) , B u l letin 402 1 271 fo r engine
cool ant h eater.
• Refer to Procedure 0 1 0-029 (Cold Starting
Aid) i n Section 1 0 of the Service Manual ,
ISBe, I S B , aSB (Common Rail Fuel
System) , B u l leti n 402 1 271 , for air i ntake
heater(s) .
• Refer to Proced u re 007-00 1 (Engine Oil
H eater) i n Section 7 of the Service Manual ,
I S Be , I S B , aSB (Com mon Rail Fuel
System ) , B u l l eti n 402 1 271 for engine oil
h eaters.
• For any OEM i nstal led cold starting aids
(rad i ator sh utters , etc . ) , refer to the OEM
i nstructions.
Engine Performance Troubleshooting Tree - ISB Engines E [ . . . J ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J
STEP 3 8 : C h e c k electro n i c featu res an d DrOQram ma b l e Darameters.
Cond ition:
• Keyswitch ON .
• Con nect the I N S ITE™ electronic service too l .
Check if the electronic featu res and Are electronic featu res and program mable Repai r
program mable parameters are the cause for the parameters the cause for the engine sh utti ng Com p l ete .
engine sh utting down or th e no-start com plaint. down or the no-start com plai nt?
The electronic featu res and programmable YES
parameters include: I d l e S h utdown , Engine Repair:
Protection Sh utdown , and Vehicle Anti-theft
P rotectio n . Program t h e electronic featu res p e r the
customer o r OEM req u i rements.
Are electronic featu res and p rogrammable Step 3C

parameters the cause for the engine sh utting
down o r the no-start com plai nt?
NO
STEP 3C .
M omtor t he enQme SDee d d u rmQ cran k'm Q .
Condit i o n :
• Keyswitch O N .
• Connect t h e I N S ITE™ el ectronic service too l .
Mon itor the engine speed . Is the e n g i n e speed greater than 1 50 rpm 3D
Use I N SITE™ electronic service tool to mon itor
• d u ring cran king?
engine speed w h i l e cran king the engine. YES
Attem pt to start the engine; engage the engine
starter for at l east 30 conti n uous seconds. Is the engine speed g reater than 1 50 rpm Refer to the
NOTE: Do not overheat the starter. during cran king? Engine Will
NO
Not Cran k or
NOTE: Attem pting to start the engine for 30 Cran ks
conti n uous seconds also allows the fault code Repair: Slowly
logic time to ru n . If any fau lt codes become (Electric o r
active , stop using this troubleshooting tree and Find and correct the cause for low cran king
speed . Consider the batteries , engine Air Starter)
reference the correspon d i n g fau lt code troubleshooti
troubleshooting tree . starting m otor, d rive u n its and accessory
loads. ng sym ptom
(TS) tree .
STEP 3 D : M o n itor the E C M Kevswitch I nput .
Cond ition:
• Keyswitch ON .
• Connect the I N S ITE™ el ectronic service too l .
• E n g i n e not ru n n i n g .
Mon itor User Fueling State . Does the User Fuel ing State i n d icate 3E
Use I N S ITE™ electronic service tool to mon itor
• "Cran king" or is the keyswitch voltage eq ual
fuel state w h i l e cran king the engine. to battery Voltage?
NOTE: I f the engine is i nterm ittently sh utting YES
down , User Fuel i n g State can also be mon itored
d u ring engine shut down . Does the User Fuel i n g State i n d icate Repai r
If the I N S ITE™ electronic service tool is
"Cran king" or is the keyswitch voltage eq ual com p l ete.
unavai lable:
to battery voltage?
• Disconnect the OEM h arness. NO
• Turn keyswitch ON . Repa ir:
Measure the signal voltage from the keyswitch Check the keyswitch battery supply ci rcu it.
i n put signal wire of the OEM harness to the Refer to P roced u re 0 1 9-064 (Key Switch
engine b lock g ro u n d . Battery S u pply C i rcu it) in Section 1 9 . Repai r
Measure the keyswitch voltage with t h e or replace the OEM harness , keyswitch , or
keyswitch i n the ON position and also with t h e check the battery con n ections. Refer to the
keyswitch i n the cran king positio n . OEM troubleshooting and repai r man ual for
the proper proced u res.
Refer t o t h e correspond i n g wiring d i agram for the
engine being serviced for con nector pin
identificatio n .
STEP 3 E : M O n itor t h e ECM Battery S U PPIV .
Cond ition:
• Keyswitch ON .
• Connect the I NS ITE™ electronic service too l .
• E n g i n e not ru n n i n g .
Action Specificati on/Repair Next Step
Mon itor battery Voltage. Is the ECM battery supply voltage g reater 3F
• U se I N S ITE™ electronic service tool to mon itor than + 1 1 -VDC for 1 2-volt systems or + 22
battery voltage while cran king the engine. VDC for 24-volt systems?
If the I N S ITE™ electronic service tool is YES
unavai lable:
• Disconnect the ECM power supply connectio n . Is the ECM battery supply voltage g reater Repai r
• T u r n keyswitch O N . than + 1 1 -VDC for 1 2-volt systems or + 22 complete.
VDC for 24-volt systems?
Measu re t h e voltage from t h e E C M battery
supply (-) pin(s) to the ECM battery supply ( + ) pin NO
(s) i n the ECM con n ector. Repa ir:
Measu re the ECM voltage with the keyswitch in Repai r o r replace the ECM power and g round
the ON position and also with the keyswitch i n the connections. Check the battery con n ections
Cran king position . and fuse term i nals.
Refer to the correspond i n g wiring d i ag ram for the
engine being serviced for con n ector pin
identification .
STEP 3 F : C h e c k the Loa d C arrVI n Q Ca D abT '

I Itles 0 f t he ECM P ower an d G rou n d C"I rcu lts.
Cond itio n :
• Keyswitch O F F .
• Disconnect the E C M Power Su pply Connection .
Con nect a head l i ght ( 1 2 Volt or 24 Volt systems) Do the head l i g hts i l l u m i nate brig htly? 3G
NOTE: A head l ight m ust be used to make sure YES
that the wattage rating wi l l put enough of a load
on the c i rcuit. Do the head l i g hts i l l u m i nate brig htly? Repai r
Use the ECM battery S U P P LY ( + ) pin in the NO
complete
ECM power supply con n ection for the battery
Repai r:
positive ( + ) and the ECM battery S U P P LY ( ) pin -
i n the ECM power h arness connector for the Repai r o r replace the ECM power and g round
battery negative ( ) .- con nections. Check t h e battery con nections
Refer to the correspo n d i n g wiring d i ag ram for the and fuse term inals.
engine being serviced for connector pin
identification .
STEP 3 G ' C h e c k orientat i o n o f con nector
Cond ition:
Check for the appropriate orientation of the rai l Is the sensor correctly i nstalled? 3H
fuel pressure sensor con nector. YES
NOTE : Connector can be i nstal led rotated 1 80
degrees. Is the sensor correctly instal led? 4A
NO
Repair:
Reorient connector.
S T E P 3H : v em'fv ral' 1 f u e press u re sensor accu racy.
Cond ition:
• Connect I N S ITE'M electronic service too l .
• I N S ITE™ electronic service tool mon itor.
• Engine n o t ru n n i n g .
Mon itor the fuel rai l pressure . Is t h e Fuel R a i l Pressure (measu red) less 31
than 30 bar (435 psi)?
Use I N S ITE™ el ectronic service tool to measure
the fuel rai l pressure. YES
Is the Fuel Rai l P ressure (measu red) less Repai r

than 30 bar (435 psi)? Com plete
NO
IS8, IS8e2 , IS8e3, IS8e4, QS84 [ . . . J Engine Performance Troubleshooting Tree - IS8 Engines E [ . . . J
STEP 3 1 : M o n itor fuel rai l D ress u re w h i l e cran kina the enaine.
Cond itio n :
Mon itor Fuel Rai l P ressure (measu red) and Fuel Did the Fuel Rai l P ressure (measu red) equal SA
Rai l P ressure (co m manded). the Fuel Rail P ress u re (co m m anded)?
Use I N S ITETM electronic service too l . YES
NOTE : F u e l R a i l P ress u re (co m m anded) can also
be referred to as H PC R fuel setpoint. Did the Fuel Rai l P ressure (measu red) eq ual 4A
the Fuel Rail P ressu re (co m m anded)?
Attem pt to start the engine, engage the engine

starter for at least 30 conti nuous seconds. NO
NOTE: Do n o t overheat the starter.

NOTE : A m i n i m u m of 1 00 bar [ 1 450 psi] of fuel
rai l pressure is req u i red before the i nj ectors wi l l
open and provide fue l .
NOTE : Attem pting t o start the e n g i n e f o r 30
conti nuous seconds al l ows the fault code logic
time to ru n . I f Fau lt Code 22 1 5 or 559 becomes
active , adeq uate fuel rai l pressu re is not being
developed . Discontinue using this
troubleshooti ng tree and troubl eshoot Fault Code
221 5 or 559 .
STEP 4: F u el system tro u b l eshoot i n g proced u res.

