Section 19 Electronic Engine Controls Parte 1 PDF

ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ J
. • .
Section 1 9 - Electronic Engine controls Page 1 9-a
Sect i o n 1 9 - E l ect ro n i c E ng i ne co n t ro l s
Section Contents
Service Tools………………………………………………………………………………………………………………………………………………………………19-1
Electronic Engine Controls…………………………………………………………………………………………………………………………………………19-1
Install …………………………………………………………………………………………………………………………………………………………………….. 19-5
Barometric Air Pressure Sensor ………………………………………………………………………………………………………………………………19-5
Initial Check …………………………………………………………………………………………………………………………………………………………… 19-5
Remove ……………………………………………………………………………………………………………………………………………………………………19-5
Battery Ground Circuit………………………………………………………………………………………………………………………………………………19-5
Voltage Check …………………………………………………………………………………………………………………………………………………………19-5
Clutch Pedal Position Switch ……………………………………………………………………………………………………………………………………19-6
General Information ……………………………………………………………………………………………………………………………………………… 19-6
Resistance Check………………………………………………………………………………………………………………………………………………………19-6
Check for Short Circuit to External Voltage Source……………………………………………………………………………………………………19-7
Check for Short Circuit to Ground ……………………………………………………………………………………………………………………………19-7
Clutch Pedal Position Switch Circuit………………………………………………………………………………………………………………………… 19-8
Check for Short Circuit to Ground…………………………………………………………………………………………………………………………… 19-9
Check for Short Circuit from Pin to Pin………………………………………………………………………………………………………………………19-10
Exhaust Gas Temperature Sensor………………………………………………………………………………………………………………………………19-11
General Information…………………………………………………………………………………………………………………………………………………19-11
Clean and Inspect for Reuse………………………………………………………………………………………………………………………………………19-12
InstalL…………………………………………………………………………………………………………………………………………………………………….. 19-12
Remove…………………………………………………………………………………………………………………………………………………………………… 19-12
Engine Coolant Level Sensor ……………………………………………………………………………………………………………………………………19-13
Install …………………………………………………………………………………………………………………………………………………………………….. 19-13
Remove ……………………………………………………………………………………………………………………………………………………………………19-13
Engine Coolant Temperature Sensor…………………………………………………………………………………………………………………………19-14
Initial Check …………………………………………………………………………………………………………………………………………………………… 19-14
Remove ……………………………………………………………………………………………………………………………………………………………………19-14
Cruise Control or PTO ON/OFF Switch …………………………………………………………………………………………………………………… 19-15
Marine Applications …………………………………………………………………………………………………………………………………………………19-15
Inspect for Reuse ………………………………………………………………………………………………………………………………………………………19-15
InstalL …………………………………………………………………………………………………………………………………………………………………….. 19-15
Marine Applications………………………………………………………………………………………………………………………………………………… 19-16
Resistance Check …………………………………………………………………………………………………………………………………………………… 19-16
Check for Short Circuit from Pin to Pin ……………………………………………………………………………………………………………………19-17
Cruise Control or PTO ON/OFF Switch Circuit ………………………………………………………………………………………………………… 19-17
Cruise Control or PTO Set/Resume Select Switch………………………………………………………………………………………………………19-19
Cruise Control or PTO Set/Resume Select Switch Circuit……………………………………………………………………………………………19-22
Diagnostic Test Mode Switch ……………………………………………………………………………………………………………………………………19-25
Diagnostic Test Mode Switch Circuit…………………………………………………………………………………………………………………………19-27
Electronic Control Module (ECM)………………………………………………………………………………………………………………………………19-29
Initial Check ……………………………………………………………………………………………………………………………………………………………19-29
Install …………………………………………………………………………………………………………………………………………………………………….. 19-30
Remove ……………………………………………………………………………………………………………………………………………………………………19-30
ECM Calibration Code ………………………………………………………………………………………………………………………………………………19-31
General Information …………………………………………………………………………………………………………………………………………… 19-31
Engine Brake ON/OFF Switch……………………………………………………………………………………………………………………………………19-32
Engine Brake ON/OFF Switch Circuit…………………………………………………………………………………………………………………………19-34
Check for Short Circuit to Ground …………………………………………………………………………………………………………………………19-36
Check for Short Circuit from Pin to Pin …………………………………………………………………………………………………………………19-37
Engine Brake Level Switch ………………………………………………………………………………………………………………………………………19-38
Engine Wiring Harness ………………………………………………………………………………………………………………………………………………19-39
General Information …………………………………………………………………………………………………………………………………………………19-39
Remove…………………………………………………………………………………………………………………………………………………………………… 19-40
InstalL …………………………………………………………………………………………………………………………………………………………………….. 19-42
Fan Control Circuit ……………………………………………………………………………………………………………………………………………………19-43
Resistance Check ………………………………………………………………………………………………………………………………………………………19-44
Fault Lamp ………………………………………………………………………………………………………………………………………………………………19-45
Voltage Check …………………………………………………………………………………………………………………………………………………………19-45
Fault Lamp Circuit ……………………………………………………………………………………………………………………………………………………19-45
Voltage Check …………………………………………………………………………………………………………………………………………………………19-45
Idle Adjust Switch ……………………………………………………………………………………………………………………………………………………19-46
Idle Adjust Switch Circuit …………………………………………………………………………………………………………………………………………19-46
Idle Validation Switch ………………………………………………………………………………………………………………………………………………19-50
Lubricating Oil Level Sensor………………………………………………………………………………………………………………………………………19-52
Clean and Inspect for Reuse………………………………………………………………………………………………………………………………………19-52
Remove ……………………………………………………………………………………………………………………………………………………………………19-52
Intake Manifold Air Temperature Sensor………………………………………………………………………………………………………………… 19-53
Inspect for Reuse …………………………………………………………………………………………………………………………………………………… 19-53
Install …………………………………………………………………………………………………………………………………………………………………….. 19-53
Remove ……………………………………………………………………………………………………………………………………………………………………19-53
Install …………………………………………………………………………………………………………………………………………………………………….. 19-53
Intake Manifold Pressure Sensor …………………………………………………………………………………………………………………………… 19-54
Install …………………………………………………………………………………………………………………………………………………………………….. 19-54
Remove ……………………………………………………………………………………………………………………………………………………………………19-54
Internal Actuator Wiring Harness………………………………………………………………………………………………………………………………19-55
Remove ……………………………………………………………………………………………………………………………………………………………………19-55
Inspect for Reuse………………………………………………………………………………………………………………………………………………………19-56
Install …………………………………………………………………………………………………………………………………………………………………….. 19-56
Key Switch Battery Supply Circuit………………………………………………………………………………………………………………………………19-58
Voltage Check …………………………………………………………………………………………………………………………………………………………19-58
Engine 011 Pressure Sensor ………………………………………………………………………………………………………………………………………19-59
Install…………………………………………………………………………………………………………………………………………………………………….. 19-59
Remove ……………………………………………………………………………………………………………………………………………………………………19-59
OEM Wiring Harness…………………………………………………………………………………………………………………………………………………19-59
Programmable Features and Parameters Not Correct………………………………………………………………………………………………19-59
Adjust ……………………………………………………………………………………………………………………………………………………………………. 19-59
Remote PTO Switch Circuit……………………………………………………………………………………………………………………………………… 19-62
Remote PTO Switch……………………………………………………………………………………………………………………………………………………19-64
Tachometer Circuit ………………………………………………………………………………………………………………………………………………… 19-65
Accelerator Pedal or Lever Position Sensor………………………………………………………………………………………………………………19-67
Automotive and IndustriaL……………………………………………………………………………………………………………………………………… 19-67
Automotive and Industrial…………………………………………………………………………………………………………………………………………19-67
Automotive and IndustriaL……………………………………………………………………………………………………………………………………… 19-69
Accelerator Pedal or Lever Position Sensor Circuit……………………………………………………………………………………………………19-71
Initial Check………………………………………………………………………………………………………………………………………………………………19-71
Unswitched Battery Supply Circuit……………………………………………………………………………………………………………………………19-75
Brake Pedal Position Switch ……………………………………………………………………………………………………………………………………19-77
Remove ……………………………………………………………………………………………………………………………………………………………………19-77
Voltage Check …………………………………………………………………………………………………………………………………………………………19-77
Install …………………………………………………………………………………………………………………………………………………………………….. 19-78
Brake Pedal Position Switch Circuit……………………………………………………………………………………………………………………………19-79
Vehicle Speed Sensor, Digital Input …………………………………………………………………………………………………………………………19-81
Vehicle Speed Sensor, Magnetic Pick Up …………………………………………………………………………………………………………………19-85
Inspect for Reuse …………………………………………………………………………………………………………………………………………………… 19-86
Install …………………………………………………………………………………………………………………………………………………………………….. 19-86
Remove ……………………………………………………………………………………………………………………………………………………………………19-86
Vehicle Speed Sensor Circuit ……………………………………………………………………………………………………………………………………19-89
Fuel Control Valve ………………………………………………………………………………………………………………………………………………… 19-90
Initial Check …………………………………………………………………………………………………………………………………………………………… 19-90
Measure …………………………………………………………………………………………………………………………………………………………………19-90
Install …………………………………………………………………………………………………………………………………………………………………….. 19-91
Remove…………………………………………………………………………………………………………………………………………………………………… 19-91
Rail Fuel Pressure Sensor………………………………………………………………………………………………………………………………………… 19-92
Remove…………………………………………………………………………………………………………………………………………………………………… 19-92
I nspect for Reuse ……………………………………………………………………………………………………………………………………………………19-93
Install …………………………………………………………………………………………………………………………………………………………………….. 19-93
Fuel Pump Actuator …………………………………………………………………………………………………………………………………………………19-94
Initial Check …………………………………………………………………………………………………………………………………………………………… 19-94
Install …………………………………………………………………………………………………………………………………………………………………….. 19-94
Remove ……………………………………………………………………………………………………………………………………………………………………19-94
Water in Fuel Sensor ……………………………………………………………………………………………………………………………………………… 19-95
Engine Brake Harness……………………………………………………………………………………………………………………………………………… 19-96
Intake Manifold Pressure/Temperature Sensor…………………………………………………………………………………………………………19-97
Remove ……………………………………………………………………………………………………………………………………………………………………19-97
Inspect for Reuse………………………………………………………………………………………………………………………………………………………19-98
Install …………………………………………………………………………………………………………………………………………………………………….. 19-98
Data Link Circuit, SAE J1939 ……………………………………………………………………………………………………………………………………19-99
Data Link Circuit, SAE J1587 ……………………………………………………………………………………………………………………………………19-104
Voltage Check …………………………………………………………………………………………………………………………………………………………19-108
Exhaust Brake ON/OFF Switch……………………………………………………………………………………………………………………………………19-109
Exhaust Brake ON/OFF Switch Circuit……………………………………………………………………………………………………………………… 19-111
Resistance Check ………………………………………………………………………………………………………………………………………………………19-111
Ring Terminal……………………………………………………………………………………………………………………………………………………………19-114
Connector Replacement……………………………………………………………………………………………………………………………………………19-114
Fuse, Harness In Line…………………………………………………………………………………………………………………………………………………19-115
Inspect …………………………………………………………………………………………………………………………………………………………………… 19-115
Connector, Butt Splice………………………………………………………………………………………………………………………………………………19-116
Weather Pak Connector Series…………………………………………………………………………………………………………………………………19-117
…………………………………………………………………………………………………………………………………………………………………….. 19-117
Metripack Connector Series ……………………………………………………………………………………………………………………………………19-123
Connector Replacement ………………………………………………………………………………………………………………………………………… 19-123
Pin Replacement……………………………………………………………………………………………………………………………………………………… 19-123
AMP Connector Series …………………………………………………………………………………………………………………………………………… 19-125
Pin Replacement ………………………………………………………………………………………………………………………………………………………19-125
Deutsch DRC Connector Series …………………………………………………………………………………………………………………………………19-128
Pin Replacement ………………………………………………………………………………………………………………………………………………………19-128
Deutsch DT Connector Series ………………………………………………………………………………………………………………………………… 19-132
Pin Replacement ………………………………………………………………………………………………………………………………………………………19-132
Deutsch DTM and DTP Connector Series …………………………………………………………………………………………………………………19-136
Pin Replacement …………………………………………………………………………………………………………………………………………………19-136
Deutsch HD10 Connector Series ……………………………………………………………………………………………………………………………19-138
Pin Replacement …………………………………………………………………………………………………………………………………………………… 19-138
Deutsch HDP20 and HD30 Connector Series…………………………………………………………………………………………………………… 19-142
Pin Replacement ………………………………………………………………………………………………………………………………………………………19-142
Connector Replacement ……………………………………………………………………………………………………………………………………… 19-145
ITT Cannon Connector Series……………………………………………………………………………………………………………………………………19-147
Pin Replacement ………………………………………………………………………………………………………………………………………………………19-147
AMP VP44 Connector Series ……………………………………………………………………………………………………………………………………19-149
Pin Replacement ………………………………………………………………………………………………………………………………………………………19-149
Packard Relay Connector …………………………………………………………………………………………………………………………………………19-151
Pin Replacement……………………………………………………………………………………………………………………………………………………… 19-151
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J Service Tools
Section 19 - Electronic Engine controls Page 19-1
Service Tools
Electronic Engine Controls
The followi ng special tools are recommended to perform proced u res i n this sectio n . The use of these tools
is shown i n the appropriate proced u re . These tools can be purchased from a local C u m m i ns® Authorized
Repai r Location .
Tool No. Tool Descri tion Tool Illustration

Data Link Adapter Kit
I N LI N E II adapter and associated cables are used to con nect a
3163682 com puter to an engine data l i n k .
Engine Controller
Used in conj u nction with the engine controller adapter harness to
3163890 provide fault lamps, th rottle control , and keyswitch .
Bosch® Male Test Lead

Used to test electrical ci rcu its.
3164110
Bosch® Female Test Lead

Used to test el ectrical circu its.
3164111
ECM Bench Top Calibration Harness

Used to cal i b rate electronic control mod u l es off the engine. ';'/
3164185
Engine Controller Adapter Harness

Used to separate engine wiring issues from chassis issues. Also used
3164242 on the dynometer.
Service Tools ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J
Page 1 9-2 Section 1 9 - Electronic Engine controls
Tool No. Tool Description Tool illustration

M ultimeter
Used to measu re voltage (volts) , resistance (oh m s) , and cu rrent
3164488 (am ps) i n el ectrical circu its .
Framatome Male Test Lead

Used to test electrical ci rcuits.
3164596
o
3164596
Framatome Female Test Lead

U sed to test electrical circu its .
3164597
3164597
Data Link Power Adapter Harness

Used to provide power straight fro m the ECM for the I N L I N E I I kit.
3164653
19d01981
Wi ring Repai r Kit \

Contai ns a variety of con nectors , pins, seals, termi nals, test leads,
3165117 and other tools used to repair con n ectors . Use with base Wiring
Repai r Kit , Part N u mber 3 1 64573 .
IL-
-- "---.I
Weather-Pack Term inal Removal Tool

Used to repai r Weather-Pack con nectors .
3822608
3822608
Deutsch/AM P/Metri-Pack Male Test Lead

Used to test electrical ci rcu its. II
3822758
AMP Term inal Removal Tool

Used to repai r AM P con n ectors. o
3822759
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J. . . Service Tools

Deutsch Term inal Removal Tool (Blue)
Used to repai r Deutsch con nectors.
3822760
3822760
Heat Gun
Used to repai r con n ector wi res .
3822860
Deutsch/AM P/Metri-Pack Female Test Lead

U sed to test electrical ci rcu its.
3822917
3164132
Wire Crim ping Pliers

Used when repai ring connector wi res .
3822930
3822930
Deep Well Socket (1.25 inch)

Used to remove and instal l sensors and actu ators .
3823843
3823843
Electrical Contact Cleaner

Used to clean electrical contacts and con n ectors .
3824510
oiBlogt
Deutsch Male Test Lead

Used to test electrical ci rcuits.
3824811
3164133
Deutsch Female Test Lead

Used to test electrical circu its .
3824812
3164132
Service Tools ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Page 19-4 Section 19 - Electronic Engine controls

Deutsch Term inal Removal Tool (Red)
Used to repai r Deutsch con n ectors .
3824815
3824815
INSITE™ Software Kit

Used to troubleshoot, prog ram , and adj ust CM850 ISC and I S L
3886388 engi nes. Refer t o you r local C u m m i ns Authorized Repai r Location for
Part N u m ber .
3824801
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J • . • Battery Ground Circuit
Section 19 Electronic Engine controls

- Page 19-5
Barometric Air Pressure Sensor

{019-004}
Initial Check
Connect an electro n i c service tool to the vehicle data l i n k .
T u r n t h e keyswitch t o t h e O N positi o n .
Mon itor t h e barometric air pressu re . If t h e barometric a i r
pressure is l ess t h a n or eq u al t o 523 m m H g [20.6 i n H g ]
a n d the present elevation is l ess t h a n 3.048 km [1 0 , 000
ttl. replace the barometric air p ressure sensor.
Remove
Slide the locki ng tab sideways .
Push down on the b utton towards the rear of the con n ector
and d i sco n n ect from the sensor.
The sensor is con nected to the i ntake man ifold cover by
a capscrew.
19d01894
Install
I nstal l a n ew sensor on the e n g i n e .
Attach the sensor t o t h e i ntake man ifold cover.
Torque Value: 9 N-m [80 i n- I b ]
Push the connectors together until they lock.
Slide the locking tab to the lock position .
19d01894
Battery Ground Circuit {019-008}

Voltage Check @
Check the power h arness g ro u n d con n ection for loose ,
corroded , or b roken con nections.
1 9803965
Clutch Pedal Position Switch ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Page 19-6 Section 19 Electronic Engine controls
-
A CAUTION A
The leads must fit tightly in the connector without
expanding the pins in the connector otherwise the
connector will be damaged .
I nsert the lead i nto the electronic control mod u l e (ECM)
battery su pply negative ( ) of the ECM power harness
-
con nector. Connect the al l igator clip to the m u ltimeter

probe. Touch the other m u ltimeter probe to the e n g i n e
b l o c k g r o u n d a n d measu re the resistance. T h e resistance
must be 1 0 ohms or less.
1 9c0 1 1 48
If the resistance val ue i s not correct , check the batteries ,

cables, and cabl e con nections.
Repai r or replace the parts as req u i red.
Clutch Pedal Position Switch (019-009)

General Information
The cl utch pedal position switch circuit is used to disab le
the PTO and cru ise control features .
The circuit consists of an open control switc h , a cl utch
pedal position switch signal wire, and a switch return .
When the cl utch pedal position switch is instal led and
adj usted , the contact poi nts are held closed . When the
cl utch pedal is depressed , the cl utch pedal position switch
is in its normally open position . This will disable the PTO
or cruise control operation .
Resistance Check
If I N S ITE™ is avai lable, mon itor the cl utch switch for
proper operation . If not , fol l ow the troubleshooti ng
proced u res i n this sectio n .
F i n d the cl utch pedal position switc h . T h e location will
depend o n the OEM instal lation proced u res.
Disco n nect the wiri n g harn ess attached t o the switch
term i n als.
Adj ust the m u ltimeter to m easu re resistance.
Touch the probes of a m u lti meter to the two term i n als in
the con nector of the cl utch pedal position switch .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . . . Clutch Pedal Position Switch
Section 19 -Electronic Engine controls Page 19-7
Release the cl utch pedal. The m u lti m eter must show a

closed circuit (1 0 ohms or less) .
If t h e switch is not closed w h e n the cl utch is f u l ly engaged ,
adj ust the cl utch switch tri p lever. If the switch is not
closed after adj usti ng the trip l ever, the switch has fai led .
Refer to the OEM trou bleshooting and repai r man ual for
the replacement proced u res.
Depress the cl utch pedal . The cl utch pedal position switch
m ust ope n . The m u lti meter must show an open circuit
(1 00k ohms or more) .
I f t h e switch is not open when t h e cl utch is fully engaged ,
adj ust the cl utch switch trip lever. If the switch is not open
after adj usti n g the trip l ever, the switch has fai led . Refer
to the OEM troubleshooting and repai r man ual for the
replacement proced u res.
Check for Short Circuit to Ground

Remove one m u lti meter probe from the cl utch pedal
position switch con n ecto r and touch the probe to the
chassis g ro u n d . The m u ltimeter must show an open
circuit (1 00k ohms or more) when the cl utch pedal is
released . If the c i rcuit is closed , replace the cl utch pedal
position switc h .
Refer t o t h e OEM troubleshooting and repai r man ual .
Check for Short Circuit to External Voltage

Source
Turn the keyswitch to the ON positio n .
Adj ust t h e m u ltimeter t o measure VDC.
I nsert one of the m u ltimeter probes i nto the cl utch pedal
position switch connector.
Touch the other m u lti meter probe to the engine block
ground and measu re the voltage. The voltage must be 1 . 5
VDC or less with the cl utch pedal released and depressed .
If the voltage val u e is mo re than 1 . 5 VDC, there is a short

circuit to an external voltage sou rce.
NOTE: An external voltage sou rce is any wire i n the OEM
harness wiring that carries the voltage.
Remove the external voltage source.
If the cl utch pedal position switch passed all previous
checks, connect the switch to the wiring h arness . The
cl utch pedal position switch c i rcuit must be checked .
0300rrA COM
1 9cO0724
Clutch Pedal Position Switch Circuit ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
-
Clutch Pedal Position Switch Circuit

(019-010)
Resistance Check
A CAUTION A
If I N S ITE™ electronic service tool is avai lable, mon itor the
cl utch pedal position switch circuit for proper operatio n . If
not , fol l ow the troubleshooting proced u res i n this sectio n .
Disco n n ect t h e origi nal eq u i pment manufacturer (OE M)
harness con nector from the electronic control mod u l e
(ECM) .
I nsert a test lead i nto t h e cl utch pedal position switch
return p i n depen d i n g on the OEM appl ication of the OEM
con nector. I nsert the other test l ead i nto the cl utch pedal
position switch signal pin of the OEM con nector.
Con n ect the alligator c l i ps to the two probes of the

m u lti m eter. Adj ust the m u lti meter to measu re resistance.
The m u lti meter must show a closed circuit ( 1 0 ohms or
less) when the cl utch pedal ( 1 ) is released .
Depress the cl utch pedal ( 1 ) . The m u lti meter must show

an open circuit (1 00k ohms or more) . If the resistance
val ues are not correct , the cl utch pedal position switch
signal wire and the return wire must be checked for an
open c i rcuit, provided the cl utch pedal position switch was
previously checked .
If the values are correct , the circuit must sti l l b e checked
for a short circuit to g rou n d , a short circuit from p i n to pi n ,
and a short circuit t o a n external voltage sou rce.
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J Clutch Pedal Position Switch Circuit

- Page 19-9

CRUISE CONTROL ENGINE
BRAKE
REMOTE
PTO
DIAGNOSTIC
SWITCH
IDLE SPEED
ADJUST
To isolate the cl utch pedal position switch circuit when

checki ng for a short circuit to g ro u n d , turn all cab panel
switches to the OFF or neutral positio n .
Idle Validation
Set t h e service b rake u s i n g t h e trai ler b rake hand valve . Switch
Disco n nect the cl utch pedal position switc h , the idle

val idation switc h , and the th rottl e pedal .
Remove the test l ead from the switch return p i n .

Disco n nect t h e m u lti m eter probe from t h e al l i gator c l i p .
C)oo ••
1 9c0 1 1 53
Touch t h e other m u ltimeter probe t o t h e e n g i n e block

g ro u n d . Measure the resistance. The m u ltimeter must
show an open c i rc u it ( 1 00k ohms or more) . If the circuit is
@l
1 . :. . "",.9-1-·1
not open , there is a short circuit to g round in the cl utch
pedal position switch circuit. ..
Repai r o r repl ace the wire con nected to the cl utch pedal
position switch signal pin in the OEM harness accord i n g
t o t h e vehicle man ufacturer's proced u res.
11 If
Con n ect all com ponents when the repai r is complete.

O'M
C)oo-
1 9c0 1 1 54
Clutch Pedal Position Switch Circuit ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
-
Check for Short Circuit from Pin to Pin

Isolate the cl utch pedal position switch circuit as
described i n previous step. Set all cab panel switches to
the OFF or neutral positio n , and d isco n n ect the cl utch
pedal position switch and the th rottle pedal .
Adj ust the m u lti meter to m easu re resistance. Then i n se rt
one test l ead i nto the cl utch pedal position switch signal
p i n of the OEM harness connector. I nsert the other test
lead i nto the cl utch pedal position switch return pi n .
Con n ect the alligator cl i ps to the m u lti meter probes.
M easu re the resistance. The m u lti meter must show an
open circuit (1 00k ohms or more) .
With the fi rst test l ead sti l l touch i n g the cl utch pedal
position switch signal p i n , remove the test lead from the
cl utch pedal position switch return pin and touch it to all
other pins, one at a time. The m u lti meter must show an
open ci rcuit (1 00k ohms or more) at all pins.
If the c i rcuit is not open , there is a short circuit between
the w i re connected to the cl utch pedal position switch
signal pin and any pin that shows a closed circuit. Repai r
or replace the wi res i n the OEM harness accord i n g to the
vehicle man ufacturer's proced u res.
Remove the test lead from the cl utch pedal position switch
signal p i n and touch it to the cl utch pedal position switch
return p i n . Touch the other test lead to al l other p i n s , one
at a time. Measure the resistance . The m u lti meter must
show an open circuit (1 00k ohms or more) , except for the
cl utch pedal position switch return p i n .
If t h e ci rcuit is not ope n , there is a short circuit between
the wire con nected to the cl utch pedal position switch
return wire and any p i n that m easu red a closed circuit.
Repai r o r replace the wi res i n the OEM harness accord i n g
t o t h e vehicle man ufacturer's procedures.
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J .. • Exhaust Gas Temperature Sensor

Source
Isolate the cl utch pedal position switch circuit as
described i n the previous steps. Set the cab panel I :" . . ".:" . : ·1
..
switches to the OFF or neutral positi o n , and d isconnect

the cl utch pedal position switch and the th rottle pedal .
Turn the keyswitch to the ON positio n . Adj ust the
m u ltimeter to m easu re VDC.
I nsert test lead con nected to the posit ive m u lti meter probe
i nto the cl utch pedal position switch sig nal pi n . Disconnect
the negative m u lti m eter probe from the test lead and touch
1 9c0 1 1 58
it to the engine block g rou n d . Measu re the voltage. The
voltage must be 1 . 5 VDC or less.
NOTE: An external voltage sou rce is any wire in the OEM
wiring that carries voltage.
If the voltage val u e is more than 1 . 5 VDC , there is a short
circuit between the wire con nected to the cl utch pedal
position switch signal pin and a w i re carrying power in the
OEM harness. Repai r the OEM harness accord i n g to the
vehicle man ufactu rer's proced u res.
Remove the test lead from c l utch pedal position switch
signal pin and insert it i nto the cl utch pedal position switch
return p i n . With the m u ltimeter probe sti l l touch i n g the
engine block g ro u n d , meas u re the voltage. The voltage
must be 1 . 5 VDC or less. If the voltage val ue is not
correct , there is a short circuit between the wire connected
to the cl utch pedal position switch return and a wi re
carrying power in the OEM h arness. Repai r the OEM
harness accord i n g to the vehicle man ufacturer's
proced u res.
Con n ect all components after completing the repai rs.
Exhaust Gas Temperature Sensor

(019-013)
General Information
The Exhaust Gas Tem peratu re Sensors ( 1 ) are located i n
the exhaust m uffle r o n either side o f the catalyst brick.
The tem perature sensors are part of the aftertreatment
system and are used to mon itor the catalyst i n let and
outlet tem perat u res.
Exhaust Gas Temperature Sensor ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Et5
Remove
a CAUTION a
The Exhaust Catalyst will stay hot to touch for long
periods of time after the engine has been tu rned off.
Lift u p on the locki ng tab and p u l l the electrical con nectors
apart.
Disco n n ect the exhaust gas tem peratu re sensor from
OEM wi ri ng harness.
Loosen the retai n i ng nut and remove the exhaust gas
temperatu re sensor from the exhaust catalyst.
Clean and Inspect for Reuse

Visually i nspect the exhaust gas tem peratu re sensors for
damage to wiring or body.
Visually inspect the tip of the exhaust gas tem peratu re
sensor for damage and carbon b u i l d u p
19901463
Install
Apply anti-sieze compound to the sensor th reads of the
exhaust gas temperatu re sensor.
Make s u re the exhaust gas temperatu re sensors are
con nected to the correct position on the OEM wiri n g
harness. Swapped i n let a n d outlet temperatu re sensors
wi l l result i n active fau lt codes.
Push the sensor and sensor harness con nectors together
until they lock.
Tig hten the n ut that secu res the sensor to the after
treatment system .
Torque Value: 30 N - m [ 22 ft-I b I
ISB, IS , ISBe3, ISBe4, QSB4 [ J ... Engine Coolant Level Sensor
Engine Coolant Level Sensor (019-017)

