g and Repair Manual ISM/QSM11 Series Engines Troubleshootin: G Ls a te? ISForeword ‘This manual provides instructions for troubleshooting and repairing this engine in the chassis. Component and assembly rebuild procedures are provided in the engine shop manual. Refer to Section i Introduction for instructions ‘on how to use this manual. Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i = Introduction. ‘The manual is organized to guide a service technician through the logical steps of identitying and correcting problers related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment ‘manufacturer for repair procedures. ‘Aseries of specific service manuals (for example: Shop, Specifications, and Alternative Repair) are available and can be ordered by filling out and mailing the Literature Order Form located in Section L.- Service Literature, “The repair procedures usedin this manual are recommended by Cummins Engine Co., Inc. Some service procedures require the use of special service tools. Use the correct tools as described. Cummins Engine Company, Inc. encourages the user of this manual to report errors, omissions, and recommendations for improvement. Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for ‘communicating your comments. “The specifications and rebuild information in this manual are based on the information in effect at the time of printing, Cummins Engine Company, Inc. reserves the right to make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact a Cummins Authorized Repair Location Or call 1-800-DIESELS (1-800-343-7357) toll free in the U.S. and Canada. ‘The latest technology and the highest quality components are used to manufacture Cummins engines. When re- placement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts. These parts can be identified by the following trademarks: Cca™= WizTable of Contents Section Introduction i Engine Identification E ‘Troubleshooting Symptoms 1s ‘Complete Engine - Group 00 ° Cylinder Block ~ Group 01 1 Cylinder Head - Group 02 2 Rocker Levers ~ Group 03 ... 3 Cam Followers/Tappets - Group 04 4 Fuel System ~ Group 05 6... 5 Injectors and Fuel Lines - Group 06 6 Lubricating Oi! System ~ Group 07 7 Cooling System - Group 08 8 Drive Units - Group 09 8 Air Intake System - Group 10 10 Exhaust System - Group 11 1 Compressed Air System - Group 12 12 Electrical Equipment - Group 13 13 Engine Testing - Group 14 4 Mounting Adaptations - Group 16 16 Miscellaneous Hardware ~ Group 17 sono 7 Vehicle Braking - Group 20 20 Service Literature . Component Manufacturers M Specifications v Idx nntennnnnnnnnnnnininnninnnnnnnnntnntnnnntinnnnsnninenst xism Section i - Introduction Page i-a Section i - Introduction Section Contents Page About the Manual... ‘Acronyms and Abbreviations... General Cleaning Instructions Glass or Plastic Bead Cleaning Solvent and Acid Gleaning Steam Cleaning General Repair Instructions. Welding on a Vehicle with an Electronic Controlled Fuel System General Safety instructions... Important Safely Notice .... How to Use the Menual. Illustrations. Symbols.ism Section i - Introduction THIS PAGE LEFT INTENTIONALLY BLANK.ism ‘About the Manual ‘Section i - Introduction Page it About the Manual This Troubleshooting and Repair Manual is intended to aid in determining the cause of engine related problems and to provide recommended repair procedures. ‘The manual is divided into sections. Each section is equivalent to a group used in Cummins film card system. Sor sections contain reference numbers and procedure numbers. Reference numbers provide general information, specifications, diagrams, and service tools where applicable. Procedure numbers are used to identify and referenc> specific repair procadures for correcting the problem. This manual is designed so the troubleshooting trees are used to locate the cause of an engine problem. Tha troubleshooting trees then direct the user to the correct repair procedure. The repair procedures within a section ara In numerical