S T E P 4A: Check for a i r i n the fuel su I line.
Cond ition:
• Keyswitch OFF.
• Engine OFF.
• Connect req u i red service tools at the fuel fi lter head d iag nostic port (i n let) .
• Turn Keyswitch O N .
Check fo r air i n the fuel . Is air p resent i n the fuel supply? Repai r
YES complete
Refer to P rocedure 006-003 (Ai r i n Fuel) i n
Section 6 o f t h e Service Manual , I S B e , I S B , and Repair:
aSB (Common Rail Fuel System) , B u l letin
402 1 271 . Locate and correct the cause of air i ngestion
i n the fuel supply system . Sou rces of air
Operate the fuel lift p u m p . ingestion i nclude loose fuel fi lters , loose fuel
NOTE: A t i n itial key o n , the l ift p u m p will run for line fittings, loose or cracked fuel tank stand
60 seconds and then turn off. The l ift p u m p can pi pes , o r severe restrictions i n the fuel supply
also be operated , use I NS ITETM electronic service l i nes and fi lters that cause cavitation at h i g h
tool l ift p u m p override test. f u e l flow rates .
Is ai r present i n the f u e l supply? 4B

NO
OOd00080
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISB Engines E [ . . . J
STEP 4 8 : M easure f u e l fl ow/ ress u re a t t h e i n let of t h e on e n i n e f u e l filter.
Cond ition:
• Keyswitch OFF.
• Engine OFF.
• Connect req u i red service tools at the fuel fi lter head d i agnostic port (inlet) .
Measu re fuel i n let press u re and flow at the i n l et Was the p ressu re/flow measu red wit h i n 4E
diagnostic port of the fuel fi lter. specification?
Refer to Proced u re 005-045 (Fuel Lift P u m p) in NOTE: Record the measu red fuel i n l et
Section 5 of the Service Manual , ISBe, I S B , aSB press u re for use i n the next step.
(Common Rai l Fuel System), B u l leti n 402 1 271 ; YES
Refer to P roced u re 006-0 1 5 (Fuel Fi lter (Spi n-on
Type)) in Section 6 of the Service M an u al , ISBe,
I S B , aSB (Com mon Rai l Fuel System), B u l leti n Was the p ressu re/fl ow measu red wit h i n 4C
402 1 271 . specification?
NO
Operate the fuel lift p u m p .
NOTE: At i n itial key o n , the l i ft p u m p wi l l run for
60 seco nds and then turn off. The l i ft p u m p can
also be operated , use I N S ITE™ electronic service
tool l ift p u m p override test.
Fuel flow rate for lift p u m p (eng i n e not ru n n i ng)
g reater than 300 m l i n 30 seconds.
Measure the pressu re at h i g h i d l e :

• Fuel pressure range l i ft p u m p (engine ru n n i ng)
- 0 to 0.8 bar [0 to 1 1 . 6 psi ] .
Record the fuel filter i n l et flow and pressure

measu red .
1 9d02005
Engine Performance Troubleshooting Tree - ISB Engi nes E [ . . . J ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
STEP 4C: M easure t h e fuel i n let restrictio n .
Conditi o n :
• Keyswitch OFF.
• Engine OFF.
• Connect req u i red service tools at the fuel lift pump i n let.
Measu re the fuel i n l et restrictio n . Is the fuel i n l et restriction g reater than the Repai r
specification? Complete .
Refer t o Proced u re 006-020 (Fuel I n let
Restriction) i n Section 6 of the Service Manual, YES
ISBe, ISB, aSB (Com mon Rail Fuel System), Repai r:
B u l letin 402 1 271 .
Find and correct cause of high i n l et
Operate the engine at h i g h i d l e : restriction . Look for pl ugged OEM fuel fi lters
M axi m u m i n l et restriction - 6 i n . H g (vac u u m) or screens, or a restricted ECM cooler,
20 . 3 kPa pinched OEM fuel l i nes or a restricted stand
pipe in the OEM fuel tan k.
NOTE: If the engine wi l l not start , operate the lift
p u m p , use I N S ITE'M electronic service tool Fuel
Lift Pump Override Test. Is the fuel i n l et restriction g reater than the 4D
specification?
NOTE: If the issue is i nterm ittent (no start or
engine sh uts off u nexpected ly) and no issues can NO
be found while the engine is being serviced , there
may be debris i n the fuel system causing an
i nterm ittent restrictio n . I nstall a fuel fi lter m i nder,
Fleetg uard™ Part N u m ber 3892576s , at the
con n ection betwee n the OEM fuel supply l i nes
and the engine. A fuel fi lter m i nder wi l l capture
the peak restriction in m i l l i meters and i nches of
mercury. If the issue occurs agai n , the fuel fi lter
m i nder can be checked to see if there is
something on the OEM side causing an
i nterm ittent h i g h restrictio n .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISB Engines E [ . . . J
STEP 40: Check if the e n a l n e IS ea u l P ped with a l i ft p u m p vo taae rea u ator.
Condition :
Check if the engine is eq u i pped with an on Is the engine eq u i p ped with a lift p u m p Repai r
engine voltage reg u l ator to convert 24 volts to 1 2 voltage reg u l ator? Complete
volts. YES
This allows for the use of a 1 2 volt l ift p u m p in a Repa ir:
24 volt engine config u ratio n .
If eq u i pped , verity the voltage reg u l ator is
NOTE: If eq u i p ped , t h e voltage reg u l ator i s operating p roperly. Replace if necessary. If
mou nted below t h e EC M . OK, replace the electric fuel l i ft pump. Refer
to P roced u re 005-045 (Fuel Lift P u m p) i n
Section 5 o f t h e Service Manual , I S B e , I S B ,
a S B (Co m m o n R a i l F u e l System), B u l letin
402 1 271 .
I s the engine eq u i p ped with a lift p u m p Repai r

voltage reg u l ator? Complete
NO
Repa ir:
Replace the electric fuel l ift p u m p . Refer to

Proced u re 005-045 (Fuel Lift P u m p) in
Section 5 of the Service Manual , ISBe, I S B ,
a S B (Co m m o n Rail Fuel System) , Bul letin
402 1 271 .
. , i·, .· •.
Relay Control
from ECM
05d00768
STEP 4E: M easu re fuel ress u re at the outlet of the o n e n i n e fuel filter
Cond i t i o n :
• Keyswitch OFF.
• Con nect req u i red service tools at the fuel fi lter head diagnostic port (outlet).
Act i o n S pecification/Repair N ext Step
Measu re fuel outlet press u re outlet d iag nostic Is the press u re d rop across the fi lter g reater Repai r
port of the fuel filter. than the specification? com pl ete
Refer to P roced u re 006-0 1 5 (Fuel Fi lter (Spin-on YES
Type)) i n Section 6 of the Service Manual , I S B e , Repai r:
I S B , aSB (Com mon Rai l F u e l System), B u l l etin
402 1 271 . Replace the fuel filter. Refer to P roced u re
006-0 1 5 (Fuel Fi lter (Spi n-on Type) i n Section
Calcu late the pressure d rop across the fuel filter 6 of the Service Manual , ISBe, I S B , aSB
by su btracting the p ressu re m easu red h ere from (Common Rai l Fuel System), B u l l etin
the pressu re measu red i n Step 4 B . 402 1 271 .
Measu re the pressure at l ow i d l e :
• Maxi m u m p ress u re d rop across the f u e l fi lter Is the pressu re d rop across the fi lter g reater 4F
0 . 35 bar [5 psi] . than the specification?
NOTE : If the engine wi l l not start , use I N SITETM NO
electronic service tool Fuel Lift P u m p Override
Test to operate the lift p u m p .
1 9d02004
STEP 4 F : Perform I NS I T E'" electro n i c service t o o l s i n a l e cvl i nde r c u tou t test .
Condition:
• Engine ru n n i ng at low i d l e .
• Con nect I N SITE™ electronic service too l .
Perform single cyl inder cutout test. Can the m i ss or excessive smoke be Repai r
attributed to a single cyl i nder? complete
NOTE: If the engine will not start or is d ifficult to
start , m ove to the n ext step. YES
• I n the ECM Diagnostic Tests menu of I N S ITE™ Repai r:

electronic service too l , click on the Cyl inder
Look for a cause of the complaint, i n c l u d i n g
Cutout Test, and fol l ow the i n structions on the
scree n .
that m ay i n d i cate power cyl i nder damage, o r
• Operate t h e engine under t h e cond itions i n
camshaft l o b e wear. If no other damage is
which t h e com plaint occurs .
fou nd , rep l ace the fuel i nj ector i n the cyl i nder
• U s e I NS ITE'" electronic service tool t o perform
that was identified using the single cyl inder
the Cyl inder Cutout Test to d isable i n d ividual
cut-out test. Refer to Proced u re 006-026
i nj ectors .
( I nj ector) in Section 6 of the Service Manual ,
NOTE: I f this test is performed and there is not a ISBe, I S B , aS B (Common Rail Fuel System) ,
sign ificant change while cutting out one i nj ector, Bullet i n 402 1 271 .
there m ay be a problem with more than one
i nj ector. It m ay be necessary to cut out m u ltiple Can the m i ss or excessive smoke be 4G
cyl inders at a time. attrib uted to a single cyl inder?
NO
STEP 4G : Perform a manual s i n
Cond i t i o n :
e Turn keyswitch OFF.
e I nstal l the i nj ector leakage isolation too.
e Turn keyswitch O N .
Perform a manual cut-out test. Did the e n g i n e start after blocking off a Repai r
e With the engine not ru n n i n g , d i scon nect the cyl inder(s) or can the m iss or excessive com pl ete
fuel l i n e ru n n i ng from the rai l to cyl i nder smoke be attributed to a cyl i nder(s)?
n u mber 1 . Refer to P roced u re 006-051 YES
(I njector Supply Lines (High P ressu re» in
Section 6 of the Service Man ual , IS8e, I S 8 , Repa ir:
aS8 (Common Rai l F u e l System) , 8 u l letin Look for a cause of the com plaint, i ncluding
402 1 271 . valve lash and excessive cran kcase p ressu re
e I nstall the i nj ector leakage isolation tools. that can i n d icate power cyl i nder damage or
For 3.9L and 5.9L engines, i nstal l the i nj ector camshaft lobe wear. If no other damage is
leakage isolation tool , Part N u m ber 3 1 64325 , on found , replace the fuel i nj ecto r i n the cyl i nder
the rai l where the n u m ber 1 cyl inder fuel l i n e that was identified using the manual single
connects . cyl inder cut-out test . Refer to P roced u re
006-026 ( I nj ector) i n Section 6 of the Service
Torq ue Val ue: 30 N e m [22 ft-Ib] . Man ual , I S 8e , I S 8 , aS8 (Com mon Rail Fuel
Attem pt to start the engine or operate the engine System), 8 u l leti n 402 1 271 .
at idle.
Repeat the above test , as necessary, with each Did the engine start after b locki ng off a 4H
cyl i nder blocked off. cyl inder(s) or can the m iss or excessive
smoke be attributed to a cyl i nder(s)?
NO
06d002S9
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ J . . . Engine Performance Troubleshooting Tree - ISB Engi nes E [ J . . .
STEP 4 H : Measu re t h e i n ·ector return fuel drain flow from t h e c l i nde r h ead .
Condition :
• Keyswitch OFF.
• Connect appropriate service tools to measu re i njector fuel d rain flow from the cyl inder head .
Measu re the i nj ector return fuel d rain flow from Is i njector fuel d rain flow fro m the cyl i nder 41
the cyl i nder head . head g reater than specification?
Refer to Proced u re 006-026 ( I njector) i n Section YES
6 of the Service Manual , ISBe, I S B , aSB
(Common Rail Fuel System), B u l leti n 402 1 271 .