Remove
.A WARN I N G .A
Do not remove the pressu re cap from a hot engine.
Wait until the coolant tem peratu re is below SO°C
[120°F] before removing the pressu re cap. Heated
coolant spray or steam can cause personal inju ry .
.A WARN I N G .A
Coolant is toxic. Keep away from ch ild ren and pets. If
not reused , dispose of in accordance with local
envi ronmental regulations.
Remove the rad iator cap .
D rai n enough coolant from the cool i n g system to em pty
the rad iator top tan k. Refer to P roced u re 008-0 1 8 i n the
Troubleshooting and Repai r Man ual , ISC, OSC8 . 3 , ISL
and OSL9 Engi nes, B u l leti n 402 1 4 1 8 or Troubleshooting
Repai r Man ual , ISBe, ISB, and OSB5.9 (Common Rai l
Fuel System), B u l l et i n 402 1 271 .
Lift up on the locki ng tab and p u l l the electrical connectors

l'D-'i'
apart.
'\l:;>"!l
Remove the sensor.
Install
I nstall and tig hten the new sensor accord ing to the veh icle
manufacturer's proced u res.
Push the electrical connectors together until they lock.
Fill the cool i n g system and check for leaks. Refer to
P roced u re 008-0 1 8 i n the Troubleshooti ng and Repai r
Manual , I SC , OSC8 . 3 , I S L and OS L9 E n g i n es , B u l l etin
402 1 4 1 8 or Troubleshooting Repai r Man ual , I S Be , ISB,
and OSB5.9 (Common Rail Fuel System), B u l letin
402 1 271 .
Engine Coolant Temperature Sensor ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]
Engine Coolant Temperature Sensor

(019-019)
Initial Check
Con n ect I N S ITE™ electronic service tool and verify the
coolant temperatu re read i n g is the same on I N S ITE™
electronic service tool as the gauge read i n g .
Remove
WARNI NG
Do not remove the pressu re cap from a hot eng ine.
Wait until the coolant tem perature is below 50°C
[120°F] before removing the pressu re cap . Heated
coolant spray or steam can cause personal inj ury.
WARN ING
Coolant is toxic. Keep away from children and pets. If
not reused , dispose of in accordance with local
envi ronmental regulations.
D rai n the coo l i n g system . Refer to Proced u re 008-0 1 8 i n
t h e Troubleshooting a n d Repai r Man ual , I S C , OSC8 . 3 ,
I S L a n d OSL9 Engi nes, B u l letin 402 1 41 8 o r
Troubleshooting Repai r Man ual , I S Be, I S B , a n d OSB5.9
(Common Rail Fuel System), B u l l etin 402 1 27 1 .
Lift u p on the locki ng tab and p u l l the el ectrical con nectors

apart .
Remove the sensor.
IS8, IS8e2, IS8e3, IS8e4, QS84 [...J Cruise Control or PTO ON/OFF Switch
Inspect for Reuse

I nspect the e n g i n e harness con n ector and coolant
temperatu re sensor for the fol l owi n g :
- cracked o r b ro ken con n ector shell
- m issi ng or damaged con nector seals
- d i rt , debris, or moisture in or on the con n ector pins
- corroded , bent, b roke n , pushed back, o r expanded
pins.
Install
Make sure the new sensor has an o-ri ng instal led .
Lubricate the o-ri ng with clean engine oil .
I nstall the new sensor i nto the e n g i n e . Tighten the sensor.
Push the connectors together u ntil they lock.
Torque Value: 23 N - m [ 1 7 ft-I b ]
Fill the coo l i n g system and operate the engine to check

for leaks. Refer to Proced u re 008-0 1 8 i n the
Tro u bleshooting and Repai r Man ual , ISC, OSC8 . 3 , I S L
a n d OSL9 Engi nes, B u l let i n 402 1 4 1 8 or Troubleshooting
Repai r M an ual , ISBe, ISB, and OSB5.9 (Common Rai l
Fuel System), B u l letin 402 1 271 .
Mon itor the e n g i n e coolant temperatu re sensor with
I N S ITE™ electronic service tool for proper operatio n .
<:p (j)
Cruise Control or PTO ON/OFF Switch
(019-021) 0 0
General Information 1
,
1
, .
Marine Applications
The Cru ise 1 /2 control switch is located on the control
CRJlSE2
IDLE
B ENGINE
MAl NT.
panel and has th ree settings, Cruise 1 , Cru ise 2 and OFF.
STOP CHECK
The rocker switch is used to activate o r d isabl e the cru ise ENGINE EN91NE
control operation . The cruise control ON and OFF circuit
consists of the Cruise Control 1 and 2 signal l i nes, switch 0 0
common g round and the rocke r switch.
13200069
Cruise Control or PTO ON/OFF Switch ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
-
Resistance Check
Marine Applications
If I N S ITE™ electronic service tool is available, mon ito r the
switch for proper operatio n . I f not , fol low the
troubleshooti ng proced u res in this section .
Locate and remove the Cru ise 1 1 2 switch from the
con nector.
Adj ust the m u ltimeter to m easu re resistance.
Touch the m u ltimeter probes to the Cru ise 1 signal switch
pro n g (3) and the battery ground prong switch prong (2) .
Turn the switch to the OFF position and measure the
resistance . The m u ltimeter must show an open circuit
( 1 00k ohms or more) .
If the c i rcuit is not ope n , the switch has fai led. Replace
the switc h .
Touch the m u ltimeter probes t o the Cru ise 2 signal switch
prong ( 1 ) and the battery g ro u nd prong switch prong (2) .
resistance. The m u lti meter must s how an open circuit
If the circuit is not ope n , the switch has fai l ed . Replace
the switch .

Marine Applications
Touch the m u lti meter probes to the Cru ise 1 signal switch
prong (3) and the battery ground prong switch prong (2) .
Turn the switch to the Cru ise 1 position and measure the
resistance . The m u lti meter must show an closed c i rcuit
(1 0 ohms or less) .
If the c i rcuit is not closed , the switch has fai l ed . Replace
the switc h .
Touch the m u lti meter probes t o t h e Cru ise 2 signal switch
prong ( 1 ) and the battery g ro u nd p rong switch prong (2) .
Turn the switch to the Cru ise 2 position and measure the
resistance. The m u lti meter must show an closed c i rcuit
If the c i rcuit is not closed , the switch has fai led . Replace
the switc h .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J Cruise Control or PTO ON/OFF Switch Circuit

Marine Applications
Check for a short c i rcuit from p i n to pi n .
Touch the m u lti meter probe to the Cru ise 1 switch signal
prong (3) . Touch the other m u lti m eter probe to the Cruise
2 switch signal prong ( 1 ) .
Turn the cruise control switch t o t h e O F F positi o n .
T h e m u lti m eter m ust show an o p e n circuit (1 00k ohms or
more) .
If the circuit is not open , there is a short c i rcuit between
the Cruise Control 1 and Cru ise 2 signal l i nes. Replace the
switch.
Cruise Control or PTO ON/OFF Switch

Circuit (019-022)
Resistance Check
A CAUTION A
The leads must fit tig htly in the connector without
expand ing the pins in the connector otherwise the
switch ci rcuit for proper operatio n . If not , follow the
trou bleshooti n g proced u res in this sectio n .
EE<3
Disco n nect t h e origi nal eq u i p m ent man ufacturer (O EM)
harness con n ecto r from the electronic control mod u l e
(EC M). I.
I nsert the test lead i nto the cru ise control ON/OFF switch
signal pin of the original eq u i pment man ufacturer (OEM)
harness connector and attach it to the m u lti m eter probe.
$j
Touch the other p robe to the engine b lock g rou n d .
0"
O=AA ".
-
-
1 9c0 1 1 66
EE<3
Move t h e O N/O FF switch t o t h e O N positio n . The
[
m u lti mete r must show a closed c i rcuit (1 0 ohms or less) .
If the circuit is not closed , inspect the cru ise control ON/
OFF switch i n put for an open ci rcu it. Refer to the OEM
@!
troubleshooti n g and repai r man ual .
If the resistance is with i n specificatio n , the cruise control
ON/OFF switch i n put must be checked for a short circuit
to g ro u n d , a short c i rcuit from term i n al to term inal , and a
0 '"
short ci rcuit to an external voltage source.
0000 ••
-
-
1 9c0 1 1 67
Cruise Control or PTO ON/OFF Switch Circuit ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
-

To isolate the cruise control ci rcuit when checking for a
short circuit, discon n ect the OEM harness con nector from
CRUISE CONTROL ENGINE REMOTE DIAGNOSTIC IDLE SPEED
the ECM and the OEM harness from the cruise control
t ij
SETI BRAKE PTO SWITCH ADJUST
t
(., switc h .
D Disco n n ect t h e cl utch pedal position switch, idle val idation
OFF R : ' OFF OFF OFF (_,------1 on/off switc h , and the accel erator pedal position switc h .
S e t al l cab panel switches t o the O F F or neutral positio n .
Set t h e service brake u s i n g t h e trai ler b rake hand valve .
1 9200292
Adj ust the m u ltimeter to m easu re resistance. I nsert a test

l ead i nto the cru ise control O N/OFF switch i n put of the
O E M harness con nector and attach it to a m u lti meter
probe. Remove the other m u lti meter probe from the
al l igator c l i p and touch it to the engine block g ro u n d .
M easu re the resistance.
The m u ltimeter must show an open circuit (1 OOk ohms or
more). If the circuit is not open , there is a short circuit to
g round i n the cruise control circuit, provided that the
switch has been previously checked .
1 9c0 1 1 66
Repai r or replace the wire con nected to the cruise control
O N/OFF switch i n put i n the OEM harness accord i n g to the
veh icle man ufacturer's proced u res.

C h eck for a short c i rcuit fro m pin-to-pi n . Isolate the cru ise
control circuit by setting the switches as i n the previous
section . Set the cruise control/PTO ON/O FF switch to the
OFF position. I n sert the l ead i nto the cru ise control ON/
OFF switch i n put. Con nect the al l igator cl i p to the
m u lti m eter. With the other l ead i nserted i nto the switch
return wi re(s) , measu re the resistance.
more) .
Remove the lead from the cru ise control ON/O FF switch
i n put and check all other pins. M easu re the resistance .
The m u lti m eter must show an open circuit (1 OOk ohms or
more) .
If the circuit is not open , there is a short circuit between
the cru ise control ON/OFF switch i n put ci rcuit and any pin
that shows a closed circuit, provided the switch has
previously been checked .
Repai r or replace the wi res i n the OEM harness accord ing
to the veh icle man ufactu rer' s proced u res .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ ] Cruise Control or PTO Set/Resume Select Switch
Section 19 - Electronic Engine controls
• • .
Page 19-19
.' ·
Source
Turn the vehicle keyswitch to the ON position . Set the
M
tw
cruise control/ PTO O N/OFF switch to ON. Adj ust the
m u lti meter to meas u re VDC . I nsert a test lead i nto the
cruise control ON/OFF switch i n put and attach it to a
m u lti meter probe. Disconnect the other m u ltimeter probe
from the other l ead and touch it to the e n g i n e block
g rou n d . Measu re the voltage. The voltage must be 1 . 5
VDC or less.
If the voltage is not correct , there is an external voltage
1 9c0 1 1 69
sou rce co n nected to the circuit, o r there is a short circuit
between the cru ise control/PTO O N/OFF switch circuit
and a wire carrying power in the OEM harness. Remove
the voltage sou rce or repai r the wiring in the OEM harness
accord i n g to the vehicle man ufact u rer's procedures.
Con n ect all components after completing the repair.
NOTE: If the cruise control/PTO ON/OFF switch circuit
was approved in al l of the previous tests , it is function i n g
correctly.
Cruise Control or PTO Set/Resume

--
Select Switch (019-023) ON 8ETI
CIIASf Push Down and
General Information i
OFF
Release to
IncreasefMPH
The cru ise control/PTO set/resu m e sel ect switch has two -===:::;;===.1
positions: SET/COAST and RES U M E/ACC EL.
The switc h can be used for: Cru ise Control SET/COAST Push Up and
and RES U M E/ACCEL, PTO I N CREAS E/DECREAS E , fi. Release to
I D LE WI
"=' Decrease 1 MPH
I NC R EASE/D ECREAS E , ROAD SPEED
OFF
GOVERNOR I NC R EAS E/DECREAS E , DIAG N OSTI C 1l= ==:::!1
FAU LT C O D E I NC R EAS E/D ECREAS E . F o r add itional
i nformation , see Section F.
The operator can set the vehicle cru ising speed when the
switch is i n the S ET/COAST positio n . The SET/COAST
position can also be used to reduce the vehicle cruising
speed . Hold the switch i n the S ET/COAST position and
the vehicle wi l l coast down to a lower speed . When the
select switch is released , th e cru ising speed wi l l be reset.
NOTE: Some O E M ' s have switches l abeled S ET/ACCEL
and RESUM E/COAST.
The operator can resum e cruise control , after cl utch i n g or

b raki n g , by movi ng the switch to RES U M E/ACCEL. The
vehicle speed wi l l return to the last set m p h .
T h e RESUM E/ACCEL position can also b e used to
CRUISE CONTROL
increase the vehicle cruising speed . Hold the sel ect switch ON 4� T
in the R ES U M E/ACCEL positio n and the vehicle wi l l
i ncrease i n speed . When the switch is released, the
OFF RESUME!
cruising speed will be reset . ACCEL
gp8swgk
Cruise Control or PTO Set/Resume Select Switch ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]
The cruise control/PTO set/resu m e switch circuit consists

of the switch return, the cruise control/PTO resu me/accel
switch signal , cru ise contro l/PTO set/coast switch signal
and the veh icle mou nted switc h .
1 9c0 1 1 80
Resistance Check
If I N S ITETM is avai lab l e , mon itor the cru ise control/PTO set/
resume select switch for proper operatio n . If not , follow
the tro u bleshooting proced u res i n this section .
Label the wi res with the location on the switch or the wire
n u m ber. Remove the th ree electrical con nectors from the
switch .
1 9c0 1 1 8 1
Adj ust the m u lti meter to m easu re resistance.

Touch one m u lti meter probe to the center term i n al of the
switc h . Touch the other m u ltimeter probe to the RES U M E/
ACC E L termi nal of the switc h .
100k O h m s Hold the switch i n the S ET/COAST positio n . The

m u ltimeter must show an open ci rcuit ( 1 00k ohms or
more) when the switch is held i n the SET/COAST position
and after it is released . If the circuit is not ope n , the switch
has fai led .
Refer to the OEM troubleshooting and repai r manual for
SETICOAST
RESUMEIACCEL RESUMEIACCEL 19900504

ISB, ISBe2, ISBe3, ISBe4, QSB4 [ ...J Cruise Control or PTa Set/Resume Select Switch
Hold the switch i n the RES U M E/ACCEL position . The

m u ltimeter must show a closed circuit ( 1 0 ohms or less) 'rf!!!£
when the switch is held i n the RES U M E/ACC E L position .
When the switch is released , the m u lti m eter must show

an open c i rcuit ( 1 00k ohms or more) . If the m u ltimeter
does not show the correct val ues in either test , the switch
has fai led .
If the resistance val u e is correct , the switch must sti l l be
checked for a short circuit to g ro u n d .
Touch one m u ltimeter probe t o the center term inal o f t h e

switch. Touch the other m u ltimeter probe t o t h e SET/
COAST term i n al of the switch .
Hold the switch i n the S ET/COAST positio n .
T h e m u ltimeter must show a closed circuit (1 0 o h m s or
less) wh i l e the switch is held to the S ET/COAST position .
When the switch is released , the m u ltimeter must show

an open c i rcuit ( 1 00k ohms or more) . I f the m u lti meter
does not show the correct val ues in either test, the switch
has fai led .
replacement proced u res .
('M .. ' ,...-'tL__::::::;;)
100k Ohms
or More ee8swko
Cruise Control or PTO Set/Resume Select Switch Circuit ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Move the switch to the RES U M E/ACC E L positio n .

T h e m u lti meter m ust show an o p e n circuit ( 1 00k ohms o r
more) w h e n the switch is held i n the RES U M E/ACCEL
position and when it is rel eased . If the circuit is not open ,
the switch has fai led .
Refer to the OEM troub leshooti ng and repai r manual fo r

Touch one m u ltimeter probe to the RES U M E/ACCEL
term i n al of the switc h . Touch the other m u ltimeter probe
to the chassis gro u n d . M ove the switch to the S ET/COAST
positio n then to the RES U M E/ACCEL positio n . M easu re
the resistance.
Engine
The m u lti meter must show an open circuit ( 1 00k ohms or
�---11"'-""=>I111 more) when the switch is i n all positions. If the circuit is
'-::::QL----� Block
100k Ohms not ope n , the switch h as fai led . Refer to the OEM
or More troubleshooti ng and repai r man ual for replacement
ee8swkl
proced u res.
Touch one m u lti meter probe to the SET/COAST term i n al

of the switc h . Touch the other m u ltimeter probe to chassis
g ro u n d . Move the switch to the RESU M E/ACCEL positi o n ,
t h e n t o the SET/COAST position . Measure the resistance.
The m u lti meter must show an open circuit (1 OOk ohms o r
more) w h e n the switch is i n all positions. If the circuit is
not ope n , the switch h as fai led . Refer to the OEM
troubleshooti ng and repai r man ual for replacement
proced u res.
100k Ohms
or More
ep.8swkq
Cruise Control or PTO Set/Resume

Select Switch Circuit (019-024)
General Information
SET!
t! t t! t! t!
BRAKE PrO SWITCH ADJUST
(+)-----, I n add ition to cru ise contro l functions, the cru ise control
select switch also provides for i ncreasing/decreasing idle
OFF R I
(_)-----.J speed , PTO speed , fault cod e flashout, and road speed
OFF OFF OFF
governor l i m it.
1 9200292
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J Cruise Control or PTO Set/Resume Select Switch Circuit
Resistance Check
CAUTION
The leads m ust fit tig htly in the connector without
If I NS ITE™ electronic service tool is avai lable, mon itor the
cruise control/PTO seU resu m e select switch circuit for
proper operation . If not , follow the troubleshooting
proced u res i n this sectio n .
Disco n n ect t h e origi nal eq u i pment manufacturer (OEM)

(ECM). ItI" "" " JJ.J I
Insert a test lead i nto the cruise control/PTO seUcoast
switch signal of the OEM harness con n ecto r and con nect
the alligator C l i p to the m u lti meter probe.
Touch the other probe to e n g i n e block g rou n d .
1 9c0 1 1 82
H o l d t h e cru ise control select switch i n t h e SET/COAST

positio n . The m u ltimeter must show a closed circuit (1 0
ohms or l ess) while holding the switch i n the SET/COAST
position and return to an open c i rcuit (1 OOk ohms or more)
when the switch is rel eased . The ci rcu it must remai n an
open c i rcuit (1 OOk ohms or more) when the switch is in the
RES U M E/ACCEL positio n .
If t h e resistance val ues are not correct, make sure the
cruise control/PTO set/coast i n put and the cruise control/
PTO resume/accel i n put wi res are properly i nstal led on
the cruise control select switch . If both control wi res are
correctly i nstal led , i nspect the cruise control/PTO set/
coast i n put and the cruise control/PTO resume/accel
wi res for an open c i rcuit, provided the cruise control select
switch has been pr eviously checked .
Remove the lead from the cruise control/PTO seUcoast

switch signal and insert it i nto the cruise control/PTO
ffi
'Cl:>'<$)
resume/accel switch signal .
1 9c0 1 1 84
Cruise Control or PTO Set/Resume Select Switch Circuit ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Hold the cru ise control select switch i n the RESU M E/

ACC E L position . The m u ltimeter must show a closed
c i rcuit (1 0 ohms or less) when the switch is in the
RES U M E/ACCEL position and an open c i rcuit (1 OOk ohms
or more) when the switch is released .
The circu it must remain an open circu it ( 1 00k ohms or
more) when the switch is held i n the S ET/COAST positi o n .
SETICOAST If the resistance val ues are not correct, make s u r e t h e

f!j
SET/COAST
@
cru ise control/PTO resume/accel wire is properly instal led
on the cruise control select switch . If the cru ise control/
PTO resume/accel wi re is properly i n stalled o n the cruise
@ control select switc h , i n spect the cruise control/PTO

resume/accel Signal for an open circuit, provided the
cruise control select switch h as been previously checked .
If the resistance val ues are correct i n the previous checks,
the cruise control/PTO set/coast sig nal and cru ise control/
PTO res u me/accel signal must sti l l be checked for a short
c i rc u it to g rou n d , a short c i rcuit from pin to p i n , and a short
c i rcuit to an external voltage sou rce .

Isolate the cruise control/PTO set/resu m e select switch
circuit as described in the previous sectio n . I nsert a test
1..., ,0.11
.........
l ead i nto the cru ise control/PTO set/coast switch signal pin
of the OEM harness con n ector. I nsert the other lead i nto
the fi rst p i n in the con nector. Con n ect the alligator cl i ps to
the m u lti meter probes. M easu re the resistance.
The m u lti meter must show an open circuit (1 00k ohms or
m o re) .
Remove the lead from the fi rst p i n i n the con n ector and
check al l other pins. The m u ltimeter must show an open
c i rcuit ( 1 00k ohms or more) .
If t h e circuit is not ope n , there is a short circuit from the
wire connected to the cruise control/PTO set/coast switch
signal pin and any pin that m easu red less than 1 OOk ohms.
Repai r or rep lace the wi res i n the OEM harness. Refer to
P roced u re 0 1 9-07 1 .
Remove the lead from the cru ise control/PTO set/coast
signal p i n and i nsert it i nto the cru ise control/PTO resume/
accel switch signal p i n . I nsert the other l ead i nto the fi rst
p i n in the con nector.
M easu re the resistance. The m u ltimeter must show an
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J • . . Diagnostic Test Mode Switch
Section 1 9 -Electronic Engine controls Page 1 9-25
Remove the lead from the fi rst p i n i n the connector and SET/COAST
measure the resistance to all other pins. The m u lti meter
must show an open circuit ( 1 00k ohms o r more). If the
c i rcuit is not ope n , there is a short c i rcu it between the wire
o
con nected to the cruise control/PTO resume/accel switch
signal pin and any p i n that m easu red less than 1 00k ohms.
L."."."." . PJI
.
Repai r or replace the wi res i n the OEM harness. Refer to

Proced u re 0 1 9-07 1 .
1 9c0 1 1 87

Source
Isolate the cru ise control/PTO resume/accel switch circuit
as described i n the previous section . Turn the vehicle
keyswitch to the O N position. Adj ust the m u lti meter to
measure VDC. I nsert a test lead i nto the cruise control/
PTO resume/accel switch signal of the OEM harness
con n ector . Connect the test lead al l igator clip to the
positive (+) m u lti m eter probe. Touch the negative (-)
m u lti meter probe to the e n g i n e block g round and measu re
the voltage. The m u lti meter must show less than 1 . 5 VDC.
If the voltage val ue is not co rrect, there is an external
voltage sou rce short circuit to the cruise control/PTO set/
coast switch signal in the OEM harness. Remove the
voltage sou rce. Repai r or replace the wire in the OEM
harness. Refer to P roced u re 0 1 9-071 .
Remove the l ead from the cruise control/PTO set/coast
switch i n put p i n and i nsert it i nto the cruise control/PTO
resume/accel switch i n put p i n . Touch the negative
m u ltimeter probe to the e n g i n e block g round and measure
the voltage. The m u ltimeter must show less than 1 . 5 VDC.
If the voltage val u e is not correct, there is an external
voltage source short circuit to the cru ise control/PTO
resume/accel switch i n put p i n in the OEM harness.
Remove the voltage sou rce . Repai r or replace the wi re i n
t h e O E M harness. Refer t o Proced u re 0 1 9-071 .
Con n ect all com ponents after completin g the repai r.
Diagnostic Test Mode Switch

(019-027) ON
General Information
The d i ag nostic O N/OFF switch circuit signals the system
that the operator is req uesting to read any active fau lt
code recorded in the ECM .
NOTE: Some OEM ' s use a shorting plug rather than a
f OFF
switch.
gpSswvs
Diagnostic Test Mode Switch ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]
ON ON When the ECM receives the signal from the d iag nostic
I START I START
ON/OFF switc h , the yellow and red warn ing l i g hts will
OFF I I \ OFF I
.
\ com e o n and start flas h i n g if any active fau lt code is
No Fault
Codes
. · Fault
Codes
recorded in the ECM . If both warn i n g l i g hts remain o n and
do not flash , there are no active fau lt codes present.
Recorded Recorded NOTE: The eq u i pment must be stationary. If road speed
- @ .!iJ is d etected , the flash i n g seq uence will not occur.
WARNING ...... ..,.
STOP
--
C
"
ft· ......
ENGINE
PROTECT
"
I---.L \. ... @
Resistance Check
If I N SITE™ is avai lable, mon itor the sw itch for proper
operatio n . If not , fol l ow the troubleshooti n g procedu res i n
t h i s section .
Locate the desi red ON/OFF toggle switc h . Remove and
tag the two con nectors from the term i n als on the switc h .
Touch t h e m u lti meter probes t o the term i n als on the
@.M switch .
/
@- ·C::l===,",
19900590
M ove the switch to the OFF position and measure the

resistance. The m u lti meter must show an open c i rcu it
If the circuit is not ope n , the switch has fai led .
Refer to the OEM troubleshooti ng and repai r manual for
'�
100k O h m s or More
19900591
8t
ON
M ove the switch to the O N position and measure the
resistance. The m u lti meter must show a closed circuit ( 1 0
ohms or less) . If the ci rcu it is not closed , the switch has
OFF fai led.
Refer to the OEM troubleshooti ng and repai r manual for
If the resistance val ue is correct , the switch must sti l l be
checked for a short circuit to g ro u n d .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J Diagnostic Test Mode Switch Circuit

Touch one of the m u lti meter probes to one of the switch
term i n als. Touch the other probe to chassis grou n d . M ove
the switch to the ON position and meas u re the resistance .
The m u ltimeter must show an open c i rcuit ( 1 00k ohms or
more). If the c i rcuit is not ope n , the switch has fai led .
replacement proced u res. If the switch passes all of the
previous checks, the circuit m ust be checked for an open
circuit, a short circuit to g ro u n d , a short c i rcuit from pin to
pi n , and a short circuit to an external voltage sou rce.
Diagnostic Test Mode Switch Circuit

(019-028) @
Resistance Check
CAUTION
switch ci rcuit for proper operatio n . If not , fol l ow the
trou bleshooti n g proced u res in this sectio n .
Disco n nect t h e origi nal eq u i pment manufacturer (O EM)

harness con n ector from the electronic control module
(ECM). I nsert the test lead i nto the d i agnostic test mode
switch signal p i n i n the OEM harness con nector and
con nect it to the m u ltimeter probe.
Touch the other probe to the e n g i n e block g ro u n d .
Move t h e O N/OFF switch t o t h e O N position .
If the OEM wi red the switch return to chassis g rou n d , the
m u lti meter must s how a closed c i rcuit ( 1 0 ohms or less).
If the circuit is not closed , i nspect the d iagnostic test mode
switch signal wire for an open circuit.
If the OEM wi red the switch return to the OEM wire
harness, the m u ltimeter must show an open circuit ( 1 00k
ohms or more). If the circuit is not ope n , i nspect the
d i agnostic test mode switch signal wire for a closed circuit.
Refer to the OEM troubleshooting and repai r man ual .
I f the resistance is with i n specification , the diag n ostic test
mode switch signal wi re must be checked for a short
c i rc u it to g ro u n d , a short c i rcu it from term i n al to term inal ,
and a short circuit to an external voltage sou rce .
Diagnostic Test Mode Switch Circuit ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
CRUISE CONTROL ENGINE

BRAKE
REMOTE
PTO
DIAG NOSTIC
SWITCH
IDLE SPEED
ADJUST
I (+)6
ON
I ON
Cfj?t 6t
To isolate the d i agnostic test mode switch signal c i rcuit
when checki ng for an electrical short, turn all cab panel
C,L, H
switches to the OFF or neutral positio n .
Set t h e service brake u s i n g the trai ler b rake hand valve .
Disco n n ect the cl utch pedal position switc h .
Disco n n ect t h e i d l e val idation switch .
Disco n n ect the OEM harness con nector from the EC M .
I. " ,....,.,.. D.L I Set the d i agnostic test mode switch to the OFF position .
I n se rt one of the test leads i nto the d iag nostic test mode
switch sig nal pin of the OEM harness con n ector and
con nect it to a m u lti meter probe.
Touch the other probe to e n g i n e block g ro u n d .
The m u ltimeter must show an o p e n circuit (1 O O k ohms or
0'" more) .
0- .. co.
1 9c0 1 2 1 1

Check for a short circuit from pi n-to-pi n . Isolate the switch
circ u it by setting the cab panel switches as described in
the previous section . Set the d i ag nostic test mode switch
to the OFF positio n . I nsert a test lead i nto th e switch retu rn
pin of the OEM harness con n ector and con nect it to the
m u lti m eter probe. With the other l ead i nserted into the
diagnostic test mode switch signal pin of the con n ector,
measure the resistance. The m u lti meter must show an
open circuit ( 1 00k ohms o r more) .
Remove the lead from the switch return and test all p i ns
i n the con n ector. Meas u re the resistance. The m u lti meter
must show an open circuit ( 1 00k ohms or more) .
If the circuit is not ope n , there is a short circu it between
the switch circuit and any p i n that shows a closed circuit,
provided the switch has p reviously been checked . Repai r
or replace the wi res i n the OEM harness. Refer to
Proced u re 0 1 9-071 .
158, 158e2, 158e3, 158e4, Q584 [...J Electronic Control Module (ECM)
5ection 19 - Electronic Engine controls Page 19-29

Source 1"",, , , ,,, , 1.0 I
d iagnostic test mode switch to ON. Adj ust the m u ltimeter
to measu re VDC. I nsert a test lead i nto the d i agnostic test
mode switch signal p i n of the OEM harness con n ector.
Touch the other l ead to the e n g i n e block g rou n d . M easu re
the voltage . The voltage must be 1 . 5 VDC or less.
source con nected to the c i rcuit o r there is a short circuit
between the switch c i rcuit and a wi re carrying power in the
1 9c01 2 1 6
OEM harness. Remove the voltage sou rce or repair the
wiring i n the O E M harness. Refer to P roced u re 0 1 9-071 .
Con n ect all components after completing the repair.
Electronic Control Module (ECM)

(019-031)
Initial Check
Turn the keyswitch to the ON position while mon itori ng the
fau lt lamps. The fau lt lamps must i l l u m i n ate for two to
th ree seconds. Lamps"qn I /./
If the lam ps do not i l l u m i n ate, check for burned-out b u l bs .
NOTE: T h i s appl ies t o auto motive and ind ustrial only.
gpSswkb
Turn the keyswitch to the OFF position .

Co n n ect an electronic service tool to the veh icle datal i n k .
Tu rn the keyswitch to t h e O N position .
Select the monitor mode on the electronic service too l .
T h e electronic service tool must be a b l e t o com m u n icate
with ECM . If the ECM will not com m u n i cate with the
service tool , refer to the Com m u n ication Error - Electronic
Service Tool or Control Device sym ptom tree.
Electronic Control Module (ECM) ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Remove
CAUTIO N
Record all program mable parameters, features, and
calibration information from the old ECM before
disconnecting the harness connectors. This
information will be needed to program the new ECM .
Disco n n ect the ECM power, e n g i n e , and OEM harness
con nectors from the ECM if they are not al ready
d isconnected .
M ari ne Applicati o n : The OEM harness mounting plate
1 9c01 2 1 8 m ust be removed fi rst. To do so remove the OEM harness
con nector, the u nswitched power supply harness and
system intergration mod u l e .
Remove t h e capscrews that secu re the E C M t o the engine

block.
Install
@7
CAUTION
Do not paint the back side of the ECM . Make sure no
grease or dirt is between the ECM and the eng ine
block.
I n stal l the new ECM to the coo l i n g plate . Tighten the
capscrews .
Torque Value: 1 8 N - m [ 1 60 i n-Ib I
IS8, IS8e2, IS8e3, IS8e4, QS84 [ J . . . ECM Calibration Code
A CAUTION A
Do not blow compressed air into the ECM ports or ...
connectors. Com pressed air can contain moisture due
to condensation.
Use q u ick-d ry electrical contact cleaner, Part N u m ber
38245 1 0, to remove all d i rt and moisture from the ECM
con nector ports and the harness connectors .
Con n ect the ECM power, e n g i n e , and OEM harness
con nectors to the ECM . Tighten the con nector capscrews
to the ECM .
Torque Value: 3 N - m [ 27 i n-Ib I
NOTE: When an ECM is replaced , the new ECM must be
cal i b rated . Refer to P roced u re 0 1 9-032 .
ECM Calibration Code (019-032)

General Information
Electronic control mod u l e (ECM) cal i b rations can be
performed by I N S ITE™ electronic service tool .
After an ECM is repl aced or cal i b rated , the actual engine
hours I distance m ust be entered correctly i nto the ECM .
Record the val ues of ECM Distance Offset , ECM Time
Offset, Engine Distance Offset, and Engine Time Offset
prior to replacement or cal i b ration of the ECM . These
parameters can be found in the Trip I nformation section
1 9c01 2 1 7
of Featu res and Parameters .
T h e E C M cal i b ration process occu rs with the keyswitch

tu rned o n . Always fol l ow the i nstructions on the service
tool scree ns.
NOTE: If the tool will not com m u n icate with the keyswitch
in the ON position , cycle keyswitch and try agai n .
1 9800470
Con n ect the electronic service tool t o the service tool

datal i n k , which is located on the engine or in the cab .
Engine Brake ON/OFF Switch ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
See the help section with i n I N S ITE™ electronic service tool

for detai led ECM cal i b ration p roced u res.
After an ECM is replaced o r cal i b rated , the actual engine
hours / distance must be entered correctly i nto the ECM .
Record the values of ECM Distance Offset , ECM Time
Offset , Engine Distance Offset, and Engine Time Offset
prior to replacement or cal i b ration of the EC M . These
parameters can be found in the Trip I nformation section
of Featu res and Parameters.
Engine Brake ON/OFF Switch

Engine Brake
(019-034)
2 3 4
General Information
5
ON 1
6
The e n g i n e b rake ON/OFF switch c i rcuit signals the
syste m that the operator is req uesting the engine b rake
system to be activated . The engine b rake l evel switch
determi nes what percentage of engine b raki ng power w i l l
be used f o r engine b raki n g . Th ree i n puts t o t h e el ectronic
control mod u l e (ECM) from the engine b rake level switch
are used to com m u n icate the setting to the ECM . Engine
1 7cO0022 b rake selector n u m ber 1 signal , engine brake selector
n u m ber 2 sig nal , and e n g i n e b rake selector n u m ber 3
signal i n the origi nal eq u i pment man ufacturer (O EM)
con nector are used . Various com b i n ations of the th ree
wi res are used to represent the six switch positions.
After the ECM receives the signal from the engine b rake
ON/OFF switch and all other engine b raki ng preconditions
are m et (en g i n e RPM and road speed l i m its) , the ECM will
supply 1 2 VDC to the appropriate engine b rake solenoids
depe n d i n g on how the 3 o r 6 position engine brake level
switch is set .
[b Resistance Check
W If I N S ITETM electronic service tool is availab l e , mon itor the
e n g i n e b rake ON/OFF switches for proper operation . If
not , fol l ow the troubleshooti n g proced u res i n this sectio n .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J Engine Brake ON/OFF Switch
Locate the engine b rake O N/OFF switc h . Remove the

electrical con nectors from the switc h .
Label t h e wi res with t h e location o n t h e switch or t h e wire
n u m ber. Remove the electrical connectors from the
switch.
""
' '
Adj ust the m u ltimeter to measure resistance. - " ,,
o
:
')))
- "
. .
Touch one m u lti meter probe to one of the term i nals of the
switch . Touch the other m u lti m eter probe to the other
term i nal of the switch .
19900590
Move t h e switch t o t h e O F F positio n . T h e m u lti meter

must show an open circuit ( 1 00k ohms or more). If the
circuit is not ope n , the switch h as fai led . I . ,. . . . . . .
est -
. . - " 111
1 OOk O h m s or More
19900591
Place the switch i n the ON positi o n . The m u ltimeter ON
0Jt
must show a closed c i rcuit ( 1 0 ohms o r less) . If the circuit
is not closed , the switch has fai led .
OFF

Touch one of the m u lti m eter probes to one of the switch
term i n als. Touch the other probe to chassis g round . Move
the switch to the ON position and measure the resistance . I I, ='-!II
The m u ltimeter m ust show an open circuit ( 1 00k ohms or
more) . If the circuit is not ope n , the switch has fai led .
replacement p rocedures. If the switch passes all of the
previous checks , the ci rcuit must be ch ecked for an open
circuit, a short circuit to g ro u n d , a short circuit from pin-
to-pi n , and a short c i rcuit to an external voltage sou rce .
Engine Brake ON/OFF Switch Circuit ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]
Engine Brake ON/OFF Switch Circuit

(019-035)
Resistance Check
ACAUTIONA
connector will be damaged.
If I N S ITE™ electronic service tool is available, mon itor the
engine b rake switch circuit for proper operation . If not,
fol low t h e troubleshooting proced u res i n t h i s section .
Disco n n ect the original eq u i pment manufacturer (O EM)
(ECM).
I nsert one of the test leads i nto the switch return of the
OEM harness con nector and con n ect the alligator clip to
the m u ltimeter probe. I n sert the other lead i nto engine
b rake sel ector signal n u m ber 1 of the OEM harness
con nector and con nect the al l igator clip to the other
m u lt i m eter probe.
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J • . . Engine Brake ON/OFF Switch Circuit
Move the e n g i n e b rake ON/OFF switch to the ON position .

Move the engine b rake level switch to positio n n u m ber 1
for a six-position switch or to position n u m ber 2 for a th ree
L,. . :,. . . ,
position switch . The m u ltimeter must show a closed circuit
(1 0 ohms or less) . If the circuit is not closed , i nspect the . , "
switch return and engine b rake selector signal n u mber 1

for an open circuit, provid ed that the switch h as been
previously checked . Refer to the OEM troubleshooting
and repai r manual for repai r proced u res. If the resistance
is with i n the specification , the switch return and engine
b rake selector signal n u mber 1 must be checked for a
short circuit to g ro u n d , a short c i rcuit from p i n to pi n , and
a short circuit to an external voltage sou rce.
Remove the lead from e n g i n e b rake selector signal
n u m ber 1 and i n sert it i nto e n g i n e b rake selector signal
n u m ber 2 of the O E M harness con nector.
Move the engine b rake O N/OFF switch to the O N position.
Move the engine b rake l evel switch to position n u mber 2
for a six-position switch or to position n u mber 1 for a th ree
position switc h .
The m u lti m eter must show a closed circuit (1 0 o h m s or
less) . If the circuit is not closed , i nspect engine b rake
selector sig nal n u m ber 2 wire for an open c i rcuit, provided
that the switch h as been previously checked . Refer to the
OEM troubleshooti ng and repai r man ual for repai r
proced u res.
If the resistance is with i n the specificatio n , engine brake
selector signal n u m ber 2 wire must be checked for a short
circuit to g ro u n d , a short c i rcuit fro m pin to p i n , and a short
circuit to an external voltage sou rce .
n u m ber 2 and i n sert it i nto e n g i n e brake selector signal
n u m ber 3 of the OEM harness.
Move the e n g i n e b rake ON/OFF switch to the O N position .
Move engine b rake l evel switch to position n u m ber 3.
The m u ltimeter must show a closed circuit (1 0 ohms or
less) . If the circuit is not closed , inspect the engine b rake
selector sig nal n u m ber 3 wi re for an open ci rcuit, provided
that the switch has been previously checked . Refer to the
OEM troubleshooti n g and repai r manual for repai r
proced u res.
If the resistance is with i n the specification , the engine
brake selector signal n u m ber 3 wi re must be checked for
a short circuit to g ro u n d , a short c i rcuit from p i n to pi n , and
a short c i rcuit to an external voltage sou rce.
Con n ect all components after co m pleti ng the repai r.
Engine Brake ON/OFF Switch Circuit ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]

To isolate the engine brake c i rcuit when checki n g for an
electrical short , turn all cab panel switches to the OFF or
SETI neutral position .
*
BRAKE PTO SWITCH ADJUST
t t
(+) ----,
OFF R I
(_)-----l
OFF OFF OFF
1 9200292
M ove the engine brake l evel switch to pOSition n u m ber 1

for a six-position switch or position n u m ber 2 for a th ree
position switc h .
I n se rt a test lead i nto engine b rake selector signal n u m ber
1 p i n of the OEM harness con nector and con n ect it to a
m u lti meter probe.
Touch the other m u lti m eter probe to the engine block
g ro u n d .
Switch the e n g i n e b rake ON/OFF switch t o t h e OFF
position .
M easure the resistance.
The m u lti m eter must show an open circuit (1 Oak ohms or
more) . If the circuit is not ope n , there is a short circuit to
g ro u n d i n the engine b rake circuit, provided the engine
b rake ON/OFF switch and engine b rake sel ector switch
h ave been previously checked .
Repai r or replace the wire con nected to the switch return
or engine b rake selector signal n u m ber p i n 1 i n the OEM
h arness con n ector accord i n g to the vehicle
man ufacturer's proced u res .
n u m ber 1 p i n and insert it i nto engine b rake selector signal
n u m ber 2 pin of the OEM h arness connector.
M ove engine brake level switch to position n u m ber 2 for a
six-position switch or to positio n n u mber 1 for a th ree
pOSition switch.
Switch the engine brake O N/OFF switch to OFF.
M easure the resistance.
The m u ltimeter m ust show an open circuit (1 Oak ohms or
g ro u n d in the engine b rake c i rcuit, provided the engine
b rake ON/OFF switch has been previously checked .
Repai r or replace the wire con nected to engine b rake
selector signal n u m ber 2 p i n in the OEM harness
accord i n g to the vehicle man ufacturer's proced u res.
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . . . Engine Brake ON/OFF Switch Circuit

n u m ber 2 pin and i nsert it i nto engine b rake selector signal
n u m ber 3 pin of the OEM h arness con nector.
Move engine b rake l evel switch to position n u m ber 3 .
Switch the engine b rake O N/OFF switch t o t h e OFF
position .
Measure the resistance with the m u lti m eter.
The m u ltimeter must show an open c i rcuit (1 00k ohms or
more). If the circuit is not ope n , there is a short c i rcuit to
g round in the e n g i n e b rake c i rcuit, provided the engine
b rake ON/OFF switch has been previously checked .
Repai r or replace the wire con nected to engine b rake
selector signal n u m ber 3 p i n in the OEM harness
accord i n g to the vehicle man ufacturer's proced u res .

Isolate the circuit by setting the cab panel switches as
described i n the previous section . Set the e n g i n e b rake
ON/OFF switch to the ON positio n . Place engine b rake
level to position n u m ber 6 for a six-position switch or
position n u m ber 3 for a th ree-positio n switch .
I I" I B
I nsert a test lead i nto the switch return of the OEM harness
con n ector and check al l pins except the switch return ,
engine brake selector signal n u mber 1 p i n , and engine
b rake selector signal n u mber 3 p i n .
Measu re t h e resistance . T h e m u lti m eter must show an
Remove the lead from the switch return and i nsert it i nto
engine brake selector sig nal n u m ber 2 pi n . Check all pins
except the switch retu rn engine, b rake selector signal
n u m ber 1 p i n and e n g i n e b rake selector signal n u m ber 3
p i n . Measure the resistance .
The m u ltimeter must show an open circuit (1 00k ohms or
more) .
Remove the l ead from e n g i n e b rake selector signal
n u m ber 2 pin and insert it i nto e n g i n e b rake selector signal
n u m ber 3 pin. Check all pins except the switch return .
Measure the resistance.
The m u ltimeter must show an open c i rcuit (1 OOk ohms or
more) .
Remove the l ead from the e n g i n e b rake selector signal
n u m ber 3 pin and i nert it i n the engine brake selector
signal n u m ber 1 pi n . Check all pins except the switch
retu rn . M easu re the resistance .
The m u lti m eter must show an open c i rcuit (1 00k ohms or
more) .
Engine Brake Level Switch ISB, ISBe2, ISBe3, ISBe4, aSB4 [ .. .... ]

1, . . . . . I
Source
" . " .." lS
engine b rake O N/OFF switch to the O N position .
Adj ust the m u lti meter to m easu re the VDC.
rf1{!) I nsert a test lead i nto the switch signal pin of the OEM
harn ess con n ector.
o' " oC�=�"
o .... <0" Disco n n ect the m u lti meter probe from the test lead and
touch it to the engine block g rou n d . Measure the Voltag e .
T h e voltage m ust be 1 . 5 VDC o r less.
1 9c0 1 1 S9
sou rce connected to the c i rcuit, or there is a short ci rcuit
between the engine b rake on/off ci rcuit and a wire carrying
power i n the OEM h arness. Remove the voltage sou rce o r
repair the w i r i n g i n the OEM h arness accord i n g t o t h e
vehicle man ufacturer's proced u res.
Con n ect all components after completi n g the repair.
Engine Brake Level Switch (019-036)

General Information
The engine brake level switch determ i n es the percentage
of e n g i n e b raki ng power that w i l l be applied when the
engine b rakes are activated . The engine brake ON/OFF
switch needs to be tu rned O N to activate the engine brake
system . Veh icles can be wi red with a 2 or 3 position
switch .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...] Engine Wiring Harness
Resistance Check
If I N S ITE™ is avai l ab l e , mon itor the engine b rake selector
switch for proper operatio n . If I N S ITE™ is not avai lable
then follow the troubl eshooti ng proced u res for this
sectio n .
Label t h e wi res with the location o n t h e switch or the wire
n u m ber. Disco n nect the th ree electrical con nectors from
the switc h .
Adj ust the m u lti meter t o measu re resistance
Th ree Position Switch

Switch Term inal A - Engine Term inal B - Engine
Position Brake Selector Brake Selector
Signal N u m ber 1 Signal N u m ber 2
1 Closed Open
1 Open Closed
2 Open Closed
2 Closed Open
3 Closed Closed
Two Position Switch

Switch Term inal A - Engine Term inal B - Engine
Position Brake Selector Brake Selector
Signal N u m ber 1 Signal N u m ber 2
1 Closed Open
1 Open Closed
2 Closed Closed
Check the resistance for each position of the 2 or 3

position switc h . An open c i rcuit must have a resistance
g reater than 1 00k ohms. A closed c i rcuit must have a
resistance of 1 0 ohms or less .
If the m u lti meter does not show the correct val ues i n both
tests , the switch has fai led . Refer to the OEM
troub leshooti ng and repai r man ual for replacement
proced u res.
Engine Wiring Harness (019-043)

General Information
The engine uses three separate wiring harnesses to
control the engine and some of the vehicle operations.
Shown , left to right, are the ECM ports for the followi n g :
1 . 4-p i n OEM power su pply harness con nector
2. 60-pin e n g i n e harness con nector
3. 50-pin OEM harness con nector.
1 9c01 2 1 8
Engine Wiring Harness ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Remove
Remove the harness clamps from the engine block.
Disco n n ect the engine harness from the injector pass

t h rough con nectors .
Disco n n ect the 60-pin e n g i n e harness con nector from the

ECM .
Disco n n ect the 4-pin power supply harness con n ector

from the ECM .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J Engine Wiring Harness
Disco n nect the electronic fuel control actuator from the

LS/-"f
engine harness. 'CC>'-:!J
Disco n nect the e n g i n e h arness from the following :

• Cran kshaft positio n sensor. Refer to P roced u re
0 1 9-365.
• Camshaft position sensor. Refer to P roced u re
0 1 9-363.
• I ntake man ifold pressure sensor. Refer to P roced u re
0 1 9-06 1 .
• I ntake man ifold temperatu re sensor. Refer to
P roced u re 0 1 9-059 .
• Barometric pressure sensor. Refer to Proced u re
0 1 9-004, (th i s appl i es to automotive and ind ustrial
only) .
ck800wa
• Oil pressu re switc h . Refer to Proced u re 0 1 9-066.
• E n g i n e coolant temperature sensor. Refer to
P roced ure 0 1 9-0 1 9 .
• Tu rbocharger speed sensor. Refer t o Proced u re
0 1 9-390 , (th i s app l i es to automotive and ind ustrial
only) .
• Tu rbocharger compressor i n let temperatu re sensor.
Refer to P roced u re 0 1 9-395, (th is appl i es to
auto motive and ind ustrial only) .
• Tu rbocharger control valve . Refer to P roced u re
0 1 9-388 , (th i s applies to automotive and ind ustrial
only) .
• Rai l fuel pressure sensor. Refer to Proced u re
0 1 9- 1 1 5.
• Water-i n-fuel sensor. Refer to P roced u re 0 1 9- 1 27.

• Fuel lift p u m p .
Inspect for Reuse

Replace or repai r the e n g i n e harness if there is an open
c i rcuit or a short c i rcuit fou n d u nder the protective
covering of the harness body.
1 9400386
Engine Wiring Harness ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]
Install
Con nect the engine harness to the followi ng:
• Crankshaft position sensor. Refer to Proced u re
0 1 9-365 .
• Camshaft position sensor. Refer to Proced u re
0 1 9-363.
• I ntake man ifold pressu re sensor. Refer to P roced u re
0 1 9-06 1 .
• I ntake man ifold temperatu re sensor. Refer to
P roced u re 0 1 9-059.
• Barometric pressu re sensor. Refer to Proced u re
ck800wa 0 1 9-004 , (this applies to automotive and i ndustrial
only) .
• Oil pressure switch . Refer to P roced u re 0 1 9-066.
• E n g i n e coolant temperatu re sensor. Refer to
P roced u re 0 1 9-0 1 9 .
• Tu rbocharger speed sensor. Refer t o Proced u re
0 1 9-390 , (this applies to automotive and ind ustrial
only) .
• Tu rbocharger compressor i n let tem peratu re sensor.
Refer to Proced u re 0 1 9-395, (this appl i es to
automotive and industrial only) .
• Tu rbocharger control valve. Refer to Proced u re
0 1 9-388 , (this appl i es to automotive and ind ustrial
only) .
• Rai l fuel pressu re sensor. Refer to Proced u re
0 1 9-1 1 5.
• Water-i n-fuel sensor. Refer to Proced u re 0 1 9-1 27.
• Fuel lift pump.
Con n ect the el ectronic fuel control actuator con n ector.
Connect the 60-pin engine h arness con n ector to the EC M .

W Torque Value: 3 N · m [ 27 i n-Ib 1
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . . . Fan Control Circuit
Con n ect the e n g i n e harness to the i nj ector pass-through

con n ectors .
Connect the 4-pi n OEM power su pply harness con nector

to the ECM .
I nstal l the harness clamps that hold the engine harness to

the engine block.
Fan Control Circuit {019-04S}

General Information
The CM850 control system can control the fan cl utch
activation . The ECM energ izes the air valve solenoid or an
electric fan clutc h .
Refer t o vehicle man ufacturer's publ ications for more
i nformation on trou bleshooti ng and repai r of the fan cl utch
wiri n g .
1 9c0 1 233
Fan Control Circuit ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
The fan control circuit resides i n the OEM harness. The

fan control signal wire is in the OEM con nector on the
ECM . The fan control signal wi re leads to the fan cl utch
ai r solenoid through the OEM wiring harness. The fan
control signal is g rounded through the cl utch body/e n g i n e
b l o c k g rou n d .
Resistance Check
A CAUTION A
Do not use probes or leads other than Part N u m ber
3822758. The connector will be damaged . The leads
must fit tig htly in the connector without expand ing the
pins of the connector.
Disco n n ect the OEM harness con n ecto r from the ECM .
Discon nect the OEM wiri n g at the fan control solenoid .
I nsert a test lead i nto the fan control signal p i n of the OEM
harness con n ector and con n ect it to the m u lti meter probe.
Touch the other m u ltimeter probe to the con n ector
te rmi nal of the fan cl utch so lenoid. Make sure the fan
cl utch solenoid is d isco n n ected .
less) . If the c i rcuit is closed , it must sti l l be checked for a
short c i rcuit to g rou nd and a short c i rc u it from p i n to p i n .
If t h e circuit i s not closed , there is a connection problem
or an open circuit i n the wiring h arness.

Check for a short circuit between the fan control signal pin
and all of the other pins i n the OEM harness. Make sure
the fan control solenoid is d isconnected . Make sure the
battery voltage supply is d isconnected .
I nsert a test lead i nto the fan control signal p i n of the OEM
harness con nector. I nsert the other test lead i nto all of the
other pins of the OEM harness con nector, one at a time.
The m u ltimeter must show an open circuit (more than
1 00k oh ms) .
If t h e circuit is not ope n , there is a short circuit between
the fan control signal p i n and any pins that measu red a
closed circuit.
Repai r or replace the OEM wiring harness.
Refer to P roced u re 0 1 9-043 o r 0 1 9-07 1 .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . . . Fault Lamp Circuit
Fault Lamp (019-046)

General Information
The fau lt code warn i n g lamps let the operator know when
/)
a part or a system fau lt is detected . The amber lamp can
have the word WAR N I N G pri nted on it. The red lamp can
have the word STO P pri nted o n it
\ (. ;, ,f : :; : :) , ' \
The fau lt code lamp c i rcu its consist of the l i g ht b u l b , lamp
;e
\ \
signal output, and VDC supply from the keyswitch circuit. • EHSilH fj A f { ': n' ':;
functioning normally. • Proceed and re p air
Pull over and sto p. a s soon as convenient
1 9c0 1 237
Voltage Check
Measu re the voltage between each fault lamp and g ro u n d .
T u r n the keyswitch to the O N position .
Touch the positive ( + ) m u lti meter probe to the amber
warning lamp signal term i n al .
Touch the negative (-) m u lti meter probe to the chassis
g ro u n d . M easu re the voltage.
Repeat this check for the other term i n al of the amber fau lt
lamp. The m u ltimeter must show the battery voltage.
Touch the positive ( + ) m u lt i m eter probe to the red stop

1 9c01 339
lamp signal term i n al .
Touch the negative (-) m u ltimeter probe to chassis g rou n d .
Measure the voltage.
Repeat this check for the other term i nal of the red fau lt
lamp. The m u ltimeter must show battery voltage.
If battery voltage is not present, there is a problem with
the keyswitch l i n e o r the lamp has fai led . Refer to the OEM
troubleshooti ng and repai r manual for repai r proced u res.
Connect all components after the repai r is complete.
Fault Lamp Circuit (019-047)

Voltage Check
Disconnect the origi nal eq u i pment manufacturer (OEM)
I. ..::. . . ;" . : " I
.
(ECM).
Tu rn the keyswitch to the O N positio n . Adj ust the
m u ltimeter to measu re VDC. I nsert the m u ltimeter lead
i nto the amber warn i n g lamp signal p i n and attach it to the
m u lti meter probe. Touch the other m u ltimeter probe to the o
engine block. Read the d isplay on the m u ltimeter. 0-- ".
The m u ltimeter must show battery voltage. If battery 1 9c0 1 1 58
voltage is not present, there is a prob lem with an OEM

harness wire, provided the amber warning lamp has
previously been checked .
Refer to the OEM tro u b leshooti ng and repai r manual for
repai r proced u res.
Idle Adjust Switch ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Remove the lead from the amber warn i n g lamp signal p i n

@ a n d insert i t i nto t h e malfu nction i n d i cator l a m p (M I L)
signal p i n . Touch the other m u lti meter probe to the engine
I, .", ,. . . , , .
block.
,'
The m u ltimeter must show battery voltage. If battery
voltage is not present, there is a problem with the
malfu nction ind icator lamp (M I L) OEM harness wire,
provided the malfu nction i nd i cator lamp (M I L) has been
W previously checked .
0 ·' Refer to the OEM troubleshooti ng and repai r manual for
repai r proced u res.
1 9c0 1 1 58
Remove the l ead from the m alfu n ction ind icator lamp
@l (M I L) signal pin and insert it i nto the red stop lamp signal
pi n . Touch the other m u lti m eter probe to the engine block.
I, . " , , . . . , , .
,'
The m u lti m eter must show battery voltage. If battery
voltage is not present, there is a problem with the red stop
lamp OEM harness wire, provided the red stop lamp has
been previously checked . Refer to the OEM
troubleshooting and repai r man ual for repair proced u res.
W Con n ect all components after com pleti ng the repai r.
0=
O=
1 9c0 1 1 58
(j) cp
Idle Adjust Switch (019-052)
0 0
General Information
1 ,
1
I The idle adj ust switch is located on the control panel and
IDLE
B ENGINE
MAl NT.
h as th ree settings, RPM + , RPM-, and OFF. The rocker
switch is used to activate or disable the idle adj ust
operatio n . The idle adj ust c i rcuit consists of the RPM +
STOP CHECK and RPM- signal l i n es , switch com mon g round and the
ENGINE ENGINE
rocker switch.
0 0
1 3200069
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J Idle Adjust Switch
Resistance Check
If I N S ITE'M is avai lable, mon itor the switch for proper
operatio n . If not , follow the troubleshooti n g proced u res i n
t h i s sectio n .
Locate a n d remove t h e i d l e adj ust switch from the
con nector.
Adj ust the m u lti m eter to meas u re resistance.
Touch the m u ltimeter probes to the R P M + signal switch
prong (3) and the battery g round prong switch prong (2) .
resistance. The m u ltimeter m ust show an open circuit
If the circuit i s not ope n , the switch h as fai led . Replace
the switc h .
Touch t h e m u lti m eter probes to the R P M - signal switch
prong ( 1 ) and the battery g round prong switch prong (2) .
resistance. The m u lti meter m ust show an open circuit
(1 00K ohms or more) .
If the circuit is not ope n , the switch has fai led . Replace
the switc h .

Touch the m u lti meter probes to the RPM + signal switch
prong (3) and the battery g round prong switch prong (2) .
Hold the switch depressed to the RPM + position and
measure the resistance. The m u lti m eter m ust show an
closed circuit ( 1 0 ohms or less) .
If the circuit is not closed , the switch has fai led . Replace
the switc h .
Touch the m u lti m eter probes to the RPM- signal switch
prong (1 ) and the battery g round prong switch prong (2) .
Hold the switch depressed to the RPM- position and
measure the resistance . The m u ltimeter m ust show an
closed circuit ( 1 0 ohms or less) .
the switc h .