Is i njector fuel d rai n flow from the cyl i nder 4J
Flow S pecificatio n : head g reater than specification?
I d l e Cond itions NO
6 cyl inder engi nes - 1 80 m l/m i n ute [4 fl-oz per
m i n ute] maxi m u m
Cran king Conditions
NOTE: M ake sure not to overheat the starter
6 cyl inder engi nes - 90 m l/m i n ute [3 fI-oz per
m i n ute] maxi m u m
Eng i ne Performance Troubleshooting Tree - ISB Engines E [ . . . J ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
STEP 4 1 : Dete r m i n e which cyl i nder(s) is causi ng excessive i njector fuel d ra i n flow from the cyl inder
head .
Cond ition :
• Keyswitch OFF .
• Connect appropriate service tools to m easu re injector fuel drain flow from the cyl i nder head .
• I nstall the i nj ector leakage iso l ation tool .
Action S pecificati on/Repa i r N ext Step
Measu re the i nj ector return fuel d rain flow from Did blocki ng off a cyl inder(s) decrease the Repai r
the cyl inder head and isolate a cyl i nder one at a flow rate below the m axi m u m specified flow Complete
time usi n g the i nj ector leakage isolation tool . rate?
Refer to P roced u re 006-026 (I njector) i n Section YES
6 of the Service Manual , ISBe, I S B , aSB Repai r:
(Common Rai l Fuel System) , B u l letin 402 1 27 1 .
Remove the fuel con n ector and inspect for
The flow rate will decrease below the m axi m u m damage. Replace if necessary.
specified flow when t h e cyl inder with t h e leak i s
b locked . Remove the i njector and i nspect the fuel
con nector contact su rface for damage .
Flow Specification : Replace if necessary.
I d l e Cond itions 6 cyl inder engines - 1 80 m l/ Refer to P roced u res 006-052 (Fuel
m i n ute [4 fl-oz per m i n ute] m axi m u m . Con nector (H ead Mou nted) i n Section 6 in
Cran king Conditions the ISBe, I S B , and aSB Service Man ual ,
B u l leti n 402 1 271 . Refer to Proce d u re
NOTE: M ake s u re not to overheat the starter 006-026 ( I nj ector) i n Section 6 i n the I S B e ,
6 cyl inder engi nes - 90 m l/m i n ute [3 fl-oz per I S B , a n d aSB Service Manual , B u l letin
m i n ute] m axi m u m . 402 1 27 1 .
NOTE : If this test i s performed and there is not a
sign ificant change i n fuel return flow while cutting Did blocki ng off a cyl inder(s) decrease the 4J
out one i njector, there may be a problem with flow rate below the maxi m u m specified flow
more than one i nj ector. Compare the fuel flow rate?
d ifference across all i nj ectors. Is there more than NO
one i njector that caused a noticeable decrease in
fuel flow? If so , these cou ld be the i nj ectors with
the problems.
Another cause of this problem cou ld be that the
customer is operating on fuels l i g hter than
specified . Fuels with low viscosity will result in
higher i nj ector l eakage and g reater d rai n flow
rates .
ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISB Engi nes E [ . . . J
STEP 4J : M easu re fuel d rain l i n e restriction.
Condition :
• Keyswitch O F F .
• Connect appropriate service tools to meas u re fuel d rain l i n e restriction.
Measu re the fuel d rain line restriction . Is the d rain l i ne restriction less than
Perform next
specification?
troubleshooti
Refer to Proced u re 006-0 1 2 Fuel D rai n Line
Restriction) i n Section 6 i n the ISBe, I S B , and YES

ng proced u re
QSB Service Manual , B u l l et i n 402 1 271 .
as outli ned i n
Step 2 .
Operate the engine at h i g h idle:
Maxi m u m fuel d rain l i n e restriction: 0 . 1 9 bar (2 . 7 Is the d ra i n l i ne restriction less than
Repai r
psi) . specification?
Com plete
NO
Repair:
Check O E M fuel d rain l i nes to tan k for proper

size , l eaks, bends, clogs and fuel tan k vents
for p l u g g i n g .
Engine Performance Troubleshooti ng Tree - ISB Engines E [ . . . J ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J
Page TT- 1 98 Section TT - Troubleshooting Sym ptoms (New Format)
STEP 5: Ai r hand l i ng tro u b l eshoot i n g proced u res.

S T E P 5A Check i n take man ifold pressu re sensor accu racy.
Cond ition :
• Keyswitch O N .
• Engine OFF.
Start the data mon itor/logger and mon itor I ntake man ifold pressu re read i n g is less than 5B
read i n g . 1 02 mm-Hg [4 i n -Hg]?
Start I N S ITE™ electronic service tool data YES
mon itor/logger and mon itor I N S ITE™ electronic
service tool read i n g for i ntake man ifold pressure I ntake man ifold p ressure read i n g is less than Repai r
with the engine off. 1 02 m m - H g [4 i n -Hg]? com plete
NO
Repair:
Replace the i ntake man ifold p ress u re sensor.

Refer to P roced u re 0 1 9-061 (I ntake Man ifold
Pressure Sensor) i n Section 1 9 . If eq u i pped
with a combi nation I ntake Man ifold P ressu re!
Tem perature Sensor, refer to P roced u re
0 1 9- 1 59 (I ntake Man ifold P ressu re!
Tem peratu re Sensor) in Section 1 9 .
STEP 5 8 Ch ec k th e a .i r .I n t a ke svstem for I ea ks.
Cond itio n :
Check the air i ntake system for leaks. Were any ai r i ntake system l eaks found? Repai r
Refer to P roced u re 0 1 0-024 (Ai r Leaks , Air I ntake YES Com plete.
and Exhaust Systems) in Section 1 0 of the Repair:
Service Manual , ISBe, ISB, aSB (Common Rai l
Fuel System) , B u l let i n 402 1 271 . Repai r or replace the damaged com ponent.
NOTE : On engi nes eq u i pped with a
tu rbocharged air com p ressor, one often Were any ai r i ntake system leaks found? 5C
overlooked item as a sou rce for air leaks is the NO
air com p ressor i ntake l i ne . The i ntake l i n e
suppl ies i ntake ai r from t h e i ntake o f t h e engine
to the air com p ressor.
IS8, IS8e2 , IS8e3, IS8e4, QS84 [ . . . J
Engine Performance Troubleshooting Tree - IS8 Engines E [ . . . J
Page TT-1 99
STEP 5 C : C h e c k a i r i ntake restrict i o n .
Cond ition:
• Keyswitch ON .
• Engine ru n n i ng at rated speed and fu l l load .
Check the air i ntake restriction . Is the air i ntake restriction g reater than the Repai r
• I nstal l a vacu u m gauge, Part N u m ber
specification? Com plete
ST- 1 1 1 1 -3 , o r eq u ivalent, i nto the ai r i ntake
YES
system .
Repai r :
Refer to P roced u re 0 1 0-031 (Ai r I ntake
Restriction) in Section 1 0 in the Service Man ual , Correct the cause of h i g h i ntake air
ISBe, I S B , aSB (Com mon Rai l Fuel System), restriction . Check for a pl ugged air filter or
Bul leti n 402 1 271 . restricted air i ntake p i p i n g .
Maxi m u m Air I ntake Restrictio n :
Is the air i ntake restriction g reater t h a n t h e 5D
Di rty Fi lter: 2 5 i n- H 20/635 m m-H 20. specification?
Clean Fi lter: 1 0 in-H 20/254 m m- H 20 . NO
OOd00 109
Engine Performance Troubleshooti ng Tree - ISB Engines E [ . . . J ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
STEP 5 0 : Ins ect t h e tu rbochar e r b lades f o r d a m a e .
Cond itio n :
• Engine OFF.
• Remove the i ntake piping from the tu rbocharger.
I nspect the com p ressor b l ades for damage or Damage found on the tu rbocharger blades? Repai r
wear. YES
complete
Refer to P roced u re 0 1 0-033 (Tu rbocharger) i n Repair:

Section 1 0 o f t h e Service Manual , I S B e , I S B ,
aSB (Co m mon R a i l F u e l System) , B u l letin

Replace the tu rbocharger. Refer to
402 1 271 .
1 0 of the Service Manual , ISBe, I S B , aSB
(Common Rail Fuel System), B u l l et i n
402 1 27 1 .
Damage found on the tu rbocharger blades? 5E

NO
STEP 5E: Determine if the tu rbocharaer is a variable aeometrv tu rbocharaer.
Cond itio n :
Determ i n e if the tu rbocharger is a variab le Is the tu rbocharger a vari able geom etry 5F
geometry tu rbocharger. tu rbocharger?
YES
Is the tu rbocharger a vari ab le geometry 5G

tu rbocharger?
NO
ISB, ISBe2 , ISBe3 , ISBe4, aSB4 [ . . . ] Engine Performance Troubleshooting Tree - ISB Engi nes E [ . . . ]
S T EP SF : P er f orm I N S I TE™ e I ectromc service too t u r b oc h arger actuator test.
Cond ition :
• Keyswitch O N .
Action Specificatio n/Repai r N ext Step
Select tu rbocharger actuator test. Does the tu rbocharger pass the tu rbocharger Step 51
• I n the ECM Diagnostic Tests menu of I N S ITE™ actuator test?
electronic service tool click on the YES
tu rbocharger actuator test, and fol low the
instructions on the screen .
• Open and close the tu rbocharger actuator.
Does the tu rbocharger pass the tu rbocharger Repai r
actuator test? com p l ete
When opened , the actuator position will be 1 00