Check for a short c i rcuit from p i n to p i n .
Touch t h e m u lti meter probe t o t h e RPM + switch signal
prong (3) . Touch the other m u lti m eter probe to the RPM
switch signal prong ( 1 ) .
Turn the cru ise control switch t o t h e O F F position .
The m u ltimeter m ust show a n open circuit ( 1 00k ohms o r
more) .
If the circuit is not open , there is a short circuit between
the RPM + and RPM- sig nal l i nes. Replace the switch .
Idle Adjust Switch Circuit ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Idle Adjust Switch Circuit (019-053)

Resistance Check
ACAUTION A
NOTE: The idle/d iagnostic i ncrement/decrement switch is
the cruise control/PTO/set/resu m e select switch.
If I N S ITETM electronic service tool is available, mon itor the
1 9c0 1 1 66
idle adj ust switch circuit for proper operatio n . If not, follow
the troubleshooting proced u res i n this section .
Remove the origi nal eq u i pment man ufacturer (OEM)
harness con n ector from the electronic control mod u l e
(ECM).
I nsert the p i n of the test l ead i nto the cruise control/PTO
set/coast switch signal i n the O E M harness con n ector.
M easure the resistance from the cruise control/PTO set!
coast switch signal to the engine block.
Hold the idle adj ust switch i n the positive (+) i ncrement
positio n .
If t h e O E M con nected t h e return wire t o chassis g round
the m u ltimeter must show a closed circuit ( 1 0 ohms o r
less) while hold i n g the switch on a n d return t o an open
circuit ( 1 OOK ohms or more) when the switch is released .
The circu it must remai n an open c i rcuit when the switch
is in the decrement negative ( ) position .
-
I f the O E M con n ected the return wire t o the 50-pin ECM

con nector the m u lti meter must show an open circuit ( 1 OOk
o . �>==.v 0" , �>==.v ohms or more) wh i l e hold i n g the switch on and return to a
O ".f"""..
""'l .-.... O- " .r--!'l....
.- ..
1 9c0 1 245
closed circuit ( 1 0 ohms or less) when the switch is
released . The circuit must remain a closed c i rcuit when
the switch is in the decrement negative ( ) positio n .
-
If the resistance val ues are not correct, make s u r e the

return wire and the cruise control/PTO set/coast switch
signal wire are properly installed on the idle adj ust switch .
If both wi res are correctly i n stal led , i nspect the return wire
and the cruise control/PTO set/coast switch sig nal wi re for
open circu its , provided the idle adj ust switch has been
previously checked for short circu its to g rou n d .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J Idle Adjust Switch Circuit
Remove the lead from the cru ise control/PTO set/coast

switch sig nal and i n sert it i nto the cruise control/PTO
resu me/accelerator switch sig nal .
Hold the idle adj ust switch i n the negative ( ) decrement
-
positio n . The m u lti meter m ust show a closed circuit (1 0

ohms or l ess) when the switch is held i n the decrement
position and an open circuit ( 1 00K ohms or more) when
the switch is released . The circuit must remain an open
ci rcuit when the switch is in the positive (+) i n crement
positio n .
If t h e resistance val ues are not correct, make sure the
cru ise control/PTO resume/accelerato r switch signal wire
is properly i nstalled on the idle adj ust switch . If the cruise
control/PTO res u m e/accelerator switch signal wire is
properly i nstalled o n the idle adj ust switc h , inspect the
cru ise control/PTO resu me/accelerator switch signal wire
for an open c i rcuit, provided the idle adj ust switch has
been previously checked for short c i rcu its to g rou n d .

Disco n n ect the idle/d iagnostic decrement wi re (attached
to the cru ise control/PTO res u m e/ accelerator switch
signal) from the switc h .
Measure t h e resistance from t h e cruise control/PTO
resume/accelerator switch signal of the OEM harness
con n ector to the e n g i n e block.
The m u ltimeter must show an open circuit (1 OOK ohms or

more). If the circuit is not ope n , there is a short circuit to
ground in the cruise control/PTO resume/accelerator
switch sig nal c i rcuit, provided the idle adj ust switch has
been previously checked .
Repai r or replace the wire con n ected to the cruise control/
PTO resume/accelerator switch signal in the OEM
harness accord i n g to the vehicle man ufacturer's
i nstructions.
To check the idle/d iagnostic increment wire (attached the
to cruise control/PTO set/coast switch signal) for short
c i rcu its to grou n d , fol l ow the same proced u re as described
above for the idle/d iagnostic decrement wire.
Idle Validation Switch IS8, IS8e2, IS8e3, IS8e4, QS84 [...]
Page 19-50 Section 19 -Electronic Engine controls

Meas u re the resistance from the cruise control/PTa
res u m e/accelerator switch signal of the OEM harness
con nector to all other pins in the connector. The
I, ..., ..•. P-t I m u lti m eter m ust show an open c i rcuit (1 00k ohms or
more) .
If the ci rcuit is not open , there is a short circuit between
the wire con nected to the cruise control/PTa resume/
accel erator switch sig nal and any p i n that measu red less
than 1 00k ohms.
1 9c01 249
Repai r o r replace the wi res i n the OEM harness accord i n g
t o the vehicle man ufacturer's i n structions.
Remove the lead from the cru ise control/PTa resume/
accelerator switch signal of the OEM harness con n ecto r
a n d i n sert it i nto the cruise control/PTa set/coast switch
signal of the con n ector. Measure the resistance from the
cruise control/PTa set/coast switch signal to al l other pins
i n the connector. The m u lti meter must show an open
circuit ( 1 00k ohms or more) .
If the circuit is not open , there is a short c i rcuit between
the wire con nected to the cruise control/PTa set/coast
switch signal and any p i n that measu red less than 1 00k
ohm s, provided the idle adj ust switch has been previously
checked .
Repai r or replace the wi res i n the OEM harness accord i n g
t o the vehicle man ufacturer's i n structions.
Con n ect all components after co mpleting the repai r.
Idle Validation Switch (019-054)

General Information
Marine Applications
£ WARN ING £
Do not use DSES lubricant on throttle connectors.
The idle val idation switch is located on the th rottle
assembly and is activated by movi ng the th rottle to or from
the idle position . The idle val idation switch circuit consists
of the Idle Validation I d le Switch I nput, the Idle Val idation
Off Idle Switch I n put, the Idle Val idation Return and the
Idle Val idation Switch .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J Idle Validation Switch
Resistance Check
switch for proper operatio n . If not , fol low the
troubleshooti ng proced u res in this section .
Locate the th rottle assembly and d iscon nect the Idle
Val idation Switch con n ector from the Idle Val idation
Switch.
Adj ust the m u lti m eter to m easu re resistance.
Touch the m u lti m eter probes to the idle val idation idle
switch i n p ut pin and idle val idation return pin of the idle
val idation switch con nector.
Move the th rottle out of the idle position and measu re the
resistance. The m u ltimeter m ust show an open circuit
If t h e circuit is not ope n , t h e switch has fai led . Repl ace
the switc h .
Touch t h e m u ltimeter probes t o t h e idle val idation off idle
switch i n p ut p i n and the i d l e val idation return pin of the
idle val idation switch con nector.
Move the th rottle to the idle position and m easu re the
resistance. The m u lti meter m ust show an open circuit
If the circuit is not ope n , the switch has fai led . Replace
the switc h .

Touch the m u ltimeter probes to the idle val idation idle
switch i n put line and the idle val idation return line of the
idle val idation switc h .
Move t h e th rottle i nto t h e idle position a n d measu re the
resistance. The m u lti meter must show an closed circuit
the switc h .
Touch t h e m u ltimeter probes t o t h e i d l e val idation off idle
switch i n put line and the idle val idation return l i n e of the 1 9d02250
idle val idation switc h .

Move t h e th rottle o u t o f t h e idle position a n d measu re the
resistance. The m u ltimeter must show an closed circuit
(1 0 ohms o r less) .
the switc h .
Lubricating Oil Level Sensor ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]

Check for a short circuit fro m pin to p i n .
Touch t h e m u lti meter probe t o t h e i d l e val idation idle
switch i n put line. Touch the other m u ltimeter probe to the
idle val idation off idle switch i n put l i n e .
Move t h e th rottle i nto t h e idle position a n d measure the
resistance. The m u lti meter must show an open circu it
If the c i rcuit is not ope n , there is a short circuit between
the idle val idation idle switch i n put and idle val idation off
idle switch i n put l i nes. Replace the switc h .
Lubricating Oil Level Sensor (019-056)

General Information
The l u bricating oil level sensor is used to mon itor the
engine l u b ricating oil leve l . The sensor is i nteg rated i nto
the d i pstick tube on the e n g i n e .
19901464
Remove
apart.
Remove the l u b ricating oil level sensor from the d i pstick
tube.
19901465
Clean and Inspect for Reuse

Visually i nspect the l u b ricating o i l level sensor for damage
to wiring or body.
I nspect the o-ri ngs for damage.
19901466
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J Intake Manifold Air Temperature Sensor
Install
I nstall the sensor i nto the d i pstick tube.
Push the sensor and sensor harness con n ectors together
until they lock.
19901465
Intake Manifold Air Temperature EE

Sensor (019-059)
Remove
Discon nect the wiring harness connector from the sensor.
Remove the i ntake man ifold air tem perature sensor from
the intake manifold cover.
Inspect for Reuse

Use the electronic service tool to mon itor the ai r
tem perat u re sensor.
Perform a rationale check to see if the sensor is read ing
an appropriate read i n g .
Install
I nstal l the sensor and tighten the capscrew.
Torque Value: 23 N - m [ 1 7 ft-Ib I
Con n ect the wiring harness con nector to the sensor.
Turn the keyswitch O N .
Use t h e electronic service tool t o mon itor t h e tem perature
sensor to make s u re it is worki ng correctly.
Refer to the resistance charts on the wiring diag ram for
sensor resistance val ues.
Intake Manifold Pressure Sensor ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Intake Manifold Pressure Sensor

'\l5 (019-061)
Remove
Slide the locking tab on the top side of the connector to
the u n lock position.
Press down on the tab near the end of the harness
co n nector where the harness wi res l ead i nto the
con n ecto r.
P u l l outward on the con nector away from the sensor to
disco n n ect.
Use a socket or combi nation wrench to remove the sensor.
Inspect for Reuse

The sensor is located on the i ntake air manifo l d . Use the
electronic service tool to mon itor the sensor.
To val idate this read i n g , a m u lti meter with a pressure
transducer can be used to measure the pressure.
Install
W I nstal l the sensor and tig hten the capscrew.
Connect the wiring harness con n ector to the sensor and
slide the locki ng tab to the lock positi o n .
Turn the keyswitch O N .
U s e the electronic service tool t o mon itor t h e i ntake
man ifold pressure sensor to ensure it is working correctly.
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J Internal Actuator Wiring Harness
Internal Actuator Wiring Harness

(019-063)
Remove
Disconnect the th ree Deutsch 4-p i n con nectors on the
engine harness from the pass-through con nector.
Remove the cran kcase breather tube. Refer to Proced u re
003-0 1 8 i n Troubleshooti ng and Repai r Manual , ISC,
OSC8 . 3 , I S L and OSL9 Engi nes, B u l letin 402 1 4 1 8 or
Troubleshooting and Repai r M a n u al , I S Be , ISB, and
OSB5.9 Engi nes, B u l leti n 402 1 271 .
Remove the rocker lever cover. Refer to P roced u re
003-0 1 1 i n Troubl eshooting and Repai r Manual , ISC,
Troubleshooting and Repai r Man ual , I S Be , ISB, and
OSB5.9 Engi nes, B u l l etin 402 1 271 .
Remove the pigtai l capscrews from al l i njector solenoids.
Remove the rocker hous i n g . Refer to Proced u re 003-0 1 3

i n Trou bleshooti n g and Repai r Man ual , ISC, OSC8 . 3 , I S L
a n d OSL9 Engi nes, B u l leti n 402 1 4 1 8 or Troubleshooting
and Repai r Manual , I S Be, ISB, and OSB5.9 Engi nes,
B u l l etin 402 1 27 1 .
Internal Actuator Wiring Harness ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Remove the i nternal i njector harness and the plastic cl i ps

from the rocker l ever housi n g .
Remove t h e pass-through con nector from t h e rocker

housi n g .
1 9d02089
Inspect for Reuse

I nspect for damaged or exposed wires, bent or b roken
pins, or damaged con nectors .
Replace , if necessary.
Install
I nstal l the pass-through co n nector i nto the rocker housi n g .
Torq ue Value: 1 0 N e m [ 89 i n - I b I
1 9d02089
IS8, IS8e2, IS8e3, IS8e4, QS84 [ J . . . Internal Actuator Wiring Harness
Route the i njecto r wiring around the m etal tabs to the

i njectors.
I nstal l new plastic c l i ps i nto the rocker housi n g .
I nstall t h e rocker lever housi n g . Refer t o P roced u re

003-0 1 3 i n Tro u bleshooting and Repai r Manual , ISC,
Troubleshooting and Repai r Man ual , I S Be , I S B , and
OSB5.9 Engi nes, B u l leti n 402 1 27 1 .
NOTE: Verify that the i nternal i nj ector harness does not

rest on any sharp corners.
NOTE: Verify that the pigtai l wi res are not "crossed over"
to the wrong i njectors .
I nstal l pigtai l n uts on i njectors .

Torque Value : 1 . 25 N - m [ 1 1 in-Ib I
NOTE: I njecto r wire to
sign ificant.
i njector orientation is not ®
I nstall the rocker l ever cover. Refer to P roced u re 003-0 1 1

i n Troubleshooti n g and Repai r Manual , I S C , OSC8 . 3 , I S L
a n d OS L9 Engi nes, B u l leti n 402 1 4 1 8 or Troubleshooting
and Repai r Manual , I S Be , ISB, and OSB5 . 9 Engines ,
B u l l etin 402 1 271 .
Con nect the engine harness to the pass-through
con n ector.
I nstall the cran kcase b reather tube. Refer to Proced u re
003-0 1 8 i n Troubleshooting and Repai r Man ual , ISC,
OSC8 . 3 , I S L and OS L9 Engi nes, B u l letin 402 1 4 1 8 or
Troubleshooti ng and Repai r Man ual , I S Be , ISB, and
OS B5.9 Engi nes, B u l leti n 402 1 271 .
Key Switch Battery Supply Circuit ISB, ISBe2, ISBe3, ISBe4, aSB4 [...]
-
Key Switch Battery Supply Circuit

(019-064)
Voltage Check
The veh icle keyswitch supplies an i n put signal to the
el ectronic control mod u l e (ECM) which turns the ECM o n
or off.
1 9803967
Turn the keyswitch to the OFF position .

Disco n n ect the origi nal eq u i pment man ufacturer (O EM)
harness con n ector from the ECM .
I nspect the con n ector pins.
1 9400002
CAUTION
I.. " ." .. ".",,,.
Adj ust the m u lti meter to measu re V DC .
I n sert a test lead i nto t h e keyswitch i n put Signal p i n o f the
OEM h arness con nector. Con nect the l ead to the
m u ltimeter probe. Touch the oth er probe to a clean ,
u n pai nted su rface on the e n g i n e block g rou n d .
T u r n t h e keyswitch t o t h e O N positio n .
1 9c0 1 1 58 T h e m easu red voltage must show battery Voltage. If the
m easu red voltage is more than 0. 5 VDC below battery
voltag e , conti n u e with the next step.
Disco n n ect the b u l khead con n ector.

I nspect the con n ector pins. Refer to the OEM
tro u b leshooti ng and repai r man ual for the proper
proced u re .
M easu re the voltage. Refer t o the OEM troub leshooti ng
and repai r man ual for the proper proced u re.
The m easu red voltage must show battery voltage. If the
0'" " = §-......
...."" .
voltage is not correct , there is a problem with the OEM
0-·· CO" harness wire , keyswitch , or battery con nection .
Repai r or replace the OEM harness, keyswitch , or check
1 9c0 1 25 1
the battery con n ections. Refer to the OEM troubleshooti ng
and repai r manual for the proper proced u res .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . . . Programmable Features and Parameters Not Correct
Engine Oil Pressure Sensor (019-066)

Remove
Disconnect the e n g i n e wiring harness from the engine oil
pressu re sensor.
Remove the e n g i n e oil pressu re sensor.
Install
Verify the o-ri n g is i nstal led on the sensor.
I nstall the engine oil press u re sensor.
Con n ect the e n g i n e wiring harness to the engine oil
pressu re sensor. An aud ible click will be heard when the
con n ector locks i n place.
OEM Wiring Harness (019-071)

General Information
The orig i n al eq u i pment man ufact u rer (OEM) harness is
suppl ied and i n stalled by the vehicle man ufacturer. Follow
the vehicle man ufacturer's proced u res, if replacement is
necessary. Refer to the veh icle man ufacturer's
troubleshooti n g and repai r man ual .
ck800wa
Programmable Features and

Parameters Not Correct (019-078)
General Information
This proced u re was developed d u e to the i n creasing
n u m ber of parameters and featu res offered which can
affect veh icle performance. Use the fol lowi ng table to
troubleshoot performance complai nts by locating the
appropriate sym ptom in the left col u m n . Then follow the
probable cause and corrective action in the adj acent
col u m n s.
Consult the appropriate electronic service tool manual to
adj ust the parameters or feat u res.
Adjust
Programmable Features and Parameters Not Correct ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]
Program mable Featu re/Parameters Not Correct

Sym ptom Probable Cause Correction
Exceed i n g road speed governor Cruise control or road speed Change the cru ise control or road speed governor
set speed down h i l ls governor lower droop is set too lower d roop to a lower val ue. If the problem
high. contin ues, change t h e cruise control engine
b rake activation to lower val u e .
Poor acceleration u p h i l l s Cru ise control and/or road Change the cru ise control or road speed governor
speed governor u pper d roop is upper d roop to a lower val u e .
set t o o h i g h .
Cruise control t u r n s o n Cru ise control auto-resu me Turn off the cruise control auto-resu m e feature.
automatically feature is enabled .
Exhaust b rakes turn o n Cru ise control auto engine b rake Turn off the cruise control auto engine brake
automatically feature is enabled or exhaust feature or repair the switc h .
b rake switch has failed close.
U nable to obtai n m axi m u m G ear-down protection feature is Turn off or adj ust the gear-down protection
vehicle speed enabled . parameters.
Poor cl utch engagement The low idle speed is set too low I ncrease the low-idle speed usi ng the idle adj ust
for the application . switc h . Refer to P roced u re 0 1 9-052 . I ncrease the
low-idle speed paramete r.
Speedometer on the dashboard Vehicle speed parameters not M ake sure the followi ng are correct: tire size , rear
is not correct or vehicle correct. axle ratio, vehicle speed sensor type , and gear
exceed i n g road speed governor teeth per revolution .
set speed
Tri p i nformation m i l eage The tire size parameter was Set the trip information system again whenever
read i ngs are not correct changed without resetting the the tire size parameter is changed .
trip i nformation system .
Can not obtain m axi m u m T h e gear-down protection Change the top gear ratio parameter to be eq ual
veh icle speed with parameters are not correct . to the fi rst gear-down ratio, not the top gear ratio.
semiautomatic transm ission For exam ple, on a transm ission with a 0 . 75, 0.87,
and 1 .0 ratio set , the top gear ratio parameter
must be set to 0 . 87.
Engine won 't start Antitheft password active. Enter antitheft personal identification n u m ber
( P I N ) using Road RelayTM or delete password with
Zap-It.
Low power i n lower g ears or top Power trai n protection Change power trai n protection torq ue l i m its to
gear parameters set too low. match torq ue capabi l ity of the veh icl e ' s
transmission .
Semiauto matic transmission will Top gear ratio setting does not Using I N S ITE™ electronic service too l , set the
not sh ift i nto top gear m atch top gear of transmissio n . proper top gear ratio.
Centinel™ feature has been Turn off the Centi nel™ feature and turn on the Top
tu rned on but vehicle has a 2 feature usi ng I N S ITE™ electronic service too l .
Spicer Top 2TM transmissio n .
Engine recently started Fan control feature is not set Verify all fan control feature parameters are
overheating because the fan wi l l properly. properly set for the veh icle.
not turn o n
F a n wi l l not turn off Fan control feature is not set Verify all fan control feature parameters are
properly. properly set for the vehicle.
Fan control switch will not turn Fan control 1 accessory switch Turn on fan control 1 accessory switch control
on the fan control is tu rned off. using I N S ITE™ electronic service too l .
IS8, IS8e2, IS8e3, IS8e4, QS84 [ J • . • Programmable Features and Parameters Not Correct
Program mable Featu re/Parameters Not Correct

Symptom Probable Cause Correction
U nable to obtai n m axi m u m Cru ise control maxi m u m vehicle Verify or change settings using I N S ITE™
vehicle speed speed or accelerator maxi m u m electronic service too l .
vehicle speed not set h i g h
enoug h .
D river reward system i s Explain featu re t o t h e d river or change parameter
penal izing the d river with settings to more appropriate values.
red uced top vehicle speed or
cruise control maxi m u m speed
for poor fuel economy or
extended idle time.
Accelerator pedal h as no effect Vehicle is in PTO mode and PTO Turn off PTO accelerator override using I N S ITE™
o n e n g i n e speed accelerator override is turned on el ectronic service tool .
i n t h e ECM .
Vehicle has a m u ltiplexed Verify that the th rottle pedal is m u lti plexed . Turn
th rottle pedal and the o n the m u ltiplexi n g feature for the th rottle pedal
m u ltiplexi ng feature has been using I N S ITE™ electronic service too l .
tu rned off.
Remote accelerator control has Remote accelerator feature has Turn on the remote accelerator feature usi ng
no effect o n e n g i n e speed been turned off. I N S ITE™ electro n i c service too l .
Vehicle has a m u ltiplexed Verify that the remote accelerator control is
remote accelerator control and m u ltiplexed . Tu rn o n the m u ltiplexing feature for
the m u ltiplexi ng feature has the remote th rottle control using I NS ITE™
been tu rned off. electronic service too l .
Lamps do not operate 5 A or 1 5 A Power fuse in e n g i n e Check fuses and verify the E C M is getting power
harness blow n . on the keyswitch wire.
Vehicle has m u ltiplexed lamps Verify that the lamps are m u ltiplexed . Turn on the
and the m u ltiplexi ng feature h as m u ltiplexing feat u re for the lamps using I N S ITE™
been tu rned off. electronic service tool .
Engine b rakes d o not operate Vehicle has m u ltiplexed e n g i n e Verify that the e n g i n e b rake switches are
b rake switches and the m u ltiplexed . Turn o n the m u ltiplexing feature for
m u ltiplexing feature has been the engine b rake switches using I N S ITETM
tu rned off. electronic service too l .
E n g i n e w i l l not respond t o o n e Vehicle has m u ltiplexed Verify that the switches are m u ltiplexed . Turn on
or all of the operator's switch(es) switches and the m u ltiplexing the m u ltiplexi ng feature for the switches using
feat u re has been tu rned off. I N S ITE™ electro n i c service too l .
Remote PTO Switch Circuit ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Remote PTO Switch Circuit (019-079)
t ON
R emote PTO
'\l5 Resistance Check
CAUTION
The leads must fit tig htly i n the connector without
con nector will be damaged .
Disco n n ect the origi nal eq u i pment man ufacturer (O EM)
(ECM).
1 9c0 1 256
I nsert a test lead i nto the remote power take-off (PTO)
switch return p i n of the OEM harness con nector and
con nect it to the m u ltimeter probe. I nsert the othe r test
lead i nto the remote PTO switch signal pin of the
con nector and con n ect it to the other probe.
Make sure the switch is con nected to the circuit. Move the
remote PTO switch to the O N positio n . M easure the
resistance with the m u ltimeter. The m u ltimeter m ust show
a closed c i rcuit ( 1 0 ohms or less) . If the circuit is not
closed , i nspect the switch return wire and the remote PTO
switch signal wi re for an open circuit. Repai r or replace
the OEM harness , provided the switch has been
previously checked . Refer to the OEM troubleshooting
and repair man ual for the proced u res.
If the resistance is correct , the remote PTO switch return

wire and the remote PTO switch signal wire must be
e 6
checked for a short circu it to g rou nd , a short circuit from
p i n to pi n , and a short circuit to an external voltage sou rce.
1I�1""'''lI I !-!=
i. , , , ,==
=,, ,,, , I Con n ect all components after the repai r is complete .
®
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J • . . Remote PTO Switch Circuit

Remote PTO
A CAUTION A
I
Disco n nect the OEM harness from the ECM .
I n sert the test l ead i nto the remote PTO switch signal p i n
i n t h e OEM harness con n ector a n d connect i t t o the
m u lti meter probe . Touch the other probe to engine block
t OFF
gro u n d .
With t h e remote PTO switch i n the OFF position , read the
resistance .
The m u lti m eter must show an open circuit (1 00k ohms or
more) .
If the resistance val ues are not correct , make sure the
remote PTO switch signal wire and the g round wire are
properly i n stal l ed on the switc h . If both wi res are correctly
instal l ed , i nspect the wi res for a short to ground circuit,
provided the remote PTO switch has been previously
checked .

Check for a short circuit from p i n to p i n . Set the remote
PTO switch to the OFF position . I nsert the test lead i nto
the remote PTO switch return p i n of the OEM harness
con n ector and con nect it to the m u ltimeter probe . With a
test lead con nected to the other m u lti meter probe, check
al l the other pins i n the con nector. Measu re the
resistance. The m u lti meter must show an open circuit
Remove the lead from the remote PTO switch return pin
and insert it i nto the remote PTO switch signal p i n of the
harness connector. With the other test l ead , check all
other pins i n the con n ector. Meas u re the resistance . The
m u lti meter must show an open circuit (1 00k ohms or
more).
L ,,,,,,.,,! 'p�L I
If the circuit is not open , there is a short ci rcu it between
the switch circuit and any pin that d i d not m easu re an
open circuit, provided the switch has previously been
checked . Repai r o r replace the wi res in the OEM harness
Con n ect all com ponents after completi ng the repai r.
Remote PTO Switch ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Remote PTO Switch (019-080)

Remote PTO General Information
A remote PTO switch is avai lable for applications where
ON PTO operation control is desi red away from the operator
controls.
The re mote PTO switch c i rcuit consists of the remote PTO
switch signal wire and a switch com mon retu rn .
OFF
gp8sv.l<s
Resistance Check
Locate the desi red ON/OFF togg le switc h .
Remove a n d tag the two con nectors from t h e term i nals on
the switc h .
Touch t h e m u ltimeter probes t o t h e term i nals on the
switc h .
@'"
@-- "C::::F=:=�
19900590
Move the switch t o t h e OFF position a n d measure the

resistance. The m u lti meter must show 1 OOk ohms or more
I", I.. j ..... .....
(open circu it) . If the circuit is not ope n , the switch h as
fai l ed .
Replace the switch. Refer t o the O E M troub leshooting and
repair man ual for the replacement proced u res.
1 OOk O h m s or More
19900591
8t
M ove the switch to the O N position and measure the
10 Ohms or Less ON
resistance. The m u ltimeter must show 1 0 ohms or less
=•.
(closed c i rcuit) . If the circuit is not closed , the switch h as
OFF fai led .
Replace the switch . Refer to the OEM troub leshooti ng and
repair man ual for the replacement proced u res .
• ._ 0_ 0 If the resistance val ue is correct , the switch must sti l l be
checked for a short circuit to g rou n d .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . . . Tachometer Circuit
Check for Short Circuit to Ground 1 OOk O h m s o r More
Touch one of the m u ltimeter probes to one of the switch

term i n als. Touch the other probe to chassis g ro u n d . Move
the switch to the ON position and measure the resistance .
The m u lti meter must show 1 00k ohms or more (open
circu it) . If the ci rcuit is not ope n , the switch has fai l ed .
Replace t h e switc h . Refer to the O E M tro u bleshooti ng and
repai r man ual for replacement proced u res. If the switch
passes al l of the previous checks, the circuit must be
checked for an open c i rcuit, a short c i rcuit to g round , a
short c i rcuit from p i n to p i n , and a short circuit to an
external voltage source. 19900592
Tachometer Circuit {019-083}

General Information
The ECM can s u pply an output signal to operate the
vehicle tachometer.
The circuit is the tachometer signal wire and a return l i ne
i n the OEM harness.
Resistance Check
A CAUTION A
3822758. The connector will be damaged . The leads
must fit tightly in the connector without expanding
pins in the connector.
Disco n nect the OEM harness from the ECM . Disconnect
the tachometer from the OEM harness .
I nsert the test lead i nto the tachometer sig nal p i n of the
OEM harness con n ector and con nect it to the m u lti meter
probe . 1 9c01 268
Locate the tachometer connector of the OEM harness.

Con n ect the other lead to the m u ltimeter probe and
con nect it to the tachometer signal pin of the tachometer
con n ector that is com i n g from the e n g i n e ECM . Consult
the OEM troubleshooting and repai r manual for wi ri ng
schematics.
Adj ust the m u ltimeter to the resistance sett i n g . Measu re
the resistance .
The m u lti meter must show a closed circuit (1 0 ohms or
less) . If the circuit is not closed , there is an open circuit or
the wi res i n the tachometer con n ector are reversed .
Repai r or replace the wire con n ected to the tachometer 1 9c01 269
signal pin in the OEM harness accord i n g to the vehicle

manufacturer's proced u res.
Tachometer Circuit ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]
-

i" ",.".", , , .O.l \ Disco n n ect the tachometer from the OEM harness.
I nsert the test lead i nto the tachometer signal pin of the
OEM harness con n ector and con nect it to the m u lti meter
probe. Touch the other m u lti meter probe to the engine
block g ro u n d . Measure the resistance.
The m u lti m eter m ust show an open circuit (1 OOk ohms o r
more) .
If the c i rcuit is not open i n either of the prior checks , repai r
the wi res which have i ncorrect read i ngs. Refer to the OEM
1 9c01 270 troubleshooti n g and repai r man u al for the repair
proced u res.

Disco n nect the tachometer from the OEM harness. I n se rt
the test lead i nto the tachometer signal p i n of the O E M
I, ,. , ,.,. "'O.L \
...
harness con nector a n d con nect it t o the m u lti meter probe.
I nsert the other lead i nto any pin, except the tachometer
switch retu r n , of the OEM h arness con n ector, and con nect
it to the other m u lti meter probe, and m easure the
resistance.
more) .
Measu re the resistance from the tachometer signal p i n to
all other pins i n the OEM con n ecto r. The m u lti meter
must s how an open circuit.
Remove the test lead from the last tested pin, insert it i nto
the tachometer switch return p i n . Measure the resistance
from the tachometer switch return pin to the tachometer
signal pin in the OEM harness con nector.
1, • . ,.. ,. .• ",.o.L \ The m u ltimeter must show an open circuit (1 00k ohms or
more) at all pins. If any pi n-to-pin check measu res as
not open , there is a short c i rcuit between the tachometer
signal pin and any other pin that measu red a not open
circuit. Repai r or replace the OEM harness. Refe r to
P roced u re 0 1 9-071 for harness replacement.
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . . .
Accelerator Pedal or Lever Position Sensor
Accelerator Pedal or Lever Position

Sensor (019-085)
General Information
Automotive and Industrial
The accelerator pedal position sensor will vary with O E M .
Refer t o t h e vehicle man ufacturer's man ual for the
specific troubleshooting and repai r proced u res. This
section contai ns troubleshooti n g and repai r proced u res
for one typical accelerator pedal position sensor.
The accelerator pedal position sensor sends a signal to

the ECM when the operator pushes o n the accelerator
pedal . The accel erator position c i rcuit consists of the
accelerator pedal position sensor, the ECM , accel erator
pedal position + 5 volt, accelerato r pedal position sig nal ,
and accelerator pedal position return wi res .
Marine Applications
The lever position sensor wi l l vary with O E M . Refer to the
vehicle man ufact u rer's manual for the specific
troubleshooti n g and repai r proced u res. This section
contai ns troubleshooting and repai r proced u res for one
typical accel erator l ever position sensor.
The accelerator l ever position sensor sends a signal to the
ECM when the operator pushes on the accelerator l ever.
The accelerator position circuit consists of the accelerator
lever position sensor, the ECM , accelerator l ever position
+ 5 volt, accel erator l ever position signal , and accelerator
lever position return wi res .
1 9d02253
Resistance Check
If I NS ITE™ is availab l e , m o n itor the accelerator position
sensor for p roper operatio n . If not , fol low the
troubleshooting p roced u res in this section .
Disco n nect the 3-p i n con n ector from the acce lerato r
position sensor.
Con nect the test con n ector.
Accelerator Pedal or Lever Position Sensor ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Page 1 9-68 Section 1 9 Electronic Engine controls
-
2000 to 3000 Ohms Con nect the m u ltimeter positive ( + ) test lead to the
accelerator pedal position + 5 volt supply test con n ecto r
w i r e . Connect the negative (-) m u ltimeter test probe t o t h e
accelerator pedal position return test connector wire.
Meas u re the resistance. The m u lti meter m ust show
between 2000 and 3000 ohms when the accelerator pedal
is released (idle position) o r depressed (fu l l-fuel position).
If the resistance is not with i n the specificatio n , the
accelerator position sensor has fai led . Replace the
accelerator position sensor. Refer to the OEM
troubleshooti n g and repai r manual for the proced u res.
t l Bswkl
Remove the m u ltimeter probe from the accelerator pedal!

lever position + 5 volt su pply test con nector wire and
con nect it to the accelerator pedal position signal test
con n ector wire .
W h e n t h e accelerator pedal is i n t h e released (idle)
position , m easu re the resistance . The m u ltimeter must
show between 1 500 and 3000 ohms.
Dep ress the accelerator pedal assembly (fu l l-fuel position)

and m easu re the resistance. The m u lti m eter must show
between 250 and 1 500 ohms. This resistance val ue
must be at least 1 000 ohms lower than the resistance
val u e of 1 500 to 3000 ohms m easu red in the above check.
If the resistance val ues in the two previous steps are not
with i n the specificatio n , the accelerator position sensor
h as fai led . Replace the accelerator position sensor
accord i n g to the vehicle man ufacturer's proced u res. If the
resistance val ues are with i n the specifications, the
accelerator position sensor must sti l l be checked for a
short c i rcuit to g round .
Marine Applications
If I NS ITE™ is avai lable, mon itor the accel erator position
sensor for proper operation . If not , fol l ow the
troubleshooti ng procedu res in this sectio n .
Discon nect t h e 3-pin con nector from t h e accelerator
position sensor.
Con nect the test con n ector.
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . . . Accelerator Pedal or Lever Position Sensor
Connect the m u lt i m eter positive ( + ) test l ead to the 2000 to 3000 Ohms
accelerator lever position + 5 volt supply test con necto r
wire. Con n ect the negative ( ) m u ltimeter test probe to the
-
accelerator lever position return test con n ector wire.

Measu re the resistance . The m u lti meter must show
between 2000 and 3000 ohms when the accelerator lever
is released (idle position) or depressed (fu l l-fuel position).
If the resistance is not with i n the specification , the
accelerator position sensor h as fai led. Replace the
accelerator position sensor. Refer to the OEM
troubleshooting and repair manual for the proced u res .
1 9d02255
Remove the m u lti m eter probe from the accelerator lever 1500 to 3000 Ohms
position + 5 volt supply test con nector wi re and con nect it
to the accelerator lever position signal test con nector wire .
W h e n the accelerator l ever is i n the released (idle)
position , measure the resistance. The m u lti meter must
show between 1 500 and 3000 ohms.
1 9d02256
Depress the accelerator lever assembly (fu l l-fuel position) 250 to 1500 Ohms
and measure the resistance. The m u ltimeter must show
between 250 and 1 500 ohms. This resistance val ue
must be at least 1 000 ohms lower than the resistance
val ue of 1 500 to 3000 ohms measu red in the above check.
If the resistance val ues i n the two previous steps are not
with i n the specificatio n , the accelerator position sensor
has fai led . Replace the accelerator position sensor
accord i n g to the veh icle man ufacturer's proced u res. If the
resistance val ues are with i n the specifications, the
accelerato r position sensor must sti l l be checked for a
short circuit to g ro u n d .
1 9d02257

Con n ect the m u lti meter positive ( + ) probe to the
accelerator pedal position return test con nector wire.
Touch the negative ( ) m u lti meter probe to the chassis
-
g rou nd and measu re the resistance.

The m u ltimeter must show an open circuit ( 1 00k ohms or
more) .
Accelerator Pedal or Lever Position Sensor ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
-
Remove the m u lti meter positive ( + ) probe from

accelerator pedal position return test connector wire and
con nect it to the accelerator pedal position signal test
con nector wire. Measu re the resistance.
more) .
Remove the m u lti meter positive ( + ) probe from the

100k O h ms
I. ,
.•••.•,
accel erator pedal positio n sig nal test connector wi re and
con nect it to the accelerator pedal position + 5 volt su pply
test con nector wire. M easu re the resistance. The
m u lti meter must show an open c i rcuit ( 1 00k ohms or
more) .
If the resistance val ues are not with i n the specifications i n
t h e previous check, t h e accel erator position sensor h as
fai l ed . Replace the accelerator position sensor accord i n g
to the vehicle manufactu rer's proced u res.
If the accelerator position sensor has passed all the
previous checks , con nect the sensor to the wiri ng
h arness . The accelerato r positio n sensor c i rcuit must sti l l
be checked .
Marine Applications
l OOk Ohms or M ore
Connect the m u ltimeter positive ( + ) probe to the
accelerator lever position return test con nector wire.
Touch the negative ( ) m u ltimeter probe to the chassis
-
g rou nd and m easu re the resistance .

The m u lti meter must show an open circuit (1 OOk ohms or
more) .
Remove the m u ltimeter positive ( + ) probe from

l OOk Ohms or M ore
accelerator lever position return test con n ector wi re and
con nect it to the accelerato r lever position signal test
con n ector wire. M easu re the resistance.
more) .
IS8, IS8e2, IS8e3, IS8e4, QS84 [ J • • • Accelerator Pedal or Lever Position Sensor Circuit
Remove the m u lti meter positive ( + ) probe from the 1OOk Ohms or M ore
accelerato r lever position signal test con n ector wire and
con nect it to the accelerator l ever position + 5 volt supply
test con nector wire. Measu re the resistance. The
m u lti meter must show an open circuit (1 00k ohms or
more) .
If the resistance val ues are not with i n the specifications i n
t h e previous check, t h e accel erator position sensor has
fai led . Replace the accelerator positio n sensor accord i n g
t o t h e veh icle manufactu rer's proced u res.
If the accelerator position sensor has passed all the
previous checks, connect the sensor to the wiring 1 9d02260
harness . The accelerator position sensor circuit m ust sti l l
be checked .
Accelerator Pedal or Lever Position

Sensor Circuit (019-086)
Initial Check
A CAUTION A
3822758. The OEM connector will be damaged . The
leads must fit tig htly in the connector without
expanding the pins in the connector.
accelerator position sensor circuit for proper operation. If
not , follow the troubleshooting proced u res i n this section .
Resistance Check
Disco n nect the OEM harness con nector from the ECM .
Make sure the sensor is con nected t o t h e O E M harness .
I nsert a test lead i nto the accelerator pedal/lever position
+ 5 volt su pply pin of the OEM harness connector and
con n ect it to the m u lti m eter probe. I nsert the other lead
i nto the accelerator pedal/lever position return of the
con n ecto r and connect it to the other m u ltimeter probe.
With the accelerator pedal depressed , m easu re the
resistance. The m u lti meter must show 2000 to 3000 ohms
when the accelerator pedal is dow n . If the resistance is
not with i n the specificatio n , there is a prob lem with the
accelerator pedal/lever position + 5 volt supply wire or the
accelerator pedal/lever · positio n return wire in the OEM
harness , provided the accelerator position sensor has
been previously checked . Repai r the OEM harness
accord i n g to the man ufacturer's proced u res.
Accelerator Pedal or lever Position Sensor Circuit IS8, IS8e2, IS8e3, IS8e4, QS84 [...J
Repeat the check with the accel erator pedal in the

released position. Measu re the resistance. The m u lti meter
must show 2000 to 3000 ohms when the accelerator pedal
is up. If the resistance is not with i n the specification , there
is a problem with the accelerator pedaillever position + 5
volt supply wire or the accelerator position pedal/lever
return wire in the OEM harness, provided the accelerato r
position sensor h a s b e e n previously checked . Repai r t h e
OEM h arness accord i n g t o the man ufacturer's
proced u res.
Remove the test lead from the accelerator pedal/lever
position return pin and i nsert it i nto the accelerator pedal/
lever position signal pin .
Make sure the foot pedal is i n the released (id le) position .
Measu re the resistance. The m u lti m eter must show 1 500
to 3000 ohms.
Depress the accelerator pedal assem bly (fu l l-fuel) and

m easu re the resistance agai n .
The m u lti m eter m ust show 200 to 1 500 ohms. This
resistance val ue must be at least 1 000 ohms lower than
the resistance val ue of 1 500 to 3000 ohms measu red in
the above check. If the resistance val ues are not with i n
t h e specification , there is a problem with t h e accelerator
pedaillever position + 5 volt supply o r the accelerator
position pedal/l ever signal wire in the OEM harness.
Repai r the OEM harness accord i n g to the man ufacturer's
proced u res.
If the resistance val ues in the two previous checks are
with i n the specificatio n , the accelerator pedal/lever
position + 5 volt supply, the accelerator pedal/lever
position retu rn , and the accelerator pedal/lever position
signal wi re must sti l l be checked for a short circuit to
grou n d , a short circuit from pin to p i n , and a short c i rcuit
to battery su pply.
NOTE: When checki ng the OEM harness, i nspect the
b u l khead con nector and other con nectors i n the circuit for
corrosion or damage to the accelerator position sensor
wi re term i n als.

Disco n nect the accelerato r pedal/lever position sensor
and assembly from the OEM harness at the accelerator
pedaillever pOSition sensor and assembly.
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . . . Accelerator Pedal o r Lever Position Sensor Circuit
I nse rt a test lead i nto the accelerator pedal/lever position

+ 5 volt su pply pin of the OEM harness con n ector and
con n ect it to the m u ltimeter positive probe . Touch the 1. , 1 "I , ,,,, DL
.
1
m u ltimeter negative probe to the e n g i n e block ground and
m easure the resistance.
more) .
Remove the lead from the accelerator pedal/lever position
+ 5 volt su pply pin and insert it i nto the accel erator pedal/
lever position return pin of the OEM harness con n ector.
Touch the m u lti meter negative probe to the engine block
g round and measu re the resistance. 1 9c01 270
The m u lt i m eter must show an open circuit (1 OOk ohms or

more) .
Remove the lead from the accelerator pedal/lever position
return and insert it i nto the accelerator pedal/lever position
signal p i n . Touch the m u lti m eter negative probe to the
engine block g round and m easu re the resistance.
more) .
If any of these th ree resistance meas u rements are not
ope n , there is a short circuit to g ro u n d between the wi res
connected to the accelerator pedal/lever position + 5 volt
supply, the accelerator pedal/lever position retu rn , or the
accelerator pedal/lever position signal wire . Repair the
OEM harness . Refer to the OEM troubleshooting and
repair man ual for the proced u res.

Disconnect the accelerator pedal/lever position sensor
and assembly from the OEM h arness at the accelerator
pedal/lever position sensor and assem b ly.
Accelerator Pedal or Lever Position Sensor Circuit ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . . .
I nsert the test lead i nto the accelerator pedal/lever

position + 5 volt supply p i n of the OEM harness con nector.
I nsert the other lead i nto the idle val idation on-idle signal
pin of the accel erator pedal assembly connector. Connect
I,."'" O. L
.. ,, •..... I the cl i ps to the m u lti meter probes and measure the
resistance.
The m u lti meter must show an open circuit ( 1 OOk ohms or
more) .
Remove the lead from the idle val idation on-idle signal p i n
a n d test all other pins i n the OEM harness connector, o n e
at a time.
The m u lti m eter must show an o p e n circuit (1 00k ohms o r
more) a t all p i n s .
If the m u ltimeter did not i n d icate an o p e n circuit a t every
pi n , there is a short circuit between the accelerator pedal!
lever position + 5 volt supply wire and any other wire that
did not m easu re an open c i rc u it . Repai r or replace the
OEM harness. Refer to P rocedure 0 1 9-071 for harness
replacement.
Remove the lead from the accel erator pedal/l ever position
+ 5 volt su pply pin and insert it i nto the accelerator pedal/
lever position return p i n . I nsert the other lead i nto the idle
val idation on-idle signal p i n i n the OEM harness con nector
and m easure the resistance.
more) .
Remove the lead from idle val idation idle signal pin and
test all other pins i n the O E M harness con nector, one at a
time.
more) at all pins.
Remove the lead from the accelerator pedal/l ever position
return pin and insert it i nto the accelerator pedal/lever
position signal p i n . I n sert the other lead i nto the fi rst p i n
i n the OEM harness co n nector a n d measure the
resistance .
more) .
Remove the lead from the fi rst pin i n the OEM harness
con n ector and test all other pins in the connecto r, one at
a time.
The m u ltimeter m ust show an open circuit (1 00k ohms or
more) i n al l pins.
If the m u ltimeter did not i n d i cate an open circuit on every
p i n , there is a short circuit between the accel erator pedal/
lever position signal wire and any other wire that did not
i n d i cate an open circuit. Repai r the OEM harness
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J • • . Unswitched Battery Supply Circuit
- Page 19-75

Source LS(
\J::>
Disco n n ect the accelerator ped al/lever position sensor
assem b ly from the OEM harness at the accelerator pedal/
lever position sensor assem b ly.
Turn the keyswitch to the O N positi o n . Adj ust the

m u ltimeter to m easu re VDC.
I nsert a test lead i nto the accelerator pedaillever position
return pi n . Touch the m u ltimeter negative probe to the
engine block ground and m easu re the voltage.
The voltage must be 1 . 5 VDC o r less.
Remove the lead from the accel erator pedal/lever position
return pin and i n sert it i nto the accelerator pedal/lever
position signal p i n . Touch the m u ltimeter negative probe o- ".
to the engine block and measu re the voltage.
The voltage m ust be 1 . 5 VDC o r less.
If more than 1 . 5 VDC is m easu red at any pin , there is a
short circuit from the accelerator pedal/lever position + 5
volt supply, the accelerator pedal/lever position return , or
the accelerator pedal/lever position signal to a wire
carryi ng power i n the OEM harness.
harness that carries voltag e .
Replace the OEM h arness. Refer t o P roced u re 0 1 9-071 .
Connect all components after completi ng the repai r.
Unswitched Battery Supply Circuit @

(019-087)
General Information
The ECM receives constant voltage from the batteries
through the ECM battery supply positive ( + ) wi re that is
con nected d i rectly to the positive ( + ) battery post. There
is one in-line 30-amp fuse (mari ne h as 25-amp fuse) i n the
ECM su pply wi re to protect the ECM . The ECM receives
switched battery i n put through the keyswitch i n put signal
when the vehicle keyswitch is tu rned on. The ECM battery
supply negative (-) wi re is con nected d i rectly to the 1 9c01 280
negative ( ) battery post.

-
The ECM battery su pply positive ( + ) wire and the ECM

battery su pply negative ( ) wire are i n the ECM power
-
harness.
Always check the ECM battery su pply fuse when
troubleshooting the ECM and power su pply circuit.
Check the battery Voltage. Refer to Proced u re 0 1 9-008 .
Unswitched Battery Supply Circuit ISB, ISBe2, ISBe3, ISBe4, QSB4 [...J
Page 19-76 Section 19 -Electronic Engine controls
Resistance Check
Disco n n ect the ECM power h arness connector from the
ECM .

I nsert a test lead i nto the ECM battery supply negative ( )
-
pin of the ECM power con nector. Attach it to a m u lti meter

probe. Touch the other m u lt i m eter probe to the engine
block g round and measu re the resistance. The m u lti meter
must show 1 0 ohms or l ess .
1 9c0 1 1 48
If the resistance val ue is not correct , check the ECM

power harness.
Repai r or replace the ECM power harness.
When the checks have been com pleted , con nect the ECM
power harness connector.
NOTE: Some OEM appl ications have the ECM power

harness with al l 4 pins in the connector populated .
Check the battery return w i re i n the ECM power harness
for proper g ro u n d i n g . Discon nect the harness from the
ECM . Check for damaged pins i n the ECM and the
h arness.
Repai r or replace any damaged pins.
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . • • Brake Pedal Position Switch
Voltage Check
Check the battery voltage supply at the ECM battery I. ",, .. , .
, ,., , ,,
su pply positive ( + ) p i n of the ECM power con n ector.

Turn the keyswitch to the OFF positio n . Disco n nect the 4-
pin ECM power harness con nector from the ECM . Set the
m u ltimeter to meas u re VDC.
Measure the voltage from the ECM battery supply positive
( + ) to g ro u n d .
T h e voltage must read battery voltage a t this pi n .
I f the voltage i s not correct, repai r o r replace the ECM
1 9c0 1 35 1
power harness.
Brake Pedal Position Switch (01 9-088)

General Information @
.6 CAUTION .6
When trou bleshooting the brake line switch circuit,
make sure the brake pressure switch is identified . The
vehicle brake light pressure switc h , which is not a part
of the Signature system , is com monly mistaken for
the brake line switch used in the Signature system .
The b rake pedal position switch detects t h e position o f the
service b rake pedal . Certain featu res such as cru ise
control and PTO respond to the state of the brake pedal 1 9c0 1 26 1
position switch and d isengage when the brakes are

applied . The c i rc u it h as a normal ly-closed switch , switch
return wire, and b rake pedal position switch sig nal wire of
the OEM harness. The b rake pedal position switch is
mou nted in the low pressure side of the vehicle pneumatic
brake system . When the vehicle b rakes are appl ied , the
normally-closed switch opens and d isables the cruise
control operation .
Remove
" WARN I N G "
To avoid personal inj u ry or deat h , do not apply the
vehicle brakes when the switch is removed from the
brake line fitting .
Disco n nect the OEM harness from the b rake pedal
position switc h .
Remove the b rake pedal position switch from t h e fitti n g .
eb8swha
Brake Pedal Position Switch ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J
Install
I nstall the new brake pedal position switch i nto the fitting
ebBswhb
/li1r:-.. Con n ect the two wi re con n ectors to the b rake pedal
position switch.
(ill!
ebBswhc
Resistance Check
If I N S ITE™ is avai lable, m o n itor the brake pedal position
switch for proper operatio n . If not , follow the
troubleshooting proced u res in this sectio n .
T h e b rake pedal position switch ( 1 ) wi l l be located i n the
vehicle b rake line (2) . The location wi l l depend on the OEM
i n stal l ation proced u res.
D isco n n ect the two wire con n ectors from the brake pedal
position switc h .
ebBswkb
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ ] . . . Brake Pedal Position Switch Circuit
Con n ect the probes of the m u lti meter to the b rake pedal
position switch term i nals.
The m u ltimeter must show a closed circuit (1 0 ohms or
less) when the b rakes are not appl ied . If the circuit is
not closed , replace the b rake pedal position switc h .
A CAUTION A
The veh i cle must have enoug h air pressu re to activate
the brakes.
Depress the veh icle b rake pedal . The m u ltimeter m ust
show an open ci rcuit ( 1 00k ohms or more) when the
b rakes are appl i ed . I f the c i rcuit is not ope n , replace the
b rake pedal position switc h .
If t h e resistance val u e is correct , the switch must sti l l b e
checked f o r a short c i rcuit t o g ro u n d .

Touch one m u lti m eter probe to one of the b rake pedal
position switch term i nals. Touch the other m u ltimeter
probe to chassis g rou n d . Measu re the resistance. The
m u ltimeter must show an open circuit (1 00k ohms or
more) when the b rake pedal is released . If the circuit is
not ope n , replace the b rake pedal position switc h .
If t h e b rake pedal position switch passed all t h e previous
checks , con nect the switch to the wi ri n g h arn ess. The
b rake pedal position switch c i rcuit must sti l l be checked . Ground
eb8swke
Brake Pedal Position Switch Circuit

(019-089)
Resistance Check
A CAUTION A
b rake pedal position switch for proper operation. If not ,
fol low the troubleshooting proced u res i n this sectio n .
Disco n nect t h e origi nal eq u i pment manufacturer (O EM)
harness con n ecto r from the electronic control module
(EC M).
Brake Pedal Position Switch Circu it ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J
-
Make sure the brake pedal position switch is con nected to

the c i rcuit
I nsert a test lead i nto the b rake pedal position switch
Signal p i n of the OEM harness con nector. Attach the lead
to a m u ltimeter probe . I nsert the other test lead i nto the
switch return pin of the con n ector and attach it to the other
probe.
Adj ust the m u lti meter to the resistance setting and
measu re the resistance . The m u lti meter must show a
closed ci rcuit ( 1 0 ohms or less) when the brakes are not
engaged (brake pedal released). If the circuit is not
1 9c0 1 262 closed , there is a problem with the OEM harness, provided
the brake pedal position switch has been previously
checked .
A CAUTION A
The vehicle must have enough air pressure to activate
the brakes.
Depress the vehicle b rake pedal and repeat the resistance
check. The m u lti meter must show an open c i rcuit ( 1 00k
ohms or more) . If the circuit is not open , there is a problem
with the OEM harness, provided the b rake pedal position
switch has been previously checked .
If the values are correct , the circuit must sti l l be checked
@ '" " L.,;;;i'===� for a short c i rcuit to g rou n d , a short circuit from p i n to p i n ,
@ '- a n d a short circuit t o an external voltage sou rce.
1 9c0 1 263

To isolate the b rake pedal position switch circuit when
checki n g for a short circuit, turn all cab panel switches to
SETI the OFF or neutral positio n .
it i
BRAKE PTO SWITCH ADJUST
i
<+l
Disco n n ect t h e O E M harness con nector from t h e ECM
and the OEM harness from the b rake pedal position
OFF R : J OFF OFF OFF <-l----.J switch.
Set the service brake using the trai ler b rake hand valve .
Disco n n ect the cl utch pedal position switch , accel erator
positio n switch and the idle val idation on/off switch .
1 9200292
I n se rt a test lead i nto the brake pedal position switch
I. ,,,,.,,, .,,,,,, o..L I Signal p i n of the OEM h arn ess con n ector. Con nect the
lead to the m u lti meter probe. Remove the al l igator clip
from the other m u lti meter probe and touch the probe to
the engine block.
The m u lti meter must show an open circuit (1 Oak ohms or
g round in the b rake pedal position switch signal wi re,
provided that the switch h as been previously checked .
Repai r or replace the wi re con n ected to the brake pedal
position switch signal pin in the OEM harness accord i n g
1 9c01 24 1 t o the vehicle manufactu rer's proced u res.
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ J. . . Vehicle Speed Sensor, Digital I n put

Isolate the b rake pedal position switch circuit by
d iscon necting the brake pedal position switch con nector
and the OEM harness con nector at the ECM . I nsert a test
lead i nto the b rake pedal position switch signal p i n of the
OEM harness connector. I nsert the other test lead into the
switch return pin of the OEM harness con nector. Connect
the al l igator clips to the m u lti m eter probes. Measu re the
resistance. The m u ltimeter must show an open circuit
QaoomA
Remove the lead from the switch return p i n and test all
COM
other pins i n the con nector. The m u ltimeter must show an

open circuit (1 00k ohms or more) at all pins. If the circuit
is not open , there is a short c i rcuit between the wire
con nected to the service b rake switch signal p i n and any
pin that did not show an open c i rcuit.
Repai r or replace the wi res i n the OEM harness accord i n g
t o the veh icle manufacturer's p roced u res.

I I
Source
. .. .,............. L S
Disconnect the b rake pedal position switch from the OEM

harness and d iscon nect the OEM harness from the ECM .
Turn the vehicle keyswitch to the ON position . Adj ust the
m u ltimeter to measure VDC. I nsert a test lead i nto the
brake pedal position switch signal pin and con n ect it to the
positive m u ltimeter probe. Remove the lead from the
negative m u lti m eter probe and touch the probe to the
engine block g ro u nd . Measure the voltag e . The voltage
must be 1 . 5 VDC or less.
wiri n g that carries Voltage.
If the voltage is more than 1 . 5 VDC, there is a short c i rcuit
between the wire connected to the b rake pedal position
switch sig nal pin and a wire carrying power in the OEM
harness. Repai r the OEM harness accord i n g to the vehicle
man ufacturer' s proced u res.
Connect all com ponents after completi ng the repai r.
Vehicle Speed Sensor, Digital Input

(019-090) Digital
Input
General Information Signal
Device
The d i g ital i n put signal device is an OEM optional part . It
changes the signal pulses from AC to DC. This part is near
the transmission o r i n the veh icle cab . The DC voltage
pulses are then sent to the ECM and computed i nto m i les
per hour.
ee8mpgd
Vehicle Speed Sensor, Digital I n put ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J
The d i g ital vehicle speed sensor circuit consists of the

speed sensor, the digital vehicle speed sensor + 5 volt
su pply wi re , the dig ital vehicle speed sensor signal wire,
and the d i g ital veh icle speed sensor return wi re .
.6. CAUTION .6.