NO
percent ope n .
Repai r:
When closed , t h e actuator position wi l l be l ess
than 1 0 percent closed . Replace the variab le geometry tu rbocharger.
Refer to P roced u re 0 1 0-033 (Tu rbocharger)
i n Section 1 0 of the Service Manual , I S B e ,
I S B , aS B (Com mon Rai l F u e l System),
B u l let i n 402 1 271 .
Engine Performance Troubleshooti ng Tree - ISB Engi nes E [ . . . ] ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . ]
STEP 5 G : Ins e c t the waste ate actuator hose.
Cond ition:
• Engine OFF.
• Remove tu rbocharger if wastegate actuator is i n accessible.
I nspect the i ntegral wastegate actuator h ose for Holes or cracks found i n the wastegate Repai r
cracks or holes. actuator hose? com plete
Refer to P roced u re 0 1 0-050 (Tu rbocharger YES

Repa ir:
Manual , ISBe, I S B , aSB (Co m m o n Rail Fuel
System), Bul l eti n 402 1 271 . Replace the wastegate actuator hose . Refer
to Proced u re 0 1 0-050 (Tu rbocharger
Service M anual , ISBe, I S B , aSB (Co m m o n
Rai l Fuel System), B u l l etin 402 1 271 .
Holes or cracks found in the wastegate 5H

actuator hose?
NO
OOd00 1 07
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISB Engi nes E [ . . . J
STEP 5 H : Ins
Cond itio n :
• Engine OFF.
• Remove the wastegate actu ator h ose from the waste gate actuator.
Perform a leak test on the wastegate actuator Did the wastegate actuator caps u l e l eak air? Repai r
capsule. YES complete
Refer to Proced u re 0 1 0-050 (Tu rbocharger Repai r:
Wastegate Actu ator) i n Section 1 0 of the Service
Manual , ISBe, I S B , QSB (Com mon Rail Fuel Replace the wastegate actuator. Refer to
System), B u l leti n 402 1 271 . Proced u re 0 1 0-050 (Tu rbocharger
Use C u m m i ns® too l , Part N u m ber 3823799 , to Service Man ual , ISBe, I S B , QSB (Com mon
apply a reg u l ated air supply of 59 in H g (29 psi) Rai l Fuel System), B u l l eti n 402 1 271 .
to the wastegate actuator capsule. N o air should
be heard (i . e . , l eaki ng noise) t h rough a fu nctional
wastegate caps u l e . Did the wastegate actuator caps u l e l eak air? 5H-1
NO
Engine Performance Troubleshooting Tree - IS8 Engines E [ . . . ] IS8, IS8e2, IS8e3 , IS8e4, QS84 [ . . . ]
STEP 5 H - 1 :
Cond itio n :
• Remove the waste gate actuator hose from the wastegate actuator.
Check the waste gate actuator rod for movement. Does the waste gate actuator rod m ove? Step 51
Refer to P roced u re 0 1 0-050 (Tu rbocharger YES
Manual , I S Be, I S B , aSB (Com mon Rai l Fuel Does the wastegate actu ator rod m ove? Step 5 H-2
System), B u l l etin 402 1 271 .
NO
Use C u m m i ns® too l , Part N u mber 3823799, to
apply a reg u l ated ai r supply of 59 i n H g (29 psi)
to the wastegate actuator capsul e . Check for
OOd00 1 0 6
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISB Engines E [ . . . J
STEP S H - 2 :
Cond ition :
• Remove the e-c l i p from the wastegate p i n and d isconnect the actuator rod from the wastegate lever.
Action S pecification/Repai r Next Step
Check the wastegate actu ator rod for m ovement Does the wastegate actuator rod move? Repai r
with it d isconnected from the tu rbocharger YES Com plete .
wastegate .
Repa ir:
Wastegate Actuator) in Section 1 0 of the Service Move the wastegate lever back and forth and
Manual , ISBe, I S B , aSB (Co m m o n Rai l Fuel check for smooth operatio n . If the wastegate
System), B u l leti n 402 1 271 . lever d oes not move freely or b i nds, spray a
penetrating o i l on the wastegate lever j o i nt
Use C u m m i ns® Tool Part N u mber 3823799 to and try to free the wastegate lever by worki ng
apply a reg u l ated a i r supply of 59 i n H g (29 psi) the lever back and forth . If the l ever does
to the wastegate actuator caps u l e . Check for not beco m e free , replace the tu rbocharger.
wastegate actuator rod for m ovement . Refer to P roced u re 0 1 0-033 (Tu rbocharger)
i n Section 1 0 of the Service Manual , ISBe,
I S B , aS B (Common Rail Fuel System),
Bul leti n 402 1 271 .

NO Com plete.
Repa ir:

Wastegate Actuato r) i n Section 1 0 of the
Service Man ual , ISBe, ISB, aSB (Common
Rai l Fuel System), B u l letin 402 1 271 .
OOd00 1 08
STEP 5 I : .
M easu re t u r boc h arQer aXlaI and rad·l aI c I earance .
Cond i t i o n :
• Engine OFF.
Follow the proced u re for m easu ring the axial Are the axial and rad ial cl earances with i n 5J
clearance of the tu rbocharger. specification?
Section 1 0 of the Service Man u al , I S Be , I S B ,
Q S B (Common R a i l F u e l System ) , B u l leti n

Are the axial and rad ial clearances with i n Repai r
402 1 271 .
specification? Complete
NO
Repair:
Replace the tu rbocharger assem b ly. Refer to

1 0 of the Service Manual , ISBe, I S B , QSB
(Common Rail Fuel System), B u l leti n
402 1 271 .
158, IS8e2 , IS8e3 , IS8e4, QS84 [ . . . J Engine Performance Troubleshooting Tree - 158 Engines E [ . . . J
STEP 5J : I n s ect the char e air cooler.
Cond ition:
I nspect the charge air cooler for clean l i ness , Does the charge ai r cooler pass the visual Perform the
blockage, cracks , holes, or other damage. i nspection as wel l as the pressure test and next
• Refer to P roced u re 0 1 0-027 (Charge-Ai r tem peratu re d ifferential test? troubleshooti
Cooler) i n Section 1 0 of the Service Man ual , YES ng proced u re
I S Be , I S B , aSB (Common Rai l Fuel System), as outl i ned i n
B u l leti n 402 1 271 . Step 2.
NOTE: The pressure and temperatu re checks i n
Proced u re 0 1 0-027 (Charge-Ai r-Cooler) can b e Does the charge air cooler pass the visual Repai r
used t o verify charge air cooler problems i n i nspection as wel l as the pressu re test and com p l ete
Section 1 0 i n t h e Service Manual , I S Be , I S B , temperatu re d ifferential test?
a S B (Com mon R a i l F u e l System), B u l leti n NO
402 1 271 .
Repair:
Repai r or replace the charge air cooler

assem bly. Refer to Proced u re 0 1 0-027
(Charge-Ai r-Cooler) in Section 1 0 of the
Service Man ual , ISBe, ISB, aSB (Co m m o n
Rai l Fuel System), B u l letin 402 1 27 1 .
OOd00 1 1 2
Page TT -208 Section TT - Troubleshooting Symptoms (New Format)
STEP 6: EGR system c h ec ks .

STEP 6A: Check for a i r leaks i n the EGR s ste m .
Cond ition:
Action Specificati on/Re pair Next Step
Check for air leaks in the EG R con n ection tubing Air leaks found in the EG R con n ection Repai r
and other con n ections. tubing? complete
• Check for EG R at the m o u nting flange for the
YES
differential p ressu re sensor.
• Soot streaks can be noticeab le where leaks Repair:
are present. Repai r any leaks i n the EG R system .
Ai r leaks found in the EG R con n ection 68

tubing?
NO
STEP 6 8 : Check the EGR tem perat u re sensor accu racy .
Cond ition:
• Keyswitch O N .
• Connect I N S ITE™ electronic seNice too l .
•
T h e e n g i n e m u st b e tu rned off l o n g e n o u g h for e n g i n e coolant temperatu re t o be equal t o ambient a i r
temperature .
Mon itor the fol l owi ng tem peratu res. Are all temperatu re read ings with i n 5 . 6 ° C Step 6C
[ 1 0 ° F] of each other?
Use I N S ITE™ electronic seNice tool to mon itor
tem peratu re of the following: YES
• EGR temperatu re sensor

• Engine coolant temperatu re sensor Are al l tem peratu re read i ngs with i n 5 . 6 ° C Repai r
• I ntake man ifold air tem pe ratu re sensor [ 1 0 ° F] o f each other? com p l ete
• Tu rbocharger com p ressor i n let air
NO
temperatu re sensor.
Repai r :
Check for a short from the sig nal p i n of the

pins i n the harness . Refer to Proced u re
0 1 9-360 (Resistance Measurement Using a
M u lti m eter and Wiring Diag ram) (pin-to-pin
check) i n Section 1 9 . If no short is fou n d ,
replace t h e temperatu re sensor that i s
read i n g h i g h e r or lower than the other
sensors. See Section 1 9 for specifics on each
tem peratu re sensor.
S T E P 6C .
Ch ec k d I'fferentlaI press u re sensor for proper operat i o n .
Cond ition:
• Engine ru n n i n g .
• Connect I N S ITE™ electronic seNice tool .
Operate the engine until the EG R valve opens. Is the EG R differential pressure g reater than 6D
5 m m- H g (0 .2 in-Hg) when the EGR valve is
Use I N S ITE™ electronic seNice tool to mon itor
open g reater than 50 percent?
the EG R Differential Pressu re and the EGR valve
position (Percent Open). YES
NOTE: The EG R valve may not open u ntil the

engine h as reached normal operating Is the E G R differential pressure g reater than 6F
temperatu re . 5 m m - H g (0 .2 in-Hg) w h e n t h e EG R valve i s
open g reater than 50 percent?
NOTE: Once t h e e n g i n e has reached normal
operating tem perature, q u ick th rottle snaps can NO
help ind uce EGR valve movement.
Engine Performance Troubleshooti ng Tree - ISB Engines E [ . . . J ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J
Page TT-2 1 0 Section TT - Troubleshooting Sym ptoms (New Format)
STEP 6 0 : Check exhaust a as Dress u re sensor accu racv.
Cond ition:
Start the data mon itor/logger. There is l ess than a 1 02 m m-Hg [4 i n -Hgl 6E
• Use I N S ITE™ electronic service tool to difference between the exhaust pressu re
compare the read i n g for exhaust pressure sensor read i n g and the barometric air
sensor and barometric p ressu re sensor. pressure sensor read ing?
NOTE: If worki ng on an engine n o t eq u i p ped with YES
an exhaust pressu re sensor, go to the next step.
The exhaust p ress u re sensor is an absol ute There is l ess than a 1 02 mm-Hg [4 in -Hgl Repai r
pressure sensor. This means that the sensor d ifference between the exhaust p ressu re Com plete .
reads exhaust pressure plus barometric ai r sensor read i n g and the barometric air
pressure. pressure sensor read i ng?
NO
Repai r:
Remove the exhaust pressure sensor,