When the OEM-su pplied signal cond itioner is
internally g rounded, do not connect the vehicle speed
sensor signal negative (-) wire to the ECM . This will
create a g round loop in the system that will inject
unwanted electrical noise into the system . Only the
digital vehicle speed sensor + 5 volt supply wire is
requ i red in this case .
Resistance Check
.6. CAUTION .6.
1" .,....,....1. 5 I The leads must fit tig htly in the connector without
Disco n nect the OEM harness con n ector from the ECM
con n ector.
Discon nect the dig ital veh icle speed sensor from the OEM
harness.
I n sert a test lead i nto the d i g ital vehicle speed sensor + 5
1 9c0 1 387
volt su pply p i n i n the OEM harness con nector, and
con n ect it to the m u lti meter probe.
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ ] • . . Vehicle Speed Sensor, Digital I n put
Section 1 9 - Electronic Engine controls Page 1 9-83
I nsert the other test l ead to the d i g ital veh icle speed
sensor + 5 volt su pply in the vehicle speed sensor
con nector and connect the alligator cl i p to the other
m u ltimeter probe. Adj ust the m u lti m eter to the resistance
setting and measu re the resistance.
The m u lti m eter must show a closed c i rcuit ( 1 0 ohms or
less) .
If the circuit is not closed , there is an open circuit. Repai r
or replace the wi re con nected to the d i g ital vehicle speed
sensor + 5 volt supply pin in the OEM harness accord i n g
t o t h e veh icle man ufacturer's proced u res.
Remove the lead from the d i g ital veh icle speed sensor + 5
volt su pply pin and i n sert it i nto the d i g ital vehicle speed
sensor sig nal p i n of the OEM harness con n ector. Remove
the m u ltimeter lead from the d i g ital veh icle speed sensor
+ 5 volt su pply at the speed sensor con nector and con nect
it to the d i gital vehicle speed sensor sig nal pin in the
veh icle speed sensor con nector. M easu re the resistance .
T h e m u lti m eter must show a closed circuit (1 0 o h m s or
less) .
or replace the wire con nected to the vehicle speed sensor
signal pin in the OEM harness accord i n g to the vehicle
manufacturer's procedures.
Remove the lead from the d i g ital veh icle speed sensor
sig nal pin and i n sert it i nto the d i g ital vehicle speed sensor
return pin of the OEM harness con necto r. Remove the
m u lti meter lead fro m the d i g ital vehicle speed sensor
signal pin at the speed sensor con nector and connect it to
the d i gital vehicle speed sensor return pin i n the vehicle
speed sensor con n ector. M easu re the resistance.
The m u ltimeter must show a closed c i rcuit ( 1 0 ohms or
less) .
or replace the wire connected to the vehicle speed sensor
return pin in the OEM harness accord i n g to the vehicle
man ufacturer' s proced u res.
If the val ues are correct , the c i rcuit must sti l l be checked
for a short circuit to g round and a short c i rcuit from pin-to
pin.
Vehicle Speed Sensor, Digital I n put ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ]
Page 1 9·84 Section 1 9 - Electronic Engine controls

Disco n n ect the vehicle speed sensor from the OEM
I. I
h arness. Disconnect the OEM harness con nector from the
.,t;J.L
" " ,,,,,.,,,,, ECM .
I nsert a test lead i nto the d i g ital vehicle speed sensor
signal return pin of the OEM harness con nector, and
con n ect it to the m u ltimeter probe. Touch the other
m u lt i m eter probe to the engine block g rou n d . Measu re the
resistance.
1 9c0 1 1 54
more) .
Remove the test lead from the d i g ital vehicle speed sensor
Signal return pin and insert it i nto the d i g ital vehicle speed
sensor + 5 volt supply pin of the OEM harness con n ector.
Touch the other m u ltimeter probe to the engine block
grou n d . M easu re the resistance .
The m u lt i m eter m ust show an open circuit (1 00k ohms or
more) .
signal + 5 volt supply pin and i nsert it i nto the d i g ital
vehicle speed sensor signal p i n of the OEM harness
con n ector. Touch the other m u lti meter probe to the engine
block g ro u n d . Measure the resistance.
The m u lti m eter must show an open circuit (1 OOk o h ms or
more) .
If t h e c i rcuit is not open i n either of these checks , there is
a short circuit to grou nd in the d i g ital vehicle speed sensor
c i rcuit in the OEM harness.
Repai r the wi res which have a short circuit accord i n g to
the vehicle man ufacturer's proced u res.
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Vehicle Speed Sensor, Magnetic Pick U p

Disco n nect the vehicle speed sensor from the OEM
harness.
Disco n n ect the OEM harness con nector from the ECM L. :.:.Pl l '
. .
con n ecter.
I nsert one test lead i nto the d i g ital veh icle speed sensor
+ 5 volt su pply pin of the OEM harness con n ector, and
con nect it to the m u ltimeter probe . Connect the other test
lead to the other m u lti meter probe and check all pins i n
t h e OEM harness connector. M easu re t h e resistance .
The m u lti m eter must show an open circuit at al l pins (1 00k
ohms or more) .
+ 5 volt supply p i n , and i n sert it i nto the d i g ital vehicle
speed sensor sig nal return p i n .
Use t h e other test lead t o check a l l p i n s i n t h e con n ector.
The m u lti m eter m ust show an open circuit ( 1 00k ohms or
more) .
return pi n , and insert it i nto the d i g ital vehicle speed
sensor signal sig nal pi n .
Use t h e other test lead t o check a l l pins i n the co n n ector.
more) .
If t h e circuit i s not open i n any o f t h e checks , repair the
wi res that have the short c i rcu it accord i n g to the vehicle
man ufacturer's proced u res.
NOTE: If the val ues are correct for all of the circuit checks
i n Proced u re 0 1 9-090 , the vehicle speed sensor circuit is
good .
The problem is i n the vehicle speed sensor. Repai r or
replace the veh icle speed sensor accord i n g to the vehicle
man ufacturer's proced u res.
Vehicle Speed Sensor, Magnetic Pick

Up (019-091)
General Information
The vehicle speed sensor (VSS) senses the speed of the
output shaft of the transm issi o n . The veh icle's road speed
is com puted from this d ata by the electronic control
mod u l e (ECM). The ECM uses program med geari ng and
tire size data to com p ute the road speed .
Vehicle Speed Sensor, Magnetic Pick Up ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J
-
The veh icle speed sensor is located in the rear of the

transm ission housi n g .
T h e vehicle speed sensor has two coi ls. O n e coi l i s
con nected t o t h e E C M a n d t h e other coi l is con nected to
the vehicle speedometer, or some other vehicle d evice.
NOTE: Vehicle speed sensor design varies with the
appl i catio n . Refer to the origi nal eq u i pment man ufacturer
(O EM) troubleshooti ng and repai r man ual to understand
which type of vehicle speed sensor is being used in a
g iven locatio n .
Remove
Disco n n ect the engine harness from the vehicle speed
sensor.
Loosen the locknut. Turn the vehicle speed sensor out of
the transmission housi n g .
Inspect for Reuse

I nspect the tip of the vehicle speed sensor for d i rt, debris,
or physical damage (cracked pott i n g , and so forth).
Clean the tip if d i rty, o r replace the vehicle speed sensor
if damaged .
Install
aCAUTIONa
Make su re a gear tooth is aligned with the hole in the
housing . Install the vehicle speed sensor into the hole
until it touches the gear tooth.
NOTE: If the vehicle speed sensor does not turn i n with
finger pressure, check the transm ission hole th reads and
the sensor th reads for d i rt o r damage.
o n
1 9900799
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Vehicle Speed Sensor, Magnetic Pick U p
Turn the vehicle speed sensor out 1 /2 to 3/4 of a turn .
Tig hten the locknut agai nst the transm ission housi n g .
Torq ue t h e sensor accord i n g t o t h e OEM or transm ission
specifications. Refer to the OEM troubleshooti ng and
repai r manual for detailed proced u res.
I nstall both of the con nectors together until con nectors
"snap" i nto positi o n . The con nectors can be interchanged
with each other without chan g i n g the perfo rm ance of the
system .
Resistance Check
Lift the tab on the connectors and p u l l them apart .
NOTE: When measu ri ng the resistance val ue of the
vehicle speed sensor coi ls, use two female test leads. This
wi l l allow the electrical leads of the sensor to be softly
flexed to check for damaged o r partially b roken wire
strands under the i nsulation .
Use a m u lti meter to m easu re the resistance between the

two pins of each con nector o n the vehicle speed sensor.
Refer to the OEM trou bleshooti ng and repai r man ual for
detai led proced u res. If the resistance is not correct ,
replace the vehicle speed sensor. If the resistance val ue
is correct , the veh icle speed sensor must sti l l be checked
for a short circuit to g round and a short circuit between
coils.
Vehicle Speed Sensor, Magnetic Pick Up ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J
Page 1 9-88 Section 1 9 -Electronic Engine controls

Measure the resistance between the magnetic vehicle
speed sensor signal negative ( ) pin of one of the
-
con nectors and the engine block. Refer to the OEM

troubleshooting and repai r man ual for detai led
proced u res.
Measu re the resistance between the magnetic vehicle

speed sensor signal negative ( ) p i n of the othe r con nector
-
and the engine block. Refer to the OEM troubleshooting

and repai r man ual for detai led proced u res .
Check for a short circuit between coils

Use a m u lti meter to measure the resistance between the
m ag n etic vehicle speed sensor signal negative ( ) pin of
-
one of the con nectors and the magnetic vehicle speed

sensor signal ( ) pin of the other con n ector. Refer to the
-
OEM troubleshooti ng and repair manual for detai led

p roced u res.
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J Vehicle Speed Sensor Circuit
Vehicle Speed Sensor Circuit

(019-093)
I..,: . . '
Resistance Check
:
,....,.. . ',
ACAUTIONA
Disco n nect the original eq u i pment man ufacturer (O EM)
harness con n ector from the electronic control mod u l e
(ECM). M ake s u re the vehicle speed sensor is con nected
to the OEM harness.
I nsert a test lead i nto the mag n etic veh icle speed sensor
signal positive ( + ) pin in the OEM harness con nector.
I nsert the other l ead i nto the m ag n etic vehicle speed
sensor signal negative (-) p i n of the con nector.
Con nect the two alligator c l i ps to the two probes of the
m u ltimeter. Adj ust the m u lti m eter to the resistance setting
and measu re resistance. When m easu ri n g the resistance
with the sensor con nected , refer to the OEM
troubleshooti n g and repai r man ual for the correct
resistance val u e . If the val ue is not correct, there is a
problem with the OEM harness, provided that the veh icle
speed sensor component h as been previously checked .
NOTE: Repai r or replace the OEM harness. Refer to
Proced u re 0 1 9-07 1 , or to the O E M troubleshooting and
repai r man ual for OEM harness replacement.
If the val u e is correct , the c i rcu it must sti l l be checked for
a short c i rcuit to g rou nd and a short circuit from pin-to-pi n .

Check for a short c i rcuit to g ro u n d . I nsert the m u ltimeter I... . .. O I
.
" ., ,. " .,.
.
L
probe with attached test l ead i nto the magnetic vehicle
speed sensor signal positive ( + ) p i n of the OEM harness
con nector. Touch the other m u lti m eter probe to the engine
block. Measu re the resistance. The m u lti meter must show
an open c i rcuit ( 1 00k ohms or more) .
If the circuit is not ope n , there is a short circuit to ground
i n the vehicle speed sensor c i rcuit i n the engine harness
or OEM h arness.
Repai r the wi res which are shorted in the circuit accord i n g 1 9c01 24 1
t o the vehicle man ufacturer's proced u res .
Fuel Control Valve ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ]

Check for a short c i rcuit from p i n-to-pi n . I nsert the
m u lti meter probe with attached test lead i nto the magnetic
vehicle speed sensor signal positive ( + ) pin of the OEM
harness con n ector. I nsert the other test lead i nto all the
other pins, one at a time, to check for a short to another
pi n .
Measure the resistance. The m u lti meter must show an
open c i rcuit (more than 1 00k oh ms).
1 9c01 2 1 5
Fuel Control Valve (019-102)

Initial Check
Check the electronic fuel control actuator for an aud i b l e
click after a key-on-key-off cycle. If no audible click i s
h eard at key-off, measure the resistance of the el ectronic
fuel control actuator valve .
NOTE: The electronic fuel control (E FC) actuator can also
be checked usi ng an I N S ITE™ electronic service too l .
Refer t o t h e OEM service manual for instructions.
A WAR N I N G A
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal inju ry.
A WARN ING A
When using a steam cleaner, wear safety glasses or a
face shield , as well as protective cloth ing . H ot steam
can cause serious personal inju ry.
Steam-clean the fuel p u m p and the area around the fuel
pump.
D ry with compressed air.
Measure
Measure the resistance of the electronic fuel control
actuator valve . The max i m u m resistance is 5 ohms.
05d0022 1
ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ J • . • Fuel Control Valve
Remove
Remove the low-pressu re supply l i n es. Refer to Proced u re
006-024.
Remove the capscrews and electronic fuel control l'D

actuator.
'\l:>
05d002 1 9
I nstall
A CAUTION A
Do not pause more than two m inutes between Torque
Steps 1 and 2. This can cause the capscrews not to
maintain their torque value. Leakage or engine
damage can result.
NOTE: Lubricate the new o-ri n g with clean oil before
instal latio n .
I nstal l a n ew o-ri ng o n t h e electric fuel control actuator.
I nstall the electronic fuel control actu ator and capscrews ,
05d00222
and tighten .
Torque Value: Ste p 1 3 N-m [ 2 7 i n-Ib ]
Step2 7 N-m [ 6 2 i n-Ib ]
NOTE: Be sure that the electronic fuel control actuator
flange is flush with the mounti n g su rface o n the fuel p u m p .
NOTE: N ew capscrews must be used each time t h e
electro n i c f u e l control actuator is instal led . T h e capscrews
are coated with an encaps u l ated th read sealant that is
activated i n Step 1 of the tighte n i n g proced u re .
Rail Fuel Pressure Sensor ISB, ISBe2 , ISBe3, ISBe4 , QSB4 [ . . . J
I nstall the low-pressu re fuel su pply l i nes. Refer to

Proced u re 006-024.
Operate the engine and check for leaks or fau lt codes.

@
Rail Fuel Pressure Sensor (019-115)

General Information
T h e f u e l pressure sensor is located on the f u e l rai l
mou nted on the i n let manifold .
Remove
Clean the area around the fuel pressure sensor.
Disco n n ect the pressu re sensor con n ector from the
engine harness.
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ J • • . Rail Fuel Pressure Sensor
Remove the fuel pressure sensor.
I nspect for Reuse

I nspect the engine harness con nector and the fuel
pressure sensor for the fol lowi n g :
• C racked or b roken con n ector shell
• M issi n g o r damaged con n ector seals
• D i rt , debris, or moisture in or on the con nector pins
• Corroded , bent, b ro ken , pushed back, or expanded
pins.
I nspect the fuel pressure sensor for the followi n g :

• Damaged seal su rface i n t h e rai l
• Damaged seal su rface on the sensor
• Th read damage.
I nstall
I nstall a new f u e l pressure sensor.
Torque Value : 70 N · m [ 52 ft-Ib I
Con n ect the engine harness to the fuel pressu re sensor.
Start the engine and check for leaks.
Fuel Pump Actuator ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . ]
Fuel Pump Actuator (019-117)

I n itial Check
A WARNI NG A
When using a steam cleaner, wear safety glasses or a
face sh ield , as well as protective clothing . Hot steam
can cause serious personal inju ry.
A WARN ING A
Wear appropriate eye and face protection when using
compressed air. Flying debris and d i rt can cause
personal injury.
Steam-clean the fuel p u m p and the area around the fuel
pump.
D ry with com pressed ai r.
Remove
Re move the capscrews and fuel p u m p actuator.
1 9d02096
I nstal l
W I nstal l a new o-ri ng on the fuel p u m p actuator.
Lubricate the new o-ri ng with clean oil before instal l ati o n .
Be s u re that the f u e l p u m p actuator flange is f l u s h with t h e
mou nti ng su rface on the f u e l p u m p .
T u r n t h e f u e l pump actuator i n a clockwise d i rection wh i l e
pressing i t i nto t h e bore .
I nstal l t h e capscrews .
Torque Value: Step1

[ 27 i n-Ib 1
1 9d02097 Step2 [ 50 i n-Ib 1
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ J. . . Water in Fuel Sensor
Operate the engine and check for l eaks or fau lt codes.
Water in Fuel Sensor (019-127)

General I nformation
.
T h e water-i n-fuel sensor separator is located a t the base
of the fuel fi lter. The water-i n-fuel sensor sends a signal to
the electronic control mod u l e (ECM) when a set vol u m e of
water has accu m u l ated in the fuel filter. The water-i n-fuel
circuit contains two wires, the water-i n-fuel return wire and
(§)S
the water-i n-fuel signal wire .
1 9c01 282
Resistance Check
NOTE: The water-i n-fuel sensor is the water-i n-fuel signal EtS
wi re and the water-i n-fuel return wi re i n the engine

harness con n ector.
Disco n nect the engine harness from the EC M .
@
Check for damaged pins.
(§)S
Discon n ect the water-i n-fuel sensor from the engine
harness.
1 9c01 282
Return Wire Resistance - Checki n g
A CAUTION A
@j
To reduce the possibility of pin and connector

damage, use test lead , Part N u m ber 3822758, when
taking a measu rement.
I nsert the test lead i nto sensor return p i n (common retu rn)
of the engine harness con nector. Con nect the alligator clip
to the m u lti meter probe. Touch the other m u ltimeter probe
to water-i n-fuel return pin of the water-i n-fuel sensor,
harness side.
1 9c01 2S9
Engine Brake Harness ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
Measu re the resistance.

less) .
If more than 1 0 ohms are measu red , there is an open
ci rcuit i n the return wire . Repai r the wire , or rep lace the
engine h arness.
1 9c01 269
Sig nal Wire Resistance - Checki n g

I nsert the test lead i nto the water-i n-fue l signal p i n of the
engine h arness con nector. Con nect the alligator Clip to the
m u ltimeter probe. Touch the othe r m u ltimeter probe to the
signal wire p i n of the water-i n-fue l sensor, harness side.
less) .
If more than 1 0 ohms are measu red , there is an open
circ u it in the signal su pply wire. Repai r the wire , or replace
1 9c01 269
the e n g i n e harness.
Engine Brake Harness (019-136)

'\J3 Resistance Check
D isco n n ect the brake harness from the engine harness
and from the rocker lever housing pass-th rough
con nectors .
I nsert a test lead i nto p i n A i n the b rake h arness .

I n sert the other test lead i nto the correspon d i n g engine
pass-t h rough term i n al con n ector i n the brake harness.
Measure the resistance . The m u ltimeter must read a
1 98 0 1 4 3 1
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J I ntake Manifold Pressu re/Temperature Sensor
Remove the test lead from p i n A and i n sert it i nto pin B .

I nsert t h e other test lead i nto t h e corresponding engine
pass-throug h term i nal con nector.
Measure the resistance. The m u lti m eter must read a
If the resistance val u es are not correct , i nspect the wi res
for an open circuit.
Con n ect the b rake harness to the engine harness and the
rocker l ever housi n g pass-t h rough con nectors.
Intake Manifold Pressure/Temperature

Sensor (019-159)
Remove
apart .
Remove the sensor from the e n g i n e .

I ntake Manifold Pressure/Temperature Sensor ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ J
• . •
I nspect for Reuse

I nspect the engine harness connector and the i ntake
man ifold pressu re/temperatu re sensor for the fol l owi n g :
1. C
racked or b roken con n ector s h e l l
2. M issi ng or damaged con nector seals
3. D i rt , debris, or moisture in o r o n the connector pins
4. Corroded , bent, broke n , pushed back, or expanded
pins.
I nspect the i ntake man ifold pressu re/temperatu re sensor

for the followi n g :
1. S wollen o-ri ng
2. N icks or cuts i n or o n the o-ri n g .
I nstal l
Make sure the new sensor h as a n o-ri n g .
I nstall t h e new sensor i nto the e n g i n e . Tig hten t h e sensor.
Torque Value: 6 N-m [ 53 i n-Ib 1
Push the con nectors together until they lock. An aud i b l e

c l i c k will be heard a s t h e con nector locks i n place.
IS8, IS8e2 , IS8e3 , IS8e4, QS84 [ . . . ] Data Link Circuit, SAE J 1 939
Data Link Circuit, SAE J1939 (019-165)

General I nformation @
The OEM J 1 939 datal i n k circuit is located i n the OEM
wiring harness.
The pu rpose of this datal i n k is to al low the ECM to
com m u n i cate with the vehicle control-operated systems
such as the transm ission controllers , traction control
system , etc .
The trad itional OEM J 1 939 datal i n k c i rcuit is described as
a shielded twisted pai r and incl udes the wi res connected
to the J 1 939 datal i n k positive ( + ) p i n , the J 1 939 datal i n k
negative (-) pi n , a n d t h e J 1 939 (sh i eld) pin i n t h e O E M
harness.
On newer veh icles and eq u i p ment, O E M ' s can util ize an
OEM J 1 939 datal i n k ci rcuit that is d escribed as an
unsh ielded twisted pai r (UTP). The u ns h ielded twisted pai r
(UTP) J 1 939 datal i n k does not i nclude the J 1 939 (shield)
pin and only i ncl udes the J 1 939 d atal i n k positive ( + ) pin
and the J 1 939 datal i n k negative (-) p i n i n the OEM
harness.
The ECM will b roadcast public datal i n k m essages on the
OEM J 1 939 datal i n k when the ECM is powered and the
keyswitch is in the ON position . The ECM wi l l stop
broadcasting on the OEM datal i n k when the keyswitch is
turned to the OFF positi o n .
T h e Society o f Automotive E n g i n eers (SAE) J 1 939 has

strict guideli nes that must be fol l owed for successful
com m u n ication . U n derstan d i n g som e fundamentals
about SAE J 1 939 will help m ake s u re these guideli nes are
followed .
The main com ponent of an SAE J 1 939 system is a
backbone harness . The h arness can be up to 40 meters
[ 1 3 1 feet) i n length . The backbon e harness is term i n ated
at each end with a 1 20 o h m resistor.
A maxi m u m of t h i rty different devices can be attached to
the SAE J 1 939 backbon e at once. Each device , such as
the datal i n k adapter, is con nected to the backbone 1 9802395
through a stu b , which can be u p to 1 meter [3.3 tt) in
length . The stu b con nector is a 3-pi n p l u g .
T h e termi nating resistor caps ( 1 ) m ust be i n place on the

OEM backbone harness plugs (2) to mai ntai n proper
co m m u n icatio n . Each resistor is 1 20 ohms and can be
located in a removable cap.
NOTE: On appl ications with an Electronic VGT Actuator
one of the term i nati n g resistors is man ufact u red i nto the
Electronic VGT actuator and is non-serviceable.
1 9802397
Data Link Circuit, SAE J 1 93 9 ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . ]
Page 1 9-1 00 Section 1 9 Electronic Engine controls
-
Some OEMs wi l l choose to provid e a complete SAE J 1 939

backbone harness. If this is suppl ied , con nection to the
I N S ITE™ electronic service tool is accompl ished by a 9-p i n
datal i n k conn ector (1 ) , Part N u m ber 3 1 62848 .
NOTE: Some O E M ' s place a 9-pi n connector i n the cab ,
but d o not connect all of the pins to support J 1 939
protocol .
To check for the OEM J 1 939 backbon e , turn the keyswitch
to the OFF position . Meas u re the resistance from the SAE
J 1 939 datal i n k positive ( + ) pin to the SAE J 1 939 datal i n k
negative (-) pin o f t h e 9-p i n Deutsch™ con nector.
1 9c0 1 495 The m u ltimeter must read between 50 and 65 ohms for
the I N S ITE™ electronic service tool to be able to establ ish
com m u n ication with the ECM .
If the OEM does not supply the J 1 939 backbone harness
to the 9-p i n con nector, the only way to estab l ish J 1 939
com m u n ication with the ECM is through either the bench
com m u n ication setup or the engine com m u n ication setup.
Refer to P roced u re 022-999 .
NOTE: The typical SAE J 1 939 con n ector will be a 9-p i n
con nector.
Pin Signal
A G round
E D B U nswitched Battery
�::..-If---- C C J 1 939 datal i n k ( + )
F ��;;:.¢.lH-_- A D J 1 939 datal i n k (-)
B E J 1 939 datal i n k (sh i eld) (if
available)
F J 1 708 datal i n k ( + )
G J 1 708 datal i n k (-)
H Open
1 9400739
J Open
ISB, ISBe2, ISBe3, ISBe4, QSB4 [. ..J Data Link Circuit, SAE J1939
Resistance Check
" WARNING "

Batteries can emit explosive gases. To reduce the possibility
of personal injury, always ventilate the compartment before
servicing the batteries. To reduce the possibility of arcing,
remove the negative (-) battery cable first and attach the
negative (-) battery cable last •
.6 CAUTION .6
The leads must fit tightly in the connector without expanding
the pins in the connector otherwise the connector will be
damaged.
Disconnect the batteries.
Disconnect the OEM harness connector from the ECM. Turn the
keyswitch to the OFF pOSition.
Insert a test lead into the SAE J1939 datalink positive (+) pin of
the OEM harness connector, and connect it to the multimeter
probe. Insert the other test lead into the SAE J1939 datalink
positive (+) pin of the 9-pin Deutsch™ connector, and connect it to
the multimeter.
Measure the resistance. The multimeter must show a closed

circuit (10 ohms or less).
If the circuit is not closed, repair or replace the OEM harness.

Refer to the OEM troubleshooting and repair manual for the
procedures.
Insert the multimeter lead into the SAE J1939 datalink negative (-)
of the OEM harness connector. Touch the other lead to the SAE
J1939 datalink negative (-) pin of the 9-pin Deutsch'· connector.
Measure the resistance. The multimeter must show a closed
circuit (10 ohms or less)
If the circuit is not closed, repair or replace the OEM harness.

Refer to the OEM troubleshooting and repair manual for the
procedures.
If the values are correct, the circuit must still be checked for a short
circuit to ground and a short circuit from pin to pin.
Remove the lead from the SAE J1939 datalink negative (-) pin of
the OEM harness connector and insert it into the SAE J1939
datalink (shield) pin, if the shield pin is available.
If the J1939 datalink circuit is an unshielded twisted pair (UTP), the

shield pin will not be provided.
If the shield pin is provided, measure the resistance from the SAE
J1939 datalink (shield) pin of the OEM harness connector to the
SAE J1939 datalink (shield) pin of the 9-pin Deutsch'· connector.
The multimeter must show a closed circuit (10 ohms or less). If the
circuit is not closed, repair or replace the OEM harness. Refer to
the OEM troubleshooting and repair manual for the procedures.
If the (shield) pin is provided, measure the resistance from the SAE
J1939 datalink (shield) pin of the 9-pin Deutsch'" connector to the
engine block ground. The SAE J1939 datalink shield must be
grounded to the vehicle battery ground. The multimeter must show
a closed circuit (10 ohms or less). If the circuit is not closed, refer
to the OEM troubleshooting and repair manual for repair
instruction.
If more than 10 ohms are measured in any of these steps, there

can be an open circuit in the SAE J1939 datalink positive (+) pin,
the SAE J1939 datalink negative (-) pin, or the SAE J1939 (shield)
pin, or the polarity is not correct. There can also be an open circuit
from the datalink (shield) pin to vehicle battery ground.
If the values are correct, the SAE J1939 datalink positive ( + ) pin
and the datalink negative (-) pin must still be checked for a short
circuit to ground. The SAE J1939 datalink positive ( + ) pin, the
datalink negative (-) pin, and the datalink (shield) pin must still be
checked for a short circuit from pin to pin.
Data L i n k C i rcuit, SAE J1 939 ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ]
t . . . . . . O.L
I
. .. . .. . . ..
.6 CAUTION .6
Disconnect the OEM harness con n ector from the EC M .
I n sert a test l ead i nto the SAE J 1 939 datal i n k positive ( + )
pi n of the OEM harness con nector and con n ect it to a
m u ltimeter probe . Touch the other m u ltimeter p robe to the
engine block g rou nd .
1 9c01 270 M easu re the resistance. The m u lti meter must show an
open circ u it (1 00k ohms o r more) .
If the c i rcuit is not ope n , repai r or replace the OEM
harness. Refer to the O E M troubleshooting and repai r
manual .
Remove the test lead from the SAE J 1 939 datal i n k positive
( + ) pin and i nsert it i nto the SAE J 1 939 datal i n k negative
( ) p i n . M easu re the resistance from the SAE J 1 939
-
datal i n k negative ( ) p i n of the OEM harness connector to

-
the engine block g rou nd . The m u ltimeter must show an

open c i rc u it (1 OOk ohms or more).
If the circuit is not ope n , repair or replace the OEM
h arness. Refer to the OEM troubleshooting and repair
man ual .
.6 CAUTION .6
t ,",. . . ,.!lL I expanding the pins in the connector otherwise the
...
Disco n n ect the OEM harness connector from the EC M .

I n sert a test lead i nto the SAE J 1 939 datal i n k positive ( + )
p i n of the OEM harness con nector and con nect it to the
O.M
m u lti meter probe. I n sert the other test l ead i nto another
p i n i n the con nector of the O E M harness and con nect it to
L_ C)oo cc, •• :::::::
: 1 9c01 271 the other m u lti meter probe.
M easu re the resistance from the SAE J 1 939 datal i n k
positive ( + ) p i n t o t h e fi rst p i n i n t h e con nector. The
m u lti meter must show an open c i rc u it (1 00k ohms or
more) .
If the c i rcuit is not ope n , repair or replace the OEM
h arness. Refer to the O E M troubleshooting and repair
man ual .
IS8, IS8e2 , IS8e3, IS8e4, QS84 [ . . . J Data Link Circuit, SAE J1 939
Section 1 9 - Electronic Engine controls Page 1 9-1 03

positive ( + ) p i n o f t h e OEM harness con nector t o al l other
pins i n the con nector, one at a time. The m u lti meter
must show an open c i rcuit (1 00k ohms o r more) at all pins,
except the J 1 939 datal i n k negative ( ) . -
L, . : . :. . :··,·
. ..
If the circuit is not ope n , repair or replace the O E M

harness. Refer t o the OEM troubleshooting a n d repai r
man ual .
O·M
mA COM
1 9c01 2 1 5
@l
Remove the test l ead from the J 1 939 datal i n k positive ( + )
p i n and in sert it i nto the J 1 939 d atal i n k (sh ield) p i n of the
OEM harness con n ector, if the shield pin is avai lable
NOTE: If the J 1 939 datal i n k c i rcuit is an unshielded
twisted pai r (UTP) , the (shield) pin wi l l not be provided. If l'·
.:"""""'I'' d.fl
· .
the shield p i n is not p rovided , the datal i n k negative ( ) pin
-
must sti l l be checked for a short circuit to the other pins.

I n sert the other test lead i nto another p i n i n the con n ector.
The m u lti m eter must show an open circ u it (1 OOk ohms or O'
more) . C)oo..
w.
If the circuit is not open , repair or replace the O E M

1 9c01 271
harness. Refer t o t h e O E M troubleshooting a n d repai r

man ual .
@l
Measure the resistance from the SAE J 1 939 datal i n k
(sh ield) pi n , if avai lable, t o all other p i ns i n t h e connector,
one at a time. The m u lti m eter must show an open circuit
If the circuit is not ope n , repair or replace the OEM t.:,. .:" . ; :,
.. . .
harness. Refer to the OEM troubleshooting and repai r

man ual .
Remove the test lead from the SAE J 1 939 datal i n k (sh ield)
pin and insert it i nto the SAE J 1 939 datal i n k negative ( ) -
pin of the OEM h arness con nector. I nsert the other test
lead i nto another p i n in the connector. M easu re the
1, . . . ". . ,,!1.L ,
. .
resistance. "

more) .
If the circ u it is not open , repair or replace the OEM
harness. Refer to the OEM troubleshooti ng and repair
man ual .
Data Link Circuit, SAE J1587 ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J
Measure the resistance from the SAE J 1 939 datal i n k

negative (-) p i n o f t h e O E M h arness con nector t o a l l other
pins i n the con n ector. The m u ltimeter must show an open
ci rcuit ( 1 00k ohms or more) at all pins, except the J 1 939
d atal i n k positive ( + ) p i n .
If t h e c i rcuit is not ope n , repai r or replace t h e O E M
harness . Refer t o t h e OEM troubleshooting a n d repai r
manual .
Connect all the components after the repair is complete .
Data Li n k Circu it, SAE J 1 587 (0 1 9-1 66)

General Information
The OEM J 1 587 datal i n k circ u it is located i n the OEM

wiring h arness .
The pu rpose of this datal i n k is to al low the ECM to
com m u n icate to the vehicle control operated systems
such as the transm ission control lers, traction control
system , etc. The J 1 587 datal i n k incl udes the Society of
Automotive Engi neers (SAE J 1 587) datal i n k positive ( + )
and the SAE J 1 587 datal i n k negative (-) wi res i n the OEM
wiring h arn ess .
NOTE: Typical SAE J 1 587 connectors w i l l either be 2 or
6-p i n connectors .
6-Pin Connector
Position A Datal i n k positive ( + )
F B
Position B Datal i n k negative (-)
Position C Battery (1 2/ 24 VDC)
C
A Position 0 Open
Position E E n g i n e block ground
E---t-'(l� D Position F Not used
1 9400740
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J Data Link Circuit, SAE J1 587
Section 1 9 Electronic Engine controls

- Page 1 9-105
Resistance Check
ACAUTIONA
EE
$j 1..",,,,,,,,.,, I
Turn the keyswitch to the OFF position. D isconnect the
OEM h arness connector from the ECM .
I nsert a test lead i nto the SAE J 1 587 datal i n k positive ( + )
p i n of the O E M harness con nector and con nect to a O'M
m u lti meter probe. I nsert the other test l ead i nto the SAE 0300 ....
COM
J 1 587 datal i n k positive ( + ) p i n of the 6-pi n connector and

con n ect it to the other m u ltimeter probe. M easu re the
resistance. The m u ltimeter must show a closed circuit (1 0
ohms or l ess).
If the circ u it is not closed , repai r or replace the OEM
harness . Refer to the O E M troubleshooti ng and repai r
man u al .
( + ) p i n and i nsert it i nto the SAE J 1 587 datal i n k negative
( ) p i n . Remove the other test lead from the SAE J 1 587
-
datal i n k positive ( + ) p i n and i nsert it i nto the SAE J 1 587

datal i n k negative ( ) p i n of the 6-pi n con nector. M easu re
-
the resistance. The m u ltimeter must show a closed ci rcuit

If the circuit is not closed , repair or replace the OEM
harness . Refer to the O E M troub leshooting and repai r
manual .
$j
Remove the test l ead from the SAE J 1 587 datal i n k
negative ( ) p i n and i n sert it i nto the battery negative (-) p i n
-
o f the 6-pi n Deutsch con n ector. Remove the test lead from
the SAE J 1 587 datal i n k negative ( ) pin and d iscon nect it
-
from the m u lti meter p robe. Touch the m u lti meter probe to t'�I1."""';i;"
the engine block g ro u n d . M easu re the resistance . The
m u lti meter must show a closed c i rcuit (1 0 ohms or less) .
If the circu it is not closed , repair or replace the OEM
manual .
O'M
1 9c0 1 1 90
Data L i n k Circuit, SAE J1 587 ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . ]
Page 19-1 06 Section 1 9 Electronic Engine controls
-
j\WARNINGj\
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To
reduce the possibility of arcing, remove the negative
( ) battery cable first and attach the negative ( ) battery
- -
cable last.
CAUTION
Disco n n ect the batteries .
M easur e the resistanc e from the positive ( + ) battery
term i nal to battery positive ( + ) of the 6-pi n Deutsch
con n ector. The m u lti meter must show a closed circuit (1 0
ohms or less) .
If the circuit is not closed , repai r or replace the OEM
battery su pply circuit. Refer to the OEM troubleshooting
and repai r man ual for the p roced u res.
If the val ues are correct, the circuit must sti l l be checked
for a short circ u it to g rou nd and a short circu it from p i n to
pin.
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J Data L i n k Circuit, SAE J1 587
"WARNING"
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To
reduce the possibility of arcing, remove the negative
( ) battery cable first and attach the negative ( ) battery
- -
cable last.
ACAUTIONA
Disconnect the batteries.
Disco n nect the OEM harness connector from th e ECM .
Insert a test lead i nto the SAE J 1 587 datal i n k positive ( + )
p i n of the 6-pi n connector and connect it to a m u lti m eter
probe . Touch the other m u lti m eter probe to the engine
block g rou n d . M easu re the resistance . The m u ltimeter
must show an open c i rcuit (1 00k ohms or more) .
If the circ u it is not ope n , repair or replace the OEM
harness . Refer to the OEM tro u bleshooting and repai r
manual .
( + ) pin and i nsert it i nto the SAE J 1 587 datal i n k negative
(-) pin of the 6-pi n connector. Touch the other m u lti meter
probe to the engine block g ro u n d . M easu re the resistance
from the SAE J 1 587 d atal i n k negative ( ) p i n of the 6-p i n
-
con n ector t o the engine b l o c k g ro u n d . T h e m u lti meter

must show an open c i rcuit (1 00k ohms or more) .
If the circ u it is not ope n , repai r or replace the OEM
manual .
Data L i n k Ci rcuit, SAE J1 587 ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J
Page 1 9- 1 08 Section 1 9 Electronic Engine controls
ACAUTIONA
Disconnect the OEM harness con nector from the ECM .
p i n of the O E M harness connector and con nect it to the
m u lt i m eter probe. I nsert the other test lead i nto another
pin in the OEM harness and con nect it to the other
1 9c0 1 1 94 m u lti m eter probe. Measure the resistance. The m u lti meter
must show an open ci rcuit (1 00k ohms or more) .
If the c i rc u it is not ope n , repair or replace the OEM
h arness. Refer to the OEM troubleshooting and repai r
manual .
positive ( + ) p i n o f t h e O E M h arness con nector t o al l other
pins i n the con n ector, one at a time. The m u ltimeter
must show an open circuit (1 00k ohms or more) .
If the c i rcuit is not ope n , repai r or replace the OEM
harness. Refer to the OEM troubleshooting and repair
man ual .
( + ) p i n of the OEM harness con nector and i nsert it i nto
the SAE J 1 587 datal i n k negative ( ) p i n . M easu re the
-
resistance from the SAE J 1 587 datal i n k negative ( ) p i n to

-
all other p i ns in the connector. The m u lti meter must show

an open circuit (1 00k ohms or more) at all pins.
I f the c i rcuit is not ope n , repai r or replace the OEM
h arness. Refer to the OEM troubleshooting and repai r
manual .
Connect all components after repai rs are completed .
Voltage Check
Locate the datal i n k con nector on the OEM harness. The

location wi l l depend on the O E M .
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Exh aust Brake ON/OFF Switch
ACAUTIONA
Turn the keyswitch to the O N position . Adj ust the
m u lti meter to measure VDC.
p i n of the 6-pi n con necto r and connect it to a m u ltimeter
probe . Touch the other m u lti m eter probe to the engine
block g ro u n d . Meas u re the voltage.
The m u lti m eter must read 3 . 5 to 5 VDC for the voltage
check from the SAE J 1 587 datal i n k positive ( + ) p i n of the
datal i n k connecto r to g rou n d .
Remove t h e test l ead from t h e SAE J 1 587 d atal i n k positive
( + ) p i n and insert it i nto the SAE J 1 587 datal i n k negative
(-) pin of the 6-pi n Deutsch con nector. Touch the other
m u lti meter probe to the engine block ground. M easu re the
voltage.
The m u ltimeter must read 0 to 2.5 VDC for the voltage
check from the SAE J 1 587 d atal i n k negative (-) p i n of the
datal i n k con nector to g rou n d .
Remove t h e test l ead from t h e SAE J 1 587 datal i n k
negative (-) p i n a n d i nsert it i nto battery positive ( + ) p i n of
the 6-pi n con n ector. Touch the other m u lti meter probe to
the engine block g ro u n d . M easu re the voltage.
The m u ltimeter must read battery voltage for the voltage
check from p i n C of the datal i n k connecto r to g rou n d .
Remove the test l ead from the battery positive ( + ) p i n and
i nsert it i nto the battery negative ( ) pin of the 6-p i n
-
connector. Touch the other m u ltimeter p robe t o the e n g i n e

b l o c k g round. M easu re the voltage.
The m u ltimeter must read 0 voltage for the voltage check
from the battery negative (-) pin of the datal i n k con nector
to g rou nd .
Exhaust Brake ON/OFF Switch

(0 1 9- 1 93) EXHAUST BRAKE
General Information ON
The exhaust b rake on/ off switch c i rcuit signals the system
that the operator is req uesti ng the exhaust brake system . '' ' C '
U
to be activated .
. .
OFF
1 9900525
Exh aust Brake ON/OFF Switch ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ]
Page 1 9- 1 1 0 Section 1 9 Electronic Engine controls
-
After the ECM receives the signal from the exhaust brake
on/ off switc h , the ECM wi l l supply 1 2 VDC to the exhaust
EXHAUST BRAKE brake signal p i n i n the engine harness , provided the
ON engine speed is not below 1 000 rpm and the d river is
not i n cru ise control or depressing the accelerator or
cl utch pedals.
OFF
1 9900525
Resistance Check
If I N SITE™ electronic service tool is avai lable, mon itor the

exhaust brake select switch for p roper operation . If not,
follow the troubleshooting proced u res i n this sectio n .
Label t h e wi res with t h e location on t h e switch or t h e wire
n u m ber. Remove the electrical connectors from the
switc h .
1 9803969
(!j
Touch one m u lti meter probe to the center terminal of the
Set the m u lti meter t o measu re resistance.
I switc h . Touch the other m u ltimeter probe to the bottom
o"'-
" ,, ......,,
"
ter m i nal of the switc h .
,- '" ,.)))
©'"
©J>oo", 00'
19900590
{!j
Set the switch t o t h e OFF position.

The m u lti m eter must show an open circuit (1 Oa k ohms or
I", I.. j ........ ..
more) .
'"
If the circuit is not ope n , the switch has fai l ed . Replace
,_ '" *"'11
"-,- the switc h .
Refer t o t h e OEM repai r manual fo r replacement
i nstructions.
©,-
©J>oo- 00.
1 OOk Ohms or M ore

19900591
IS8, IS8e2 , IS8e3, IS8e4, QS84 [ . . . J Exh aust 8rake ON/OFF Switch Circuit
Section 1 9 - Electronic Engine controls Page 1 9-1 1 1
Set the switch to the ON position . ON

10 Ohms or Less
must
{kt
The m u ltimeter show a closed circuit (1 0 ohms or
less) .
OFF
If the circuit is not closed , the switch has fai led . Replace
the switch .
Refer to the O E M troubleshooting and repai r manual for
replacement i nstructions.
Check for Short Circuit to Ground 1 OOk Ohms or M ore
Touch one of the m u lti meter p robes to one of the switch

term i nals. Touch the other probe to chassis g rou n d . Move
the switch to the ON position , and m easu re the resistance .
I....
",,""'"

more) .
If the circ u it is not open , the switch h as fai led . Replace
the switc h . Refer to the O E M troubleshooti ng and repai r
manual for replacement i nstructions.
If the switch passes all of the previous checks, the circuit Chassis Ground
must be checked for open c i rcu its , short circu its to
19900592
g rou n d , short circu its from p i n to p i n , and short circu its to

an external voltage sou rce.
Exhaust Brake ON/OFF Switch C i rcu it

(0 1 9- 1 94)
Resistance Check
ACAUTIONA
exhaust b rake switch c i rc u it for p roper operatio n .
If not, follow t h e troubleshooti ng p roced u res i n this
sectio n .
Discon nect t h e O E M harness from the E C M connector.

Insert the appropriate test lead i nto exhaust brake ONI
OFF switch i n put pin of the OEM h arness con n ector.
Insert the other appropriate test lead i nto switch return pin
of the con n ector.
000..... COM
1 9c0 1 1 94
Exh aust Brake O N/OFF Switch Circuit ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ ... J
Page 1 9- 1 1 2 Section 1 9 - Electronic Engine controls
Set the exhaust brake switch to the ON position .

The m u lti meter must show a closed circ u it (1 0 ohms or
less) .
Set the exhaust brake switch to the OFF position .
The m u lti meter must show an open circuit (1 00k ohms or
more) .
If the resistance val ues are not correct , m ake sure

exhaust brake ON/OFF switch i n put p i n and the battery
positive ( + ) bus to switch return p i n are properly i nstal l ed
on the switc h .
If both wi res are correctly i nstal l ed , inspect exhaust brake
O N/ O F F switch i n put p i n and the battery positive ( + ) bus
to switch return p i n for open circu its to grou nd and short
c i rcu its to other pins, provided the switch has been
previously checked .
If the resistance val ues are correct i n the previous checks,
exhaust brake ON/OFF switch i n put pin and switch return
p i n must sti l l be checked for short circu its to ground and
short circu its from pin-to-pi n .
CRUISE CONTROL EXHAUST REMOTE DIAGNOSllC

SET' BRAKE PTO SWITCH
t ! it it
it
To isolate the exhaust brake c i rcuit when checki ng for an
el ectrical short , turn all cab switches to the OFF or
OFF ACCEL OFF OFF OFF N E UTRAL positio n .
1 9d01 783

engine brake ON/OFF switch ci rcu it for proper operatio n .
If not, follow t h e troubleshooting p roced u res i n this
section .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J Exh aust Brake O N/OFF Switch Circuit
Section 1 9 - Electronic Engine controls Page 1 9- 1 1 3
Disconnect the OEM harness from the ECM connector.

Insert the appropriate test lead i nto exhaust brake ONI
OFF switch i n put pin of the O E M harness connector.
Touch the other m u lti meter probe to engine block g rou n d .
more) .
If the resistance val ue is not correct , there is a short ci rcuit
to g rou nd i n the harness.
Repair or replace the OEM harness. Refer to Proced u re
0 1 9-071 .
Touch one m u ltimeter p robe to the e n g i n e block. I nsert the

other m u lti meter probe with attach ed appropriate test lead
i nto switch return p i n of the O E M h arness con nector.
The multimeter must show an open circuit (1 OOk ohms or
more).
If the resistance val ue is not correct, there is a short ci rcuit
to grou nd i n the h arness. Repai r or replace the OEM
harness. Refer to P roced u re 0 1 9-071 .
If the resistance val u e is correct i n the previous checks,
the exhaust brake O NIOFF switch i n put pin must sti l l be
checked for short circu its from p i n-to-pi n .
Isolate the switch c i rc u it as i n the p revious sectio n .

Insert t h e appropriate test lead i nto exhaust brake ONI
OFF switch i n put pin of the O E M h arness con n ector.
I n sert the other appropriate test l ead i nto p i n 1 of the
connector. Connect the alligator c l i ps to the m u lti meter
probes. M easu re the resistance .
The m u lt i m eter must show an open circuit (1 00k ohms or
more) .
C)sm..... COM
Rem ove the l ead and check all other pins.
more) .
If the circuit is not ope n , there is a short circuit between I.." :,. . , ".
·1
....
the wire connected to exhaust brake ONIOFF switch i n put
pin and any pin that measu red l ess than 1 00k ohms.
Repair or replace the OEM harness. Refer to (Proced u re
0 1 9-071 ) .
1 9c01 2 1 5
Ring Termi nal ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . ]
Page 1 9-1 1 4 Section 1 9 - Electronic Engine controls
I nsert the test lead i nto switch return pin of the OEM
harness con nector. Check al l pins of the harness
con n ector. M easure the resistance.
T he m u lti meter must show an open circuit (1 00k ohms or
more) at all pins.
If the c i rcuit is not ope n , there is a short c i rcuit to grou nd
i n the positive switch supply bus, provided the switch h as
been previously checked .
Repai r or replace the wiring con nected to switch return p i n
i n the OEM harness. Refe r t o Proced u re 0 1 9-07 1 .
Ri ng Term i nal (0 1 9- 1 97)

Connector Replacement
Term i nals are used on the engine harness for various

con nections including g rounds and fuel sh utoff valve
supply.
Use wire cri m p too l , Part N u m ber 3822930 , to cut and

remove the ri ng term inal con nector as shown .
U se wire cri m p tool , Part N u mber 3822930 , to remove 6

m m [ 1 1 4 in) of i nsulation from the harness wire.
ee8cos42
15 8, IS8e2, IS8e3 , IS8e4, QS84 [.. . J Fuse, Harness I n- L i ne
I nstal l the proper-size ring term i nal on the bare wire. The
ring term i nals that are incl uded in the wiring repai r kit, Part
N u m ber 3 1 64572, are as follows:
Ring Term i n al S ize Part N o .
No. 1 0 3823760
112 inch 382376 1
ACAUTIONA
Only use wire crimping pliers, Part Number 3822930,
when repairing electrical terminals.
Cri m p the repair wi re on the bare w i re .
U s e a heat g u n , Part N u m ber 3822860 , o r o p e n flame to
heat the s h ri n k tubing. The tubing wi l l shri n k and make the
con n ection waterproof.
Fuse, Harness In-Li ne (0 1 9- 1 98)

Inspect
Remove the fuse p rotective covers from the fuse(s) that

are being checked . Check to m ake sure the fuse is
i nstal led i n the fuse holder correctly.
There is one 30 amp fuse in the ECM battery supply
positive ( + ) l i nes.
There is also a 5 amp fuse in the keyswitch i g n ition l i n e .
19400445
If t h e fuse is i nstalled correctly, check f o r a blown fuse.

Remove the fuse(s) to be checked .
Touch each one of the m u ltimeter leads to each fuse
term i n al . M easu re the resistance .
The m u lti meter must show less than 1 0 ohms, which is a
closed circuit. If the c i rcuit is closed then put the fuse back
i nto the holder and connect the fuse cover.
0- 10 Ohms
19400446
Connector, Butt Splice ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J
Page 1 9-1 1 6 Section 1 9 Electronic Engine controls
@ Con nector, Butt Spl ice (0 1 9- 1 99)

.. General Information
C?
i IT: ' ; I
B utt splice connectors are used when repai ring harnesses
or damaged wi res .
..
@=o I :
Only use the butt splices that are suppl ied with the wiring
i :: I repai r kit, Part N u mber 3 1 64572 , when repai rs are
necessary.
---
ee8cohg
B utt spl ices are designed to p rovide the best possible cold
j o i nt con nection when properly crim ped .
Use wire cri mp too l , Part N u m ber 3822930, suppl ied with
the electrical wiring repai r kit.
ea8cohh
B utt splices also provide protection agai nst corrosio n .

After cri m p i n g t h e con n ection , heat t h e shri n k t u b e with
the h eat g u n , Part N u m ber 3822860, or an open flame,
u ntil the shrink tube has sealed the j oint.
aa800hi
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ J . . • W eather Pak Connector Series
Section 1 9 - Electronic Engine controls Page 1 9- 1 1 7
Weather Pak Con n ector Series

(0 1 9-20 1 )
Pin Replacement
This connector is used to con nect m any d ifferent

com ponents to the e n g i n e , o r other d evices. The
con nector can have many d ifferent pin confi g u rations. All
types of con nectors are repai red in the same manner. The
two-way con nector is d isplayed in this p roced u re .
Before i n stal l i ng the n ew repai r w i re , perform a test f i t to
make sure the w i re is the correct size.
19400412
Refer to the appropriate wiring repai r kit i n the service
tools tabl e in the front of Section 1 9 for the correct repai r
wire . Replace one contact wire at a time. If more than one
wire n eeds replaced , attach a lettered tag to each wire
removed .
Refer to the wiring d i ag ram i n Section E for p i n locations.
&
To replace the Weather-Pack term i nal (1 ) , pull the locki ng
tabs (3) apart on the wi re lock (4) .
\l:>':!)
ee8coge
NOTE: The wi re is held i n the con n ector body by the wire

&
lock (1 ) and two locki ng l ances (2) on the term i nal .
\l:>':!)
Open the wire lock.
Weather Pak Connector Series ISB, ISBe2 , ISBe3 , ISBe4 , QSB4 [ . . . J
Page 1 9- 1 1 8 Section 1 9 - Electronic Engine controls
ACAUTIONA
W This tool can be easily broken. Care must be taken
when using this tool. Do not force the tool into place.
I nsert the Weather-Pack extraction too l , Part N u m ber
3822608 , over the term i nal . Use a twisting motion to push
the tool to the bottom of the cavity.
ee8comg
EtS
fJ
ACAUTIONA
10 If more than one wire is being repaired, tag each wire
,,""'"
and install it in the original location. Electrical
problems can occur if wires are switched.
!
P u l l the wire and the term i nal out of the con nector body.
/
NOTE: The repair w i re and the term i n al is 1 27 m m [5 i n ]
long .
Use cri m p i n g too l , Part N u mber 3822930 , to cut 1 27 m m
[ 5 i n ] o f t h e termi nal wire.
eeScomt
EtS
Use wi re cri m pi n g tool , Part N u mber 3822930 , to re move
approximately 6 mm [V4 i n ] of insulation from the wi re.
ee8cos40
NOTE: The shroud con nector bodies (1 ) use p i n term i nals

(2) . The tower con necto r bod ies (3) use socket term i nals
(4) .
Before i nstal l i ng the new repai r wire, perform a test fit to
m ake sure the w i re is the correct size.
tools table in the front of Section 1 9 for the correct repair
wi re. Replace one contact wire at a time. If more than one
wi re needs to be replaced , attach a lettered tag to each
wi re removed .
ee8cos41
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ J . . • W eather Pak Connector Series
I nstall the correct repai r w i re on the bare wire.

Make sure that the bare w i re extends i nto the insulated
butt splice con nector.
ee8cohw
Use w i re cri m pi n g too l , Part N u mber 3822930 , to crimp

the repai r wi re on the bare w i re .
U s e heat g u n , Part N u m ber 382286 0 , t o heat t h e shrink

tubi ng. The tubing w i l l s h ri n k and make the con nection
waterproof.
.dCAUTION.d
If more than one wire is repaired or if the connector
body is replaced, make sure to insert the wires into
the same locations as they were in. Electrical
I n sert the term inal i nto the conn ector body. The term i nal
locki ng lances must click and hold the term inal in the
body.
ee8cohk
Weather Pak Connector Series ISB, ISBe2 , ISBe3 , ISBe4 , QSB4 [ . . . ]
Page 1 9-1 20 Section 1 9 - Electronic Engine controls
Close and latch the wire on the con nector body.
I n sert the two con nector h alves together.
eeBcohm
The connector is used to connect many d ifferent

com ponents to the eng i n e , or other devices. The
co n nector can h ave many d ifferent p i n config u rations. All
types of con nectors are repai red i n the same manner. The
two-way con nector is d isplayed in this proced u re .
Before i n stal l i ng t h e new con n ector, perform a test fit to
make sure the con nector is keyed correctly.
Refer to the appropriate wiring repair kit i n the service
tools tab le in the front of Section 1 9 for the correct repair
19400412
con nector.
Refe r to the wiring d iagram i n Section E for pin locations.
Replace one contact wire at a time. If more than one wire
needs to be replaced , attach a lettered tag to each wire
removed .
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . . . W eather Pak Con nector Series
&--i'
To replace the Weather- Pack connector body (2) , p u l l the
locki ng tabs (3) apart on the w i re lock (4) .
\D'-:!J
ee8coge
&--i'
The wire is head i n the con nector body by the w i re lock (1 )
and two locki ng lances (2) on the term i n al .
\D'-:!J
Open the wire lock.
ACAUTIONA
This tool can be easily broken. Care must be taken
when using this tool. Do not force the tool into place.
I n sert Weather- Pack extraction too l , Part N u mber
3822608, over the term i n al . Use a twisting motion to push
the tool to the bottom of the cavity.
P u l l the wire and the termi nal out of the connector body.
Weather Pak Connector Series ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
Before instal l i ng the new connector , perform a test fit to

m ake sure the con nector is keyed correctly.
Refer to the appropriate wiring repair kit in the service
con nector.
needs replaced , attached a l ette red tag to each wire
removed .
19400406
.6.CAUTION.6.
W If more that one wire is repaired or if the connector
body is replaced, make sure to insert the wires into
the same locations as they were in. Electrical
I nsert the term inal i nto the con n ector body. The term i n al
locki ng lances must click and hold the term inal i n the
body.
ee8cohk
Close and latch the wi re lock on the connector body.

W
I nsert the two connector halves together.
ee8cohm
ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ J • • • Metripack Con nector Series
Metri pack Connector Series (0 1 9-202)

Pin Replacement
The con nector can h ave m u ltiple p i n confi g u rations. All

types of connectors are repai red i n the same manner.
The con nector p i ns can not be rep a i red or replaced . The

connecto r must be replaced as a u n it.
Refer to the con nect o r replacement p roced u re for
replacement i n structions.
The con nector can have m u ltiple p i n configu rations. All

types of connectors are repai red i n the same manner.
1 9d0 1 80 1
The con nectors have different keying and can not be

i nterchanged with each other.
\:::/
Before i n stal l i ng the new con nector, perform a test fit to
tools table in the front of Section 1 9 for the correct repai r
connector.
needs replaced , attach a l ettered tag to each wire
removed .
Metripack Connector Series ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J
M easu re 1 52 mm [6 i n ] back from the face of the

con nector, and remove the wiring h arness protective
cover.
·ee8coa09
Before cutting the wires, measure and tag the wires .