Pedestal and exhaust pressu re sensor tube.
Refer to P roced u re 0 1 1 -027 (Exhaust G as
Pressure Sensor Tu be) i n Section 1 1 of the
Service Manual , ISBe, ISB, aSB (Com mon
Rai l Fuel System), B u l l etin 402 1 271 . Check
for condensation or foreign material b u i ld u p .
Clean or rep l ace as necessary , a n y o f the
removed com ponents.
STEP 6E· Perform t h e I NSITE™ electronic service tool EGR valve actuator test
Cond ition:
ECM d iag nostic tests. Does the EG R Valve pass the I N S ITE™ 6F
• U se I N S ITE™ electronic service tool menu on electronic service tool EG R Valve Actuator
the EG R Valve Actuator Test and fol low the Test?
instructions on the screen . YES
Open and close the EG R valve actuator.
When opened , the actuator position wi l l be 1 00 Does the E G R Valve pass the I N S ITE™ Repai r
percent open . electronic service tool EG R Valve Actuator Complete.
Test?
When closed , the actuato r position wi l l be less
than 1 0 percent closed . NO
Repai r:
Replace the EGR valve . Refer to Proced u re

0 1 1 -022 (EG R Valve) i n Section 1 1 of the
Service Manual , ISBe, ISB, aSB (Co mmon
158, IS8e2, IS8e3, IS8e4, QS84 [ . . . J Engine Performance Troubleshooting Tree - 158 Engi nes E [ . . . J
STEP 6 F : sol ate EGR S:;vste m .
Condition :
• Keyswitch OFF .
• Disconnect the EG R valve d ifferential p ressure sensor.
Discon n ect the EGR valve d i fferential p ressure Was the Perfo rmance or Excessive Smoke 6F- 1
sensor. (Black) com plaint corrected by discon necting
the EG R valve d ifferential p ressure sensor?
Refer to Proced u re 0 1 9-370 (EG R Differential
P ressure Sensor) in Section 1 9 . YES
Operate the engine at which the Performance or
Excessive Smoke (Black) com plaint occurs .

Was the Perfo rmance or Excessive Smoke Perform next
(Black) com plaint corrected by d isco n n ecti n g troubleshooti
NOTE: By d isconnecti ng the EG R valve the EG R valve differential pressu re sensor? ng proced u re
differential pressure sensor, the ECM w i l l as outl ined i n
com mand t h e EG R valve t o close . No engine NO
Step 2.
derate wi l l be com manded by the EC M . Fault
code 2274 wi l l become active with the EG R valve
d i fferential p ress u re sensor d isconnected .
Engine Performance Troubleshooti ng Tree - ISB Engi nes E [ . . . J ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
STEP 6F-1 : Check t h e EGR S ste m for Bl ocka e
Cond ition:
• Keyswitch OFF.
• Remove the EG R valve d ifferential pressu re sensor.
Remove the EG R valve d ifferential p ressure Was blockage or excessive carbon b u i ld up Repai r
sensor and inspect the passages i n the sensor found in the EG R valve differential pressure Com p lete
and i n the ai r i ntake con n ection for blockage or sensor and/or i ntake con n ection passages?
excessive carbon b u i l d u p . YES
Refer t o P roced u re 0 1 9-370 (EG R D ifferential Repai r:
Pressure Sensor) i n Section 1 9 . Refer to
Procedure 0 1 0-080 (Ai r I ntake Con n ection) i n Clean the passages i n the sensor and i n the
Section 1 0 o f t h e Service Manual , I S B e , I S B , ai r i ntake con nectio n . If the b lockage o r
a S B (Common Rai l Fuel System ) , B u l l etin carbon b u i l d u p is t o severe , replace the EG R
402 1 27 1 . valve differential p ressu re sensor and/or air
i ntake connection . Refer to P roced u re
0 1 9-370 (EG R Differential Pressure Sensor)
i n Section 1 9 . Refer to Proced u re 0 1 0-080
(Ai r I ntake Connection) in Section 1 0 of the
Service M anual , ISBe, ISB, aSB (Common
Was blockage or excessive carbon b u i l d up 6F-2

found in the EG R valve d ifferential pressure
sensor and/or i ntake connection passages?
NO
STEP 6 F-2: Check the EGR system for correct or

damaaed com Donents.
Cond ition:
• Keyswitch OFF.
Check if the air i ntake con nection is assembled Was the air i ntake con n ection assembled Repai r
properly and/o r any com ponents are damaged . properly with no damage to any Com p l ete
com ponents?
1 . Disconnect the EG R con nection tu bes from
the air i ntake con nectio n . Refer to P roced u re YES
0 1 1 -025 (EG R Connection Tu bes) i n Section 1 1 Repa i r :
of the Service Manual , ISBe, I S B , aSB (Common
Rai l Fuel System), B u l let i n 402 1 27 1 . I n spect the Replace the EG R valve d ifferential pressu re
EGR i n l et to the air i ntake con n ection to make sensor and air i ntake con nectio n . Refer to
sure the EG R flow measurement venture (1 ) is Proced u re 0 1 9-370 (EG R Differential
present and n o t damaged or b l ocked . P ressure Sensor) i n Section 1 9 . Refer to
Proced u re 0 1 0-080 (Ai r I ntake Con nection) i n
2. Remove the two-piece ai r i ntake connection Section 1 0 of the Service Manual , I S B e , I S B ,
adapter. Refer to P roce d u re 0 1 0- 1 3 1 (Ai r I ntake a S B (Co m m o n Rail Fuel System), Bul leti n
Connection Adapter) in Section 1 0 of the Service 402 1 271 .
Manual , ISBe, I S B , aS B (Com mon Rai l Fuel
System) , B u l l et i n 402 1 271 . Verify the EG R m ixer
is i nstal l ed and rem ove the EG R m ixer. Refer to Was the air i ntake con nection assembled Repai r
Proced u re 0 1 1 -02 1 (EG R M ixer) i n Section 1 1 of properly with no damage to any Complete
the Service M anual , ISBe, I S B , aSB (Com mon com ponents?
Rai l Fuel System), B u l letin 402 1 27 1 . I nspect the NO
EGR M ixer for damage or excessive carbon b u i l d
Repa ir:
up.
Replace o r clean the necessary component.
NOTE: If replaci ng the air i ntake con nection o n
For the EG R M ixer, refer to P roced u re
engi nes eq u i pped with EG R , check t o make sure
0 1 1 -02 1 (EG R Mixer) i n Section 1 1 of the
the EG R flow m easurement venture ( 1 ) is
Service Manual , ISBe, ISB, aSB (Common
properly i nstalled i n the new ai r i ntake
Rai l Fuel System), B u l leti n 402 1 271 . If the
connection .
EG R fl ow measurement venturi is damaged
or m issi n g , the enti re air i ntake con nection
must be replaced as an assem b ly. The EG R
flow m easu rement venturi can not be
serviced separately. Refer to P roce d u re
0 1 0-080 (Ai r I ntake Connection) i n Section 1 0
of the Service Manual , ISBe, I S B , aSB
(Common Rai l Fuel System), B u l leti n
402 1 271 .
1 ___
.... r-.
1 0d00249
STEP 7: Verify electro n i c featu res are operat i n g co rrectly.

S T E P 7A : Verify accele rator (th rottl e) pedal travel .
Cond ition:
• Keyswitch ON .
Action Specificati on/Repair Next Step
Use I N S ITE™ electronic service tool to mon itor Does the th rottle position read a percent 78
th rottle position w h i l e fully depressing and when the accelerator (th rottle) is rel eased
releasing the accel erator (th rottl e) pedal . and 1 00 percent when the accelerator
(th rottle) is fully depressed?
YES
Does the th rottle position read a percent Repai r

when the accelerator (th rottle) is released com plete
and 1 00 percent when the accel erator
(th rottle) is fu l ly depressed?
NO
Repai r:
Refer to the OEM Service Manual for

accelerato r (th rottle) pedal troubleshoot i n g .
STEP 7 8 : M om' t or v e h 'IC I e SDee d .
Conditi o n :
• Keyswitch ON.
Mon itor the veh icle speed . Does the veh icle speed read zero when the 7C
• Use I N S ITE™ electronic service tool to mon itor vehicle i s not movi ng?
vehicle speed wh i l e the veh icle is n o t m ovi n g . YES
Does the ve hicle speed read zero when the Repai r

vehicle is not movi ng? complete
NO
Repair:
Check the veh icle speed sensor and circ u it

for problems. Refer to the OEM · service
manual .
ST EP 7C : . feat u re settl nQs are co rrect .

v em·f y the e ectronlc
Cond ition :
• Keyswitch ON .
Use I N S ITE™ electronic service tool to verify the Are the electronic featu res set correctly? 7D
followi ng adj ustabl e parameters are correctly

YES
set:
• M axi m u m veh icle speed
• Powertrai n p rotection
Are the electronic featu res set correctly? Repai r
• Rear axle ratio NO
com p l ete
• Tai lshaft teeth
Repa i r :
• Tire revo l utions per m i l e
• G ear-down p rotection Correct p rogrammable features.

• Cru ise control d roop setti ngs
• Cru ise control maxi m u m vehicle speed
• Accel erator type
• Road speed governor
• Vehicle acceleration management
• Transm ission type.
STEP 70: C h e c k the temDeratu re sensor accu racy .
Cond ition:
• Keyswitch ON .
• T h e e n g i n e m u st be tu rned off l o n g e n o u g h for coolant tem peratu re t o be eq ual t o ambient air temperatu re.
Use I N S ITE™ elctronic service tool to mon itor the Are al l temperatu re read i ngs with i n 5 . 6 ° C Step 7E
fol l owi ng tem peratu res: [ 1 0 ° F] o f each other?
• Engine coolant temperatu re senor

YES
• I ntake man ifold air tem peratu re sensor
• If eq u i pped , the tu rboch arger com p ressor i n l et
air tem peratu re sensor Are al l temperatu re read ings with i n 5 . 6 ° C Repai r
• If eq u i pped , the EGR tem peratu re sensor.
[ 1 0 ° F] o f each other? com plete
NO
Repai r:
Check for a short from the S I G NAL p i n of the

pins i n the harness .
Refer to P roced u re 0 1 9-360 (Resistance
Meas u rement Using a M u ltimeter with a
Wiring Diag ram) i n Section 1 9 .
If no short is fou nd , replace the tem perature
sensor that is read i n g h igher or lower than
the other sensors. See Section 1 9 for
specifications on each tem perature sensor.
Engine Performance Troubleshooti ng Tree - ISB Engi nes E [ . . . J ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J
STEP 7E Che ck am b ·l ent a i r press u re sensor accu racy .
Cond ition:
• Keyswitch O N .
Action S pecifi cation/Repair Next Step
Start I N S ITETM electronic service tool data I N S ITE™ e lectronic service tool read i n g is
Perform next
mon itor/logger and compare the I N S ITE™ wit h i n 50. 8 m m-Hg [2 in-Hg] of local
troubleshooti
electronic service tool read i n g for barometric air barometric pressure?
ng proced u re
pressure to the local barometric pressure.
YES as outl ined i n
Step 2.
Refer to P roced u re 0 1 8-028 (Baro m etric
P ressu re at Altitude) i n Section V.
I N S ITE™ electronic service tool read i n g is Repai r
with i n 50 . 8 m m-Hg [2 in-Hg] of l ocal Complete
barometric p ressure?
NO
Repa ir:

Refer to P roced u re 0 1 9-004 (Barometric Air
Pressure Sensor) i n Section 1 9 .
IS8, IS8e2 , IS8e3 , IS8e4, QS84 [ . . . J Engine Performance Troubleshooting Tree - IS8 Engi nes E [ . . . J
STEP 8: Perform base e n g i n e mec h a n i cal checks .

STEP SA: Verif the overhead ad ' ustme nts are correct .
Cond ition:
• Keyswitch OFF.
• Remove valve cover.
Measu re the overhead settings. Are the overhead settings wit h i n the reset 8B
• Refer to Proced u re 003-004 (Overhead Set) i n l i m its?
Section 3 in the Service M an u a l , I S B e , I S B ,

YES
aSB (Com mon Rai l Fuel System), B u l leti n
402 1 271 .
Are the overhead settings with i n the reset Repai r
l i m its? com plete
NO
Repa i r :

P roced u re 003-004 (Overhead Set) in
Section 3 of the Service Manual , ISBe, I S B ,
a S B (Com mon Rai l Fuel System), B u l letin
402 1 271 .
Engine Performance Troubleshooting Tree - ISB Engines E [ . . . J ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J
STEP 8 8 : C h e c k the exhaust restrict i o n .
Cond ition:
• Keyswitch ON .
• Engine ru n n i n g at advertised horsepower and rpm .
Measure exhaust system back pressure. Is the exhaust back pressure g reater than the Repai r
Measure the exhaust system back p ressure by
i nstal l i n g a pressure gage, C u m m i ns® Part YES
N u m ber ST- 1 273 , or eq u ivalent, i nto the exhaust Repa ir:
system i m mediately downstream of the
tu rbocharger exhaust outlet. Correct the cause of high back p ressure, look
for col lapsed or plugged exhaust pi pes.
Maxi m u m Exhaust Back Pressure = 1 0 .2 kPa
[ 1 . 5 PS I ] .
Is the exhaust back pressu re g reater than the BC
specification?
NO
OOd00 1 1 0
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J Engine Performance Troubleshooting Tree - ISB Engines E [ . . . J
STEP B C : Verif is wit h i n s ecification .
Cond ition:
• Keyswitch OFF.
• Connect appropriate service tools to measu re blowby.
Measure engine cran kcase pressu re (blowby) . Is the engine cran kcase p ress u re (blowby) 80
l ess than specification?
Refer to P roced u re 0 1 4-0 1 0 (C ran kcase Blowby,
M easu re) in Section 1 4 of the Service Manual , YES
ISBe, I S B , QSB (Com mon Rail Fuel System),
B u l letin 402 1 271 . Is the engine cran kcase p ress u re (blowby) Refer the
less than specification? Cran kcase
NO
Gases
(Blowby)
Repai r : Excessive
NOTE : Record the engine blowby pressu re troubleshooti
for later use. ng sym ptom
(TS) tree .
OOd00 1 1 1
Engine Performance Troubleshooting Tree - ISB Engines E [ . . . J ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ]
STEP 8 0 : Check f o r mterna en�une damaae .
Cond ition:
• Keyswitch OFF.
Remove the o i l filter. Did cutting the oil fi lter open reveal evidence Repai r
of i nternal engine damage? complete
Refer to P roced u re 007-0 1 3 (Lu b ricating O i l Fi lter
(Spi n-on» i n Section 7 of the Service Manual , YES
ISBe, I S B , aSB (Com mon Rail Fuel System) , Repair:
B u l letin 402 1 271 .
Determ i ne the area of probable damage and
Cut the o i l filter open and inspect for debris and repai r as necessary. Remove the l u b ricating
area of probable damage . Refer to P roced u re o i l pan and rocker lever cover, if necessary ,
007-083 (Lubricating Oil Filter and Analysis) i n to i nspect for damage.
Section 7 o f t h e Service Manual , I S B e , I S B , aSB
(Common Rai l Fuel System), B u l leti n 402 1 27 1 . • Refer to P roced u re 007-025 (Lubricating
Oil Pan) i n Section 7 of the Service
Man ual , ISBe, I S B , aSB (Com mon Rai l
Fuel System), B u l leti n 402 1 271 .
• Proced u re 003-0 1 1 (Rocker Lever Cover)
in Section 3 of the Service Manual , ISBe,
I S B , aSB (Com mon Rai l Fuel System),
B u l l et i n 402 1 271 .
Did cutting the o i l fi lter open reveal evidence Perform n ext

of i nternal engine damage? troubleshooti
NO
ng proced u re
as outl i ned i n
Step 2.
STEP 9 : Excessive vibrat ion c h ec ks .

STEP 9A Ch ec k en�:lIne I· d le spee d .
Cond ition:
• Keyswitch O N .
• Connect I N S ITE™ el ectronic service too l .
Mon itor the engine speed . Is the e n g i n e idle speed with i n specification? 9B
U se I N S ITE™ electronic service tool to mon itor
•
YES
engine speed while engine is i d l i n g .
Repair:
See t h e e n g i n e dataplate for idle speed
specifications.
Is the engine idle speed wit h i n specification? Repai r

NO
Complete
Repai r:
Adj ust or i ncrease the engine idle speed .
STEP 98: I t h e f eatu re F ast I d le W arm uI P .IS aval· 1 a b l e an d ena bl ed .

Ch ec k ·f
Cond ition :
• Keyswitch O N .
Check the featu res and parameters with I N S ITE™ Is the feature Fast I d l e Warm Up available 98-1
electronic service too l . a n d enabled?
Check if the feature Fast Idle Warm U p is YES
avai lable and enabled.
Is the feat u re Fast I d l e Warm U p available 9C
and enabled?
NO
STEP 9 8 1
-
M omtor t he Fast Idl e W arm uI P S tatus .
Cond ition:
• Keyswitch ON .
• I N SITE™ electronic service tool mon itor.
Mon itor the Fast I d l e Warm Up I N SITE™ Is the feature Fast Idle Warm Up beco m i n g Repai r
electronic service tool status. active? Com plete
YES
Repa ir:
Adj ust the fast idle warm u p idle speed o r

check w i t h the customer on d isab l i ng t h e
feature.
NOTE : Disab l i n g the fast idle warm up
feature can affect warranty.
Is the feature Fast I d l e Warm U p beco m i n g 9C

active?
NO
STEP 9C: Check front enaine d riven accessorv(s) .
Cond ition:
• Keyswitch OFF.
• Isolate front engine d riven accessory(s) .
Isolate front engine d riven accessory(s) one at a Did isolating the front engine d riven Repai r
time, i ncl u d i n g : accesso ry(s) correct the vibratio n ? Complete.
• Alternator(s)
YES
• Refrigerant compressor(s)
• Fan h ub(s) Repair:

• Hydrau lic/Power steeri ng p u m p(s)
Repai r or replace the malfu nctio n i n g
• Water p u m p
component.
• Cooling fan
• C rankshaft d riven PTO accessories .

Did isolating the front engine d riven 9D
accessory(s) correct the vibration?
NO
S T E P 9D Check the V i bration Damper/Crankshaft speed i n d i cator rina .
Cond ition:
• Keyswitch OFF.
Check the vibration damper/ cran kshaft speed Is the vibration damper/cran kshaft speed Repai r
indicator ring for damage. indicato r ring damaged? Com plete .
For engi nes eq u i pped with a rubber vibration YES
damper, refer to P roced u re 001 -051 (Vi bration Repai r:
Damper, Rubber) i n Section 1 of the Service
Manual , ISBe, I S B , aSB (Com mon Rail Fuel Replace the damaged vibration damper/
System), Bul leti n 402 1 271 . cran ksh aft speed indicator ring.
For engi nes eq u i pped with a viscous damper,
refer to P roced u re 001 -052 (Vi b ration Damper, Is the vibration damper/cran kshaft speed 9E
Viscous) i n Section 1 of the Service Manual, indicator ri ng damaged?
ISBe, ISB, aSB (Com mon Rail Fuel System), NO
B u l leti n 402 1 27 1 .
For engi nes eq u i pped with a cran kshaft speed
indicator ring only refer to P roced u re 00 1 -07 1
(Crankshaft Speed I n d icator Ring) i n Section 1 of
the Service Man ual , ISBe, I S B , aSB (Common
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J Engine Performance Troubleshooti ng Tree - ISB Engines E [ . . . J
Section TT - Troubleshooti ng Symptoms (New Format) Page TT -223
STEP 9 E : Check the E n a l n e S U D Dort Brackets . M ou nts an d/or so ato rs .
Cond ition:
• Keyswitch OFF.
Check the engine support b rackets , mou nts and/ Are the e n g i n e support brackets , m o u nts Repai r
or isolators for damage . and/or iso l ators damaged? Com plete.
For front engine su pports, refer to P roced u re YES
0 1 6-002 (Engine S u pport Bracket , Front) i n Repa i r :
Section 1 6 of the Service Man ual , ISBe, I S B ,
a S B (Com mon R a i l Fuel System), B u l l etin Replace the damaged eng i n e support
402 1 271 . brackets, mou nts and/or isolators.
For rear engine supports , refer to Proced u re
0 1 6-003 (Engine Support B racket , Rear) i n Are the e n g i n e support b rackets , mou nts 9F
Section 1 6 o f t h e Service Man ual , I S B e , I S B , and/or iso l ators damaged?
aSB (Com mon Rail Fuel System) , B u l letin NO
402 1 271 .
STEP 9F: Check enaine aear d riven accessorv(s) .
Cond ition:
• Keyswitch OFF.
Check if the engine has an engine gear d riven/ Does the engine have an engine gear d riven/ 9F- 1
ai r com p ressor d riven hyd rau l i c pump? air com pressor d riven hydrau l i c p u m p ?
YES
Does the engine have an engine gear d riven/ 9F-2