Use w i re cutters to cut wi re A 1 1 7 m m [4-V2 i n] from the
face of the connector.
Use w i re cutters to cut wi re B 1 04 m m [4 in] from the face
[J lJ1Inm
�--104 mm [4In.J
[31/2 . n'J .
. .. . .
of the con n ector.
Use w i re cutters to cut wi re C 9 1 m m [3-V2 i n ] from the
face of the con nector.
[4 1 12 I n . J
.
t-.---117 m
19400415
Use cri m pi n g tool , Part N u m ber 3822930 , to remove 6 mm

[ % in] of insulation from all electrical wires.
Before instal l i ng the new connector , perform a test fit to
m ake sure the connector is keyed correctly.
Refer to the appropriate wiri ng repai r kit i n the service
con nector.
Refer to Section E for pin locations.
Replace one contact at a time. If more than one wi re needs
repl aced , attach a lettered tag to each wi re removed .
19400416
I nstall the term i nal repai r w i res on the bare wi res and use
wire cri m pi n g too l , Part N u m ber 3822930 , to cri m p the
term i nals.
Use heat g u n , Part N u mber 3822860, to heat the shrink
tu b i n g . The tubing wi l l shrink and make the con n ection
waterproof.
ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J AMP Connector Series
Wrap the wi res with tape , for added protection to complete

the repai r .
eeBcoa12
AM P Connector Series (0 1 9-203)

Pin Replacement
ACAUTIONA
Use care in handling the AMP connectors. They are
very fragile and easily damaged. Follow the steps
outlined in this procedure to avoid damage.
Check to be sure the con nector wedge lock is in the open
position .
NOTE: The con nector assembly is shi pped i n one piece, 3
2
with the wedge lock in the open positio n . It is possible that 19900336
d u ri n g adverse s h i p p i n g conditions that some wedge
locks can get bum ped i nto the closed positio n .
If t h e wed ge lock is closed , perform t h e fol l owi n g :

Insert screwd river b l ade (fl at) betwee n the matting seal
and one of the red wedge lock tabs.
Depress the lock tabs (Item 3 i n the fig u re i n the previous
step) .
Pry open the wedge lock to the open position.
NOTE: The wedge lock must not be removed from the
housing for i nsertion or removal of the contacts .
19900337
Remove the d amaged contacts , rotate the contact wire {'S;?

back and forth over a half turn (V4 turn i n each d i rection).
Gently p u l l the w i re until the contact is removed .
r;;:[:;>'<rJ
tools table i n the front of Section 1 9 for the correct repai r
w i re .
NOTE: Replace one contact wire a t a ti me . If more than
one wire needs replaced , attach a l ettered tag to each wire
removed .
19900338
AMP Connector Series ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J
Page 1 9- 1 26 Section 1 9 - Electronic Engine controls
Before instal l i ng the new repai r wire , perform a test fit to

make su re the wire is the correct size.
I n stal l a new wire and contact .
I nsert w i re straight i nto the appropriate circuit cavity.
B I n sert the wi re u nti l the p i n bottoms out.
P u l l back gently to be s u re the retention fingers are
hold i n g the contact.
c
II S
After all of the req u i red contacts h ave been replaced , the
wedge lock must be closed to its LOCK E D position .
Release t h e locki ng latches b y sq ueezi ng them i nward .
19900340
Slide the wedge lock i nto the housing u nti l it is flush with
the housi ng.
19900341
ACAUTIONA
Use care in handling the AMP connectors. They are
very fragile and easily damaged. Follow the steps
outlined in this procedure to avoid damage.
NOTE: The con n ector assembly is shi pped i n one piece,
with the wedge lock i n the open pOSitio n . It is possible that
d u ri n g adverse shipping conditions that some wedge
locks can get bumped i nto the closed pOSitio n .
2
3 Check t o b e sure t h e con nector wedge lock is i n t h e open
19900336 position .
ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J AMP Connector Series
NOTE: The wedge lock must not be removed from the
housing for i nsertion or removal of the contacts.
If the wed ge lock is closed , perform the fol lowi n g :
Insert screwd river blade (flat) between the matting seal
and one of the red wedge lock tabs .
Depress the lock tabs (Item 3 i n the fig u re i n the previous
step) .
P ry open the wedge lock to the open positio n .
19900337
Replace one contact wi re a t a time . Attach a lettered tag l"DA1

to each w i re removed .
'\b
Before i nstal l i ng the new con nector, perform a test fit to
Remove al l of the contacts . Rotate the contact wi res back
and forth over a half turn (% turn in each d i rection). Gently
p u l l the w i re until the contact is removed .
con n ector.
Refer to the wiring d i ag ram i n Section E for p i n locations. 19900338
I nstall a new wire and contact by:
Insert wire straight i nto the appropriate c i rcu it cavity.
Insert the wire until the p i n bottoms out.
Pull back gently to be s u re the retention fingers are
hold i ng the contact .
After al l of the req u i red contacts have been replaced , the

wedge lock must be closed to its LOCK ED positio n .
Release t h e locki ng latches b y sq ueezi ng them i nward .
19900340
Deutsch DRC Connector Series ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J
S l i d e the wedge lock i nto the housing u ntil it is flush with

the hous i n g .
19900341
Deutsch DRC Con nector Series

(0 1 9-204)
Pin Replacement
The Deutsch con nector is used to attach the appropriate

harness to the ECM .
Replace one contact wire at a time. I f more than one wi re

needs rep laced , attach a lettered tag to each wi re
removed.
Refer to the wiring d i ag ram in Section E for p i n locations.
Use the Deutsch extraction too l , listed i n the table below,
to remove a pin from the con nector.
Tool Part Number Wire Size

38248 1 5 20 gauge
3822760 1 6 gauge
38248 1 6 1 2 gauge
19400374
r6"]r;... Push the tool i nto the con nector approximately 25 m m [ 1

i n ] u ntil it bottoms on the term inal flange.
19400375
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J Deutsch DRC Connector Series
Section 1 9 - Electronic Engine controls Page 1 9- 1 29
Hold the tool on the term i nal flange and p u l l the wire and
l'D
connecting p i n out of the con nector. N ote and record the
hole from which the p i n is removed .
'Cl:>
19400376
NOTE: The repai r w i re is 1 27 m m [5 i n ] long.

Use wire crimping tool , Part N u m ber 3822930, to cut 1 27
m m [5 i n ] off the w i re and p i n .
U se t h e crimping tool t o remove 6 m m [1f4 i n ] o f i nsulation 127m",
from the wire. [5 In.]
cel37

wire .
I nstall the correct repai r wi re on the bare w i r e , make sure
that the bare wi re extends i nto the spl ice con nector.
ee8coaj
Use the w i re cri m p i n g tool to cri m p the repai r wi re onto the

bare wire.
Deutsch DRC Connector Series ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . ]
Use heat g u n , Part N u m ber 3822860 , or an open flame to

heat the shri n k tubing aro u n d the wi re. The tubing wi l l
shri n k a n d make t h e connector waterproof.
I nsert the p i n i nto the correct hole of the connector.

@! The p i n must click i nto place and hold the wire i n the
con nector.
P u l l the w i re gently to m ake sure it is seated i n the
con nector.
19400377
ACAUTIONA
Use only Cummins recommended lubricant DS-ES,
Part Number 3822934. Other lubricants, such as
lubricating oil or grease, in the connectors can cause
ECM damage, poor engine performance, or premature
connector pin wear.
Apply a small amou nt of l u b ricant to the co n nector
term i nals. Do not fi l l the enti re con nector cavity with the
lubricant.
The Deutsch con nector is used to attach the appropriate

harn ess to the ECM.
ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ J . . . Deutsch DRC Connector Series
Use the Deutsch extraction too l , listed i n the table below, &./.1
to remove a pin from the con nector.
\l:>'.:fJ
38248 1 5 20 gauge
3822760 1 6 gauge
38248 1 6 1 2 gauge
Repla ce one wi re at a ti me . Attach a lettered tag to each

wi re removed .
Refer to the wiring d i agram i n Section E for p i n locations.
19400374
&./.1
Push the tool i nto the con nector approximately 25 m m [1
i n ] until it bottoms o n the term i nal flange.
\l:>'.:fJ
19400375
&
the connecting p i n out of the con nector. N ote and record
the hole from which the p i n is removed .
\l:>'.:fJ
19400376
Before instal l i ng the new con n ector, perform a test fit to

con n ector.
Deutsch DT Con nector Series ISB, ISBe2 , ISBe3 , ISBe4 , QSB4 [ . . . J
I n sert the pins i nto the correct holes of the replacement

con nector.
Each pin must click i nto place and hold the wi res in the
con nector.
P u l l each w i re gently to make sure it is seate d in the
con nector.
19400377
ACAUTIONA
Use only Cummins lubricant DS-ES, Part Number
3822934. Other lubricants such as lubricating oil or
grease, in the connectors can cause ECM damage,
poor engine performance or premature connector pin
wear.
Apply a small amount of l u b ricant to the con nector
term i nals. Do not fi l l the enti re con nector cavity with
l u b ricant.
Deutsch DT Con nector Series

(01 9-205)
Pin Replacement
The con nector can have m u ltiple p i n configu rations. All

type of con nectors are repai red i n the same manner.
Replace one contact wire at a time. If more than one w i re
n eeds replaced , attach a lettered tag to each w i re
remove d .
Refer t o the w i r i n g d i ag ram i n Section E for p i n locations.
To replace the p i n i n the receptacle connector, remove the

orange wedge using need le nose pl iers or a hook-shaped
w i re to p u l l the wed ge straight out.
1 9d00473
ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J Deutsch DT Con nector Series
Section 1 9 - Electronic Engine controls Page 1 9·1 33
CAUTION
Locking finger can be easily broken. Care must be
taken when using this tool. Do not force the tool into
place.
To remove the contact out of the connector body, gently
p u l l wire backward , while at the same time releasing the
locki ng finger by movi ng it away from the contact with a
screwd river.
1 9d00474
CAUTION
If more than one wire is being repaired, tag each wire
and install it in the original location. Electrical damage
can occur if wire is installed in the incorrect location.
P u l l the w i re and the term i nal out of the con nector body.
Refer to the appropriate wiring repai r kit in the service

tools tabl e i n the front of Section 1 9 for the correct repai r
wi re.
Replace one contact wi re at a t i m e . If more than one wi re
removed .
Before i n stal l i ng the new repai r wire, perform a test fit to
Use wire c ri m p i ng tool , Part N u mber 3822930 , to cut 1 27
m m [5 i n ] off the wire and p i n .
U s e wire c ri m pi n g tool , Part N u m ber 3822930 , t o remove
6 mm [% i n ] of i nsulation from the wire.
I nstal l the correct repai r wi re on the bare w i re .

Make sure t h e bare wire extends i nto t h e splice connector.
ee8coaj
Deutsch DT Connector Series ISB, ISBe2 , ISBe3 , ISBe4 , QSB4 [ . . . J
Use wi re cri m ping too l , Part N u mber 3822930 , to cri m p

t h e repai r wire onto t h e bare wire.
Use heat g u n , Part N u mber 3822860 , to heat shri n k the

tubing around the w i re .
The tubing will shri n k and m ake the con n ectio n
waterproof.
ACAUTIONA
body is replaced, make sure to insert wires into the
same locations as they are in the original connector.
If wires are not in the original location electrical
damage can occur.
Replace the con n ector and i nstall the wi re and term i nal
i nto the connector body. Push the wire and term in al i nto
the seal at the back of the con n ector. Push the wi res
straight in until a click is felt. A slight tug will confi rm that
it is properly locked i n place.
(8[;) Once the wi res are i n place, i nsert the orange wedge with
arrow pOinting toward the exterior locking mechan i s m .
Push the orange wedge i n unti l it snaps i n place.
M ake sure both seals are in place and the back of the
con nector plug and receptacle. Be sure the rubber seal
h as been installed on the con nector p l u g .
1 9d00480
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . J Deutsch DT Con nector Series
Push the con nector plug i nto the connector receptacle

u ntil the external l ocki ng cl i p snaps i nto place .
1 9803641
The con n ector can have m u ltiple p i n confi g u rations. All

types of con nectors are repai red i n the same manner.
Before i n stal l i ng the new con nector perform a test fit to
connector.
&
To replace the pin i n the plug con n ector, g rasp the orange
wedge and p u l l the wedge straight out.
'Cl>
1 9d00473
.6.CAUTION.6.
Locking finger can be easily broken. Care must be
taken when using this tool. Do not force the tool into
place.
To remove the contact out of the con n ector body, gently
p u l l wi re backward , while at the same time releasing the
locki ng finger by movi ng it away from the contact with a
screwd river.
1 9d00474
Deutsch DTM and DTP Connector Series ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
CAUTION
body is replaced, be sure to insert the wires into the
same location as they were in the original connector.
@ If wires are not in the original location electrical
damage can occur.
Replace the co nnector and i nstall the wire and term inal
i nto the seal at the back of the con n ector. Push the wi res
strai ght in until a click is felt. A slight tug will confirm that
it is p roperly locked i n place.
Once the wi res are i n place , i nsert the orange wedge with
arrow pointing toward the exterior locking mechan ism .
Push the orange wedge i n until it snaps i n place.
M ake sure both seals are in place at the back of the
con n ector plug and receptacle. M ake sure the rubber seal
has been i nstalled on the con nector plug.
1 9d00480
,.6l Push the connector plug i nto the con nector receptacle
until the exte rnal locki ng c l i p snaps i nto place.
1 9803641
Deutsch DTM and DTP Con nector

Series (0 1 9-206)
Pin Replacement
The con nector can have m u ltiple p i n configu rations.

The con nector pins can not be repai red o r replaced . The
con n ector must be replaced as a u n it.
Refer to the connector replacement proced ure for
1 9802932
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J • • • Deutsch DTM and DTP Con nector Series
Before instal l i ng the new connector, perform a test fit to

Refer to the appropriate wiring repai r kit i n the service tool
table in the front of Section 1 9 for the correct repai r
con n ector.
Refer to the wiring d i agram i n Section E for pin locations. ,/
The replacement connector shown i n the followi ng

proced u re is a 4-pi n Deutsch series. All sizes of DTM
con nectors are replaced in the sam e manner.
.
1 9802932
Measure 1 52 m m [6 i n ] back from the face of the con nector

and remove the wiring harness p rotective cover.
Before cutting the wires, measure and tag all wi res.
Use wi re cri m p i ng too l , Part N u m ber 3822930 .
Cut wire A 1 02 m m [4 i n ] from the face of the connector.
Cut wire B 1 02 m m [4 i n ] from the face of the conn ector.
Use wire c ri m pi n g too l , Part N u m ber 3822930 , to remove

6 mm [V4 i n ] of insu lation from both electrical wi res.
6 mm
[ 1/4 ir:a.J
6 mm
[ 1 /4 in.]
ee8coau
Deutsch H D 1 0 Connector Series ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ]
r6lra-.. I n stal l the con nector repair wi res and use wire cri m p i n g
tool , Part N u m ber 3822930 , to cri m p the term i nals.
Use heat g u n , Part N u mber 3822930 , to heat the shri n k
tu b i n g . T h e tubing wi l l shrink a n d make t h e con nection
waterproof.
,...;J ,", Wrap the wi res with tape, for added protectio n , to
W complete the repai r.
Deutsch H D1 0 Connector Series

(0 1 9-207)
Pin Replacement
These con nectors are available with m u ltiple pin

configurations.
w i re . Replace one contact at a time. If more than one wire
needs replaced , attach a lettered tag to each wire
removed .
Refe r to the wiring d iagram i n Section E for p i n locations.
U n lock theconnector. Rotate the locki ng tab
counterclockwise by hand . Do not use pl iers; they can
damage the con nector.
Remove the two clamp capscrews (1 ) from the rear of the
con nector. Turn the rear support of the con nector
counterclockwise until the two pieces are separated .
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ J • . • Deutsch HD10 Connector Series
These connectors are available with m u ltiple pin

configu rations.
Use the Deutsch extraction too l , listed i n the tab le below,
to remove a pin from the conn ector.

38248 1 5 20 gauge
3822760 1 6 gauge
38248 1 6 1 2 gauge
Replace one contact wire at a t i m e . If more than one wire

removed .
Push the tool i nto the connector approximately 25 m m [1

i n ] until it bottoms on the term i n al flange.
ee8comn
l'D-i'
Hold the tool on the term i nal flange and p u l l the wi re and
the con n ecting p i n o ut of the connector. N ote and record
\J:::>
ee8como
NOTE: The repai r w i re is 1 27 m m [5 i n ] long.

Remove about 6 m m [ % i n ] of i nsu lation from the wi re.
wire .
Replace o n e contact wire a t a t i m e . If more than o n e wire
removed .
Refer to the wiring d iagram i n Section E for p i n locations.
Deutsch H D 1 0 Connector Series ISB, ISBe2, ISBe3 , ISBe4 , QSB4 [ J
. . .
I nstal l a repai r wire on the bare w i re . M ake sure the bare

w i re extends i nto the splice .
ee8coaj
,.6l Use w i re cri m pi n g tool , Part N u mber 3822930 , to cri m p

the repai r wi re onto the bare w i re .
I n sert the p i n i nto the correct hole of the connector.
W
The p i n must lock i nto place and hold the wire i n the
connector.
Pull the w i re gently to m ake sure it is seated i n the
con n ector.
ee8coam
I nstal l the rear con nector support .

Tig hten the two wi re clam p capscrews .
Torque Value: 1 N-m [ 9 in-Ib 1
ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . ] Deutsch H D 1 0 Connector Series
These connectors are available with m u ltiple pin

configurations.
Use the Deutsch extraction too l , listed i n the table below,
to remove a pin from the connector.

38248 1 5 20 gauge
3822760 1 6 gauge
38248 1 6 1 2 gauge
ee8comm
Replace one contact wire at a ti me . If more than one wire

removed .
Push the tool i nto the con nector approximately 25 m m [1

i n ] u nti l it bottoms on the term i nal flange.
ee8comn
l"Y-il
Hold the tool on the term i nal flange and p u l l the wi re and
the connecting p i n out of the connector. N ote and record
'Cb'-!!J
ee8como
Deutsch H DP20 and HD30 Connector Series ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J
Before instal l i n g the new connector , perform a test fit to

make sure the connector is keyed correctly.
tools table i n the front of Section 1 9 for the correct repai r
con nector.
Refe r to the wiring d i ag ram i n Section E for p i n locations.
1 94004 1 9
Insert the pins i nto the correct holes of the replacement

con nector.
The pin must click i nto place and hold the wire i n the
con nector.
P u l l the wire gently to m ake sure it is seated i n the
con nector.
ee8coam
Deutsch HDP20 and HD30 Con nector

\B Series (0 1 9-208)
Pin Replacement

con nector.
Turn the retai ner of the con nector counterclockwise until
the two pi eces are separated .
e e 8c o a 0 1
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ J . . . Deutsch H DP20 and HD30 Connector Series
Use the Deutsch extraction too l , listed in the tab le below, &/.1
to remove a p i n from the connector. 'CD'-:!J
38248 1 5 20 gauge
3822760 1 6 gauge
38248 1 6 1 2 gauge
Before i n stal l i ng the new repai r w i re , perform a test fit to

wire .
Replace one contact wi re at a t i m e . If more than o n e wire
removed .
Push the tool i nto the connector about 25 m m [ 1 i n ) u ntil

it bottoms on the term i nal flange.
ee8comn
Hold the tool on the term i nal flange and pull the wi re and &/.1
the con necti ng p i n out of the connector. N ote and record
'CD'-:!J
ee8como
Deutsch H DP20 and HD30 Connector Series ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . J
NOTE: The repai r wire is 1 27 mm [5 i n ] long.

Before i n stal l i ng the new repai r wire , perform a test fit to
make s u re the wire is the correct size.
Refer to the appropriate wiring repair kit tools table i n the
front of Section 1 9 for the correct repai r wire .
Replace one contact wire a t a time. If m o r e t h a n one wire
needs replaced , attach a l ettered tag to each wi re
removed .
Refer to the wiring d iag ram i n Section E for p i n locations.
U se w i re cri m pi n g too l , Part N u m be r 3822930 , to cut 1 27
m m [5 i n ] off the wire and p i n .
U se t h e wi re cri m pi n g tool t o remove 6 m m [ 1/4 i n ] of
insulation from the wire.
I nstall the correct repai r w i re on the bare wire.
@; M ake sure the bare w i re extends i nto the splice co nnector.
ee8coaj
rf1
\@
U se the wire cri m p i n g tool to cri m p the repair wire onto the
bare wire.
U se heat g u n , Part N u mber 3822860 , or an open flame to

heat shri n k the tubing around the wire. The tubing will
shri n k and make the con nector waterproof.
IS8, IS8e2, IS8e3, IS8e4, QS84 [ J . . . Deutsch H DP20 and H D30 Connector Series
I nsert the pin i nto the correct hole of the con n ector.
The p i n must click i nto place and hold the wire i n the
con nector.
P u l l the wire gently to make sure it is seated i n the
con nector.
ee8coam
I nstall the retainer. Tighten the two clamp capscrews .

Torque Value: 1 N-m [ 9 in-Ib ]
ee8

con nector.
Turn the retainer of the connector counterclockwise u nti l
the two pieces are separated .
ee8coa0 1
Deutsch H D P20 and H D30 Connector Series ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ . . . ]
U se the Deutsch extraction tool , listed in the tabl e below,

to remove a pin from the connecto r.

38248 1 5 20 gauge
3822760 1 6 gauge
38248 1 6 1 2 gauge

m ake sure the wire is the correct size.
ee8comm
tools tab le in the front of Section 1 9 for the correct repair
wire.
Replace one contact wire at a time. If more than one wi re
removed .
Push the tool i nto the con nector about 25 m m [ 1 in] until
tW it bottoms on the term i nal flange.
ee8comn
con n ecti ng p i n out of the con n ector. N ote and record the
hole from which the p i n is removed .
ee8como
ISB, ISBe2 , ISBe3 , ISBe4, QSB4 [ . . . ] ITT Cannon Connector Series
Before i n stal l i n g the new connector, perform a test fit to

tools tabl e i n the front of Section 1 9 for the correct repair
con nector.
Refer to the wiring d i ag ram i n Section E for pin locations.
1 9400421
I nsert the pins i nto the correct holes of the connector.

The pin must click i nto place and hold the wi re i n the
con nector.
Pull the w i re gently to make sure it is seated i n the
con nector.
ee8coam
I nstall the retainer. Tig hten the two clam p capscrews

Torque Value: 1 Nem [ 9 i n-Ib I
eeBcoa02
ITT Can no n Con n ector Series

(0 1 9-209)
Pin Replacement
The con nector p i ns can not be repai red or replaced . The

connector must be replaced as a u n it .
Refer t o the Con n ector Replacement proced u re for
1 9400421
ITT Cannon Connector Series ISB, ISBe2, ISBe3, ISBe4 , QSB4 [ . . . J
M easu re 1 52 mm [6 in] back from the face of the conn ector

1 52 mm in.] and remove the wiring harness protective cover.
Before i nstal l i ng the new connector , perform a test fit to
m ake sure the con nector is keyed correctly.
tools table in the front of Section 1 9 for the correct repa i r
con n ector.
Replace one contact wire at a time. If more than one w i re
needs replaced , attach a lettered tag to each w i re
1 9c01 369 removed .
Use wi re cri m pi n g too l , Part N u m be r 3822930 , to cut the

Cut wi res . Cut the fi rst wire 9 1 m m [3-112 in] from the face of
Cut the con nector.
Cut Cut the remai n i n g seven wi res i n increments of 1 2 m m Ph
i n ] back from the previous cut.
91 mm [3.5 in.]
1 04 m m [4 i n .]
1 1 7 mm [4.5 i n.]
1 9c0 1 370
Use the wi re cri m p i n g tool to remove 6 m m [ % in] of

insulation from all eight el ectrical w i res.
1 94004 1 6
I nstal l the termi nal repair wi res on the bare wi res and use
the w i re cri m pi n g tool to cri m p the term inal .
Use heat g u n , Part N u m ber 3822860, or an open flame to
heat the shri n k tubi n g . The tubi ng w i l l shri n k and make the
ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ ] . . . AMP VP44 Con nector Series
For added p rotectio n , wrap the w i re with tape to complete

the repai r.
1 9c01 372
AMP VP44 Con nector Series (0 1 9-2 1 0)

Pin Replacement
The con nector p i ns can not be repai red or replaced . The

connector must be replaced as a u n it .
Refer t o the Connector Replacement step i n t h i s
proced u re f o r replacement i nstructions.
1 9d00680
This con nector is used to connect the V P44 fuel p u m p to

the EC M .
The p i ns i n this con n ector can not b e repai red o r replaced .
The con nector m ust be replaced as a u n it.
Measure 1 78 m m [7 i n ] back from the face of the con nector

and remove the wiring harness p rotective cover.
AMP VP44 Connector Series ISB, ISBe2 , ISBe3 , ISBe4, aSB4 [ . . . J
Wire C Before cutting the wi res , measure and tag all of the w i res.
1 40 mm
[5 .5 in] Use w i re cri m ping too l , Part N u m ber 3822930 , to cut the
wi res.
Wire D
1 30 mm
Cut w i re A 1 65 mm [7 i n ] from the face of the connector.
[5 .0 in] Cut w i re B 1 52 m m [6-1/2 i n ] from the face of the con n ecto r.
Wire E
1 1 7 mm Cut wire C 1 40 m m [6 in] from the face of the connector.
[4.5 in] Cut w i re D 1 30 m m [5-1/2 i n ] from the face of the con nector.
Wire F Cut w i re E 1 1 7 m m [4_1/2 in] from the face of the con nector.
104 mm
[4.0 in] Cut wi re F 1 04 m m [4 i n ] from the face of the con nector.
1 9d00880
Cut w i re G 9 1 m m [3-112 i n ] from the face of the connecto r.
Use the wi re cri m pi n g tool to remove 6 m m [ 1/4 in] of

insulation from al l el ectrical w i res.
6 mm
[0.25 in]
1 9d0088 1
Before instal l i ng the new connector, perform a test fit to

tools tabl e i n the front of Section 1 9 for the correct repair
con n ector.
Refer to the wiring d iag ram in Section E for pin locations.
I n stal l the p i n repair wi res and con n ector onto the bare
wi res of the harness and use the w i re cri m p i n g tool to
cri m p each repair w i re onto the harness.
For added p rotection , wrap the wi res with tape to complete

the repair.
1 9d00883
ISB, ISBe2, ISBe3, ISBe4, QSB4 [ . . . J Packard Relay Connector
Packard Relay Con nector (0 1 9-21 1 )

Pin Replacement
The con n ector pins can not be replaced . The con nector
must be replaced as a u n it.
Refer to the Connector Replacement proced u re for
Before instal l i n g the new connector, perform a test fit to

make sure the con nector is keyed p roperly.
con nector.
removed .
Measure 1 52 m m [6 i n ] from the face of the connector, and

remove the wiring harness p rotective cover. "J[)
< 1 52 mm
[6 in]
o
1 9d00778
Before cutting the wi res m easu re and tag them.
Use wire cri m pi n g tool , Part N u m ber 3822930.
Cut wire A 1 30 m m [5 i n ] from the face of the con n ector.
Cut wi re B 1 1 7 m m [4_1/2 i n ] from the face of the con nector.
Cut wire C 1 04 m m [4 i n ] from the face of the connector.
Cut wire D 91 m m [3-V2 in] from the face of the connector.
1 9d00779
Packard Relay Connector ISB, ISBe2, ISBe3 , ISBe4, QSB4 [ . . . J
Use cri m pi n g tool , Part N u m ber 3822930 , to remove 6 mm

[ 1/4 i nch ] of insu lation from the electrical wi res.
Befo re instal l i ng the new connector , perform a test fit to
m ake sure the con n ector is keyed correctly.
tools table in the front of Section 1 9 for the correct repa i r
con n ector.
Refe r to the wiring d i ag ram i n Section E for pin locations.
rem oved .
1 9d00780
I nstall the term inal repair wi res on the bare wires. Use w i re
cri m p i ng too l , Part N u mber 3822930 , to cri m p the
term i nals.
Use h eat g u n , Part N u mber 3822860 , o r an open flame to
h eat the shri n k tubi n g . The tubing will shri n k and make the
1 9d0078 1
Wrap the wi res with tape, for added protectio n , to

Wl!J complete the repai r.
1 9d00782
A CAUTION A
Use only Cummi ns-recommended l u bricant DS-ES,
Part N u m ber 3822934, other lubricants, such as
l u bricating oil or g rease , in the connectors can cause
ECM damage, poor engine performance, or prematu re
connector pin wear.
Apply a small amount of lubricant to the con nector
term i nals. Before instal l i n g , fi l l the enti re con nector cavity
with l u b ricant.

Section 19 Electronic Engine Controls Parte 1 PDF

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Section 19 Electronic Engine Controls Parte 1 PDF

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ISB, ISBe2 , ISBe3, ISBe4, QSB4 [ J

Section 1 9 - Electronic Engine controls Page 1 9-a

Section 19 - Electronic Engine controls Page 19-1

Tool No. Tool Descri tion Tool Illustration

Bosch® Male Test Lead

Bosch® Female Test Lead

ECM Bench Top Calibration Harness

Engine Controller Adapter Harness

Tool No. Tool Description Tool illustration

Framatome Male Test Lead

Framatome Female Test Lead

Data Link Power Adapter Harness

Wi ring Repai r Kit \

Weather-Pack Term inal Removal Tool

Deutsch/AM P/Metri-Pack Male Test Lead

AMP Term inal Removal Tool

Tool No. Tool Descri tion Tool Illustration

Deutsch/AM P/Metri-Pack Female Test Lead

Wire Crim ping Pliers

Deep Well Socket (1.25 inch)

Electrical Contact Cleaner

Deutsch Male Test Lead

Deutsch Female Test Lead

Tool No. Tool Descri tion Tool Illustration

INSITE™ Software Kit

Section 19 Electronic Engine controls

Barometric Air Pressure Sensor

Attach the sensor t o t h e i ntake man ifold cover.

Torque Value: 9 N-m [80 i n- I b ]

Push the connectors together until they lock.

Slide the locking tab to the lock position .

Battery Ground Circuit {019-008}

con nector. Connect the al l igator clip to the m u ltimeter

If the resistance val ue i s not correct , check the batteries ,

Clutch Pedal Position Switch (019-009)

Release the cl utch pedal. The m u lti m eter must show a

Check for Short Circuit to Ground

Check for Short Circuit to External Voltage

If the voltage val u e is mo re than 1 . 5 VDC, there is a short

Clutch Pedal Position Switch Circuit

Con n ect the alligator c l i ps to the two probes of the

Depress the cl utch pedal ( 1 ) . The m u lti meter must show

Section 19 Electronic Engine controls

Check for Short Circuit to Ground

To isolate the cl utch pedal position switch circuit when

Disco n nect the cl utch pedal position switc h , the idle

Remove the test l ead from the switch return p i n .

Touch t h e other m u ltimeter probe t o t h e e n g i n e block

Con n ect all com ponents when the repai r is complete.

Check for Short Circuit from Pin to Pin

Check for Short Circuit to External Voltage

switches to the OFF or neutral positi o n , and d isconnect

Exhaust Gas Temperature Sensor

Clean and Inspect for Reuse

Engine Coolant Level Sensor (019-017)

Lift up on the locki ng tab and p u l l the electrical connectors

Page 19-14 Section 19 - Electronic Engine controls

Engine Coolant Temperature Sensor

Lift u p on the locki ng tab and p u l l the el ectrical con nectors

Inspect for Reuse

- m issi ng or damaged con nector seals

- d i rt , debris, or moisture in or on the con n ector pins

- corroded , bent, b roke n , pushed back, o r expanded