air com p ressor d riven hydrau l i c p u m p ?
NO
STEP 9F-1 : Isolate enaine gear driven accessol"Yls).
Cond ition:
• Keyswitch OFF.
• Isolate/remove the gear/ai r com p ressor d riven hyd rau l i c p u m p .
Isolate/remove the gear d riven/ai r com p ressor Did isolating/removi ng engine gear d riven/ai r Repai r
d riven hyd rau l i c p u m p and operate the engine. compressor d riven hydrau l i c pump correct Com plete.
t h e vi b ration?
Refer to Proced u re 009-0 1 6 (Hyd rau l i c P u m p
Drive) i n Section 9 of the Service Manual , ISBe, YES
I S B , aSB (Co m m o n Rail Fuel System) , B u l letin Repair:
402 1 27 1 , for general hydrau l i c pump remove and
i nstal l i nstructions. Repai r or replace the malfu nction i n g
com ponent.
NOTE: S o m e engines req u i re an accessory d rive
to d rive the hyd rau l i c pump. It may be necessary
to isolate this as wel l . Refer to P roced u re 009-00 1 Did isolat i n g/re movi ng engine gear d riven/air 9F 2 -
(Accessory D rive) i n Section 9 of the Service com p ressor d riven hyd rau lic p u m p co rrect
Manual , ISBe, I S B , aS B (Common Rail Fuel the vibration?
System), B u l leti n 402 1 271 . NO
STEP 9 F-2 : Check if t h e e n !=l i n e is ea u i ooed with an air comoressor .
Cond ition:
• Keyswitch OFF.
Check if the engine is eq u i pped with an engine Is the engine is eq u i pped with an engine gear 9F-3
gear d riven air com p ressor. d riven air com pressor?
YES
Is the e n g i n e is eq u i pped with an engine gear 9G

d riven air com pressor?
NO
STEP 9 F-3 U n load t h e A i r Compressor and Ooerate.
Cond ition:
• Keyswitch OFF.
• U n l oad the ai r com p ressor.
Action Specification/Re pair Next Step
With the air com p ressor u n loaded , operate the Did u n load i n g the air compressor 9F-4
engine i n the condition i n which the vibration sign ificantly red uce or el i m i nate the
com plaint occ u rs . vibration?
T h e ai r com p ressor can be u n l oaded by: YES
1 . Disconnecting the air governor sig nal l i ne and

connecting reg u l ated shop air, with a pressure Did u n load i n g the air com p ressor Repai r
gauge, to the air com p ressor governor air sig nal sign ificantly red uce or e l i m i nate the Complete .
port . vibration?
NOTE: Typically 62 1 k P a (90 p s i ) o f ai r pressu re NO
is the set point for u n load i n g the air com p resso r.
Refer to the OEM Service Manual .
2. Discon nect the air com p ressor d ischarge l i ne
and air i ntake h ose from the a i r com p ressor.
NOTE: On tu rbocharged air com p resso rs , make
sure to plug the air i ntake hose attached to the
i ntake manifo l d .
Engine Performance Troubleshooting Tree - ISB Engines E [ . . . J
Page TT-225
STEP 9 F-4 : Check A i r Compressor T i m i n a .
Cond ition:
• Keyswitch OFF.
• Check the ti m i n g of the air com p ressor.
Check that the air com pressor is correctly timed Was the air com pressor correctly ti m ed to the Repai r
to the engine. engine? Complete.
Refer to P roced u re 0 1 2-0 1 4 (Ai r Compressor) i n YES
Section 1 2 o f t h e Service Manual , I S B e , I S B , Repa ir:
a S B (Common Rai l Fuel System), B u l leti n
402 1 271 . Replace the air com p ressor. Refer to
Proced u re 0 1 2-0 1 4 (Ai r Com p ressor) i n
NOTE : When troubleshooting a vibration issue i n Section 1 2 o f t h e Service Manual , I S B e , I S B ,
which i t is suspected that t h e ai r com pressor is a S B (Co m m o n R a i l F u e l System), B u l leti n
the cause of the vib ration , it may be necessary to 402 1 271 .
isolate the air com p ressor from the engine.
Was the a i r com p ressor correctly timed to the Repai r

engine? Complete.
NO
Repa ir:
Correctly time the air com p ressor to the

eng i n e . Refer to Proced u re 0 1 2-0 1 4 (Ai r
Compressor) i n Section 1 2 o f t h e Service
Manual , I S B e , I S B , aSB (Com mon Rai l Fuel
System), B u l leti n 402 1 271 .
STEP 9G : Ch ec kli so ate ename d riven

' componen ts.
Cond ition:
• Keyswitch OFF.
• Isolate/remove any engine d riven com ponents.
Isolate/remove any engine d riven co m ponents Did isolating/removi ng any engine d riven Repai r
and operate the engine. com ponent correct the vibration? Complete.
Engine d riven components i nclude: YES
• Transm issions (Torq ue converters/Cl utches) Repai r:

• Hydrau lic p u m ps
Replace the malfu nction i ng com ponent.
• D i rect d rive shafts
Refer to the OEM i nstructions.
• Flywheels, refer to Proce d u re 0 1 6-005
(Flywheel) in Section 1 6 of the Service Manual ,
ISBe, I S B , aSB (Common Rai l Fuel System), Did isolating/removi ng any engine d riven 9H
B u l let i n 402 1 271 . com ponent correct the vibration?
• Flexp late, refer to Proced u re 0 1 6-004 NO
(Flexplate) i n Section 1 6 of the Service
Manual , I S Be , I S B , aSB (Common Rail Fuel
System), B u l l eti n 402 1 271 .
STE P 9 H : Ch ec k the FIIyw h ee I H ousmg AI" n men t .
Conditi o n :
• Keyswitch OFF.
• Engine d riven com ponents removed .
Measu re the flywheel housing bore and face Is the flywheel housing bore and face runout 8A
runout. with i n specification?
Refer to P roced u re 0 1 6-006 (Flywheel Housi ng) YES

in Section 1 6 of the Service Manual , I S B e , I S B ,
a S B (Common R a i l Fuel System), B u l let i n Is t h e flywheel housing bore and face runout Repai r
402 1 271 .
with i n specification? Com plete.
NO
Repai r:
Refer to Proced u re 0 1 6-006 (Flywheel

Housi ng) in Section 1 6 of the Service Man u al ,
I S Be , I S B , aS B (Common Rail Fuel System),
Bul leti n 402 1 271 , for flywheel housing repai r
options.
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . ] Fuel Economy Troubleshooting Tree
Fuel Economy Troubleshooting Tree
T h i s tro u b l eshoot i n g p roced u re s h o u l d be fo l lowed for the fo l lo w i n g sym pto ms:

• Fuel Consu m ption Excessive
How to U se T h i s T ro u b l eshooti ng P roced u re :

T h i s sym ptom tree is t o b e used t o troubleshoot fuel economy complai nts. T h i s tree is used along with t h e Fuel
Consumption - C ustomer Com plaint Form and the D riveabi l ity Low Power/Excessive Fuel - Consu m ption Checkl ist to
help isolate engine, chassis, or d river issues associated with excessive fuel consu m pti o n .
Shop Talk:
The Fuel Consu m ption - General I nformation section of this manual and Trou bleshooti ng Excessive Fuel
Consu m ption , B u l leti n 3666094, m ust be referenced prior to any trou b l eshooti ng being performed on a customer's
engine.
The cause of excessive fuel consu m ption is d ifficult to diagnose and correct because of the potential n u m ber of factors
i nvolved . Actual fuel consu m ption problems can be caused by any of the fol l owi ng factors :
• Engine factors
• Veh icle factors and specifications
• Enviro n mental factors
• D river tec h n i q u e and operating practices
• Fuel system factors
• Low power or d riveabi l ity p roblems.
Before troubleshooti n g , it is i m portant to determ ine the exact com plaint. Is the complaint based on whether the
p roblem i s real o r perceived , or does not meet d river expectations? The Fuel Consu m ption - Customer Complaint
Form is a val uable l ist of q u estions that can be used to assist the service tec h n ician i n d eterm i n i n g the cause of the
problem. Complete the form before troubleshooting the com p l a i nt . The fol l owi ng are some of the factors that m u st
be considered when troubleshooti ng fuel consumption com plaints.
• Excessive i d l i n g t i m e : I d l i n g the engine can use from 0.5 to 1 . 5 gallons per hour depending on the engine i d l e
speed .
• Veh icle Aerodynam ics : The largest single power req u i rement for a truck is the power needed to overcom e air
resistance. As a general rule , each 10 percent red uction i n a i r resistance resu lts i n a 5 percent i ncrease i n m i l e per
gal l o n .
• Rol l i n g Resistance: Rol l i n g resistance is the second largest consumer o f power on a truck. The type o f t i re and
tread design h ave a sizeabl e effect on fuel economy and performance. Changi n g fro m a bias ply to a low p rofi le
rad ial tire can red uce rol l i n g resistance by about 36 percent.
• Enviro n mental and Seasonal Weather Changes: There can be as much as 1 to 1 . 5 m i l e per gallon d ifference i n fuel
cons u m ption , depen d i n g o n the season and the weather con d itions.
• Truck Route and Terrai n : East and west routes experience almost conti n ual crosswinds and h ead winds. Less fuel
can be used on north and south routes where parts of the tri p are not o n ly warmer, but have less wind resistance.
• D river Tech n i q u e and Operating Practices: A 1 m i l e per hou r i ncrease i n road speed equals a 0 . 1 m i l e per gallon
increase i n fuel consu m ption. This means that increasing road speed from 50 to 60 m ph w i l l result i n a loss of fuel
m i leage of 1 m pg .
• Result o f a Low Power or D riveabil ity P roblem : A n operator wi l l change d rivi ng style t o compensate for a low power
or d riveability problem . Some thi ngs the d river is l i kely to do are (a) shift to a h i g h engine rpm or (b) run on the
d roop cu rve i n a l ower gear instead of u psh ifting to d rive at part-t h rottle cond itions. These changes i n d rivi ng style
will i ncrease the amount of fuel used .
Add itional veh icle factors , vehicle specifications and axle al i g n ment, can also affect fuel consu m ption . For add itional
i nformation on tro ub l eshooti ng fuel consu m ption complaints , refer to Troubleshooting Excessive Fuel Cons u m ption ,
B u l leti n 3666094.
Fuel Economy Troubleshooting Tree ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J
T RO U B LESH OOTI N G S U M MARY
STEPS S P EC I F I CATI O N S S RT CO D E
STEP 1 : Verify the c o m p l a i n t .
STEP 1 A : F i l l out the Fuel Consu m ption -
Custom e r Com plaint Form .
STEP 1 B : R u n V EIV M S .
STEP 2: Electro n i c Chec ks , u s e I N S I T E™ electro n i c service too l .

STEP 2A: Check for fau lt codes.
STEP 2 B : Confi rm Featu res and
Parameters .
STEP 2C: Check the ECM cal i brations.
STEP 2 0 : Mon itor vehicle speed .
STEP 20-1 : I nspect t h e e n g i n e and
chassis g ro u nds .
STEP 3: E n g i ne performance.
S T E P 3A: Engine performance
troubleshooting .
STEP 1 : Verify the c o m p l a i n t .

STEP 1 A F I" I I t h e F u e I C onsu m pf I . t F orm .
1 1on - C us t omer C o m Dlam
Cond ition:
Fi l l out the Fuel Consu m ption - Customer Is the p roblem caused by vehicle factors, Repai r
Complaint Form in the Troubleshooti ng and envi ronmental factors , or d river tech n i q ue? complete
Repai r Manual , ISC, QSC8. 3 , ISL and QS L9 YES
Engi nes, Bul leti n 402 1 4 1 8 .
Is the p roblem caused by vehicle factors , 1B
envi ron mental factors , or d river tech niq ue?
NO
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ J
• • . Fuel Economy Troubleshooting Tree
Section TT Troubleshooting Sym ptoms (New Format)
• Page TT·229
STEP 1 8 · R u n V E/V M S
Cond ition:
Fill out the D riveabi l ity/Low Power/Excessive Taki ng i nto consideration the adverse effect 2A
Fuel Consu m ption · Checkl ist in Tro u bleshooting of am b ient conditions, does the VENMS fuel
and Repai r Manual , ISC, QSC8 . 3 , I S L and QS L9 economy confl ict with the customer's cu rrent
Engi nes , B u l l et i n 402 1 4 1 8 . fuel economy?
U s e t h e data gathered t o ru n VENMS o r p rovide YES
the data to the appropriate suppo rt personnel to
run VENMS . Taki ng i nto consideration the adverse effect Repai r
NOTE: VENMS does not accou nt for adverse
of ambient cond itions, does the VENMS fuel complete
am bient con d itions.
economy confl ict with the customer's cu rrent
fuel economy?
NO
Repai r:
Explain to the customer the effects of d rivi ng

habits on fuel cons u m ptio n .
S T E P 2: E l ectro n i c Checks , use I N S ITE™ electro n i c service too l .

STEP 2A" Check for fau l t codes .
Cond ition:
Use I N S ITE™ electronic service tool to read the Are there any active or h i g h cou nts of i n active Troubles hoot
fau lt codes. fau lt codes? fau lt codes
YES
Are there any active or h i g h cou nts of i n active 2B

fau lt codes?
NO
Fuel Economy Troubleshooting Tree ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ]
STEP 2 8 ' Confirm Featu res a n d Parameters
Cond ition:
Confirm the P rog ram mable Featu res and Are the Featu res and Parameters set 2C
Parameters are set correctly. correctly?
YES
Are the Featu res and Parameters set Repai r

correctly? complete
NO
Repair:
Reset the Featu res and Parameters to their

appropriate val ues.
STEP 2 C ' Check the ECM cal i b ration
Cond ition:
Com pare the ECM code with the engine rating Is the cal i b ration correct? 20
and C P L . Verify the cal i b ration is correct. YES
Is the cal i b ration correct? Repai r

NO
complete
Repai r:
Recal i brate the ECM with the correct ECM

code .
STEP 2 0 M omtor ve h 'IC I e spee d .
Cond ition:
Use I N S ITE™ electronic service tool to mon itor

Does veh icle speed read 0 when the veh icle 3A
Veh icle Speed wh i l e the veh icle is not movi ng.
is not movi ng?
YES
Does vehicle speed read 0 when the veh icle 20- 1

is not m ovi ng?
NO
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J Fuel Economy Troubleshooting Tree
STEP 20 - 1 : I nsoect t h e enj:lme and chassIs j:l rou n ds .
Cond ition:
Check for loose or corroded e n g i n e , chassis, or Are all grounds present, properly g rou nded , Repai r
battery g round con n ection . free of corrosion , and tig ht? com p l ete
• Check the engine ground conn ection
YES
• Check the chassis g round con n ections
• Check the battery term i nal co n n ections. Repa ir:
Check the VSS and the VSS circuit.

Refer to P roced u re 0 1 9-09 1 (Veh icle Speed
Sensor, M agnetic Pick U p) i n Section 1 9 .
Are al l g ro u nds p resent, p roperly g rounded, Repai r

free of corrosion , and tig ht? com pl ete
NO
Repa ir:
Replace , clean , or tighten the g rou nds.
STEP 3: E n g i n e performance.
STEP 3A: E n a i n e oerformance trou bl esh ootma .
Condition :
Perform the Fuel System Checks, Air Hand l i n g Poor f u e l economy com plaint sti l l exists? Repai r
Checks , and Base Engine C hecks in the Engine YES com p l ete
Perform ance Tro u bleshooting Tree .
Repai r:
Perform the Fuel System Checks, Air

Hand l i ng Checks, and Base E n g i n e Checks
i n the E n g i n e Performance Troubleshooting
Tree.
Poor fuel economy com plai nt sti l l exists? Repai r

NO complete
Fuel Economy Troubleshooting Tree ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . ]
N otes

Section TT - Troubleshooting Symtoms PDF

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Section TT - Troubleshooting Symtoms PDF

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ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J • . .

Section TT - Troubleshooting Symptoms (New Format) Page TT-a

Section TT - Troubleshooting Symptoms (New Format)

Fuel Economy Troubleshooting Tree TT-227

This Page Left Intentionally Blank

ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . • • ECM - No Communication Troubleshooting Tree

Section TT - Troubleshooting Symptoms (New Format) Page TT-1

ECM - No Communication Troubleshooting Tree

This troubleshooting procedure should be followed for the following symptoms:

• No com m u n ication and e n g i n e w i l l start

• No com m u n ication related I N SITE™ electronic service tool e rrors

How t o Use This Troubleshooting Procedure:

Page TT-2 Section TT - Troubleshooting Symptoms (New Format)

STEPS SPECIFICATIONS SRT CODE

STEP 1B: INSITE'M electronic service tool Is INSITE™ electronic service

STEP 1D: ECM password check Does INSITE™ electronic service

STEP 3: Bench communication setup checks

STEP 3A-1: Engine start check Will engine start?

STEP 3B: Initial bench setup Does the ECM communicated

STEP 3B-1: Engine start check Will engine start?

STEP 4: ECM power up circuit check

Section TT - Troubleshooting Symptoms (New Format) Page TT-3

STEP 4A-2: Coolant temperature sensor Is the coolant temperature signal

STEP 4C: Check the ECM power and

STEP 5: Initial electronic tool check

STEP S8: Second vehicle availability

STEP SC: Initial electronic tool

STEP 6: data link adapter power check

STEP 6G: Computer serial port voltage

STEP 7: data link circuit check

STEP 8: Initial electronic tool check

STEP 88: Initial electronic tool

STEP 9: Detailed electronic tool check

STEP 10: Serial cable and computer check

Page TT-4 Section TT - Troubleshooting Symptoms (New Format)

STEP 11: ROM boot ECM

STEP 118: ROM boot ECM Does the ECM communicate?

STEP 1: INSITE™ electronic service tool error code check

Action Specification/Repair Next Step

code 5023 . 5023 present?

• U se I N SITE™ electronic service tool to read the YES

Is I N SITE™ electronic service tool error code 1B

Action Specification/Repair Next Step

Perform the ECM cal ibration download

Is I N SITE™ electronic service tool error code 1C

Section TT - Troubleshooting Symptoms (New Format) Page TT-5

Action Specification/Repair Next Step

See the I N S ITE™ Electronic Service Tool

Are any I N S ITE™ electronic service tool error 1D

STEP 10: ECM Dassword check

Action Specification/Repair Next Step

E nter correct password

Does I N S ITE™ electronic service tool i ndicate 2A

Page TT-6 Section TT - Troubleshooting Symptoms (New Format)

Action Specification/Repair Next Step

Turn keyswitch o n . Are the com m u n ication l i g hts on the data l i n k 2C

Are the com m u n ication l i g hts on the data l i n k 2B

STEP 26 data r In k adapter reset check

I N SITE™ electronic service tool con nected to veh icle.

Action Specification/Repair Next Step

• Connect power agai n to the I n l i ne adapter

STEP 2C· Initial INSITE™ electronic service tool check

Action Specification/Repair Next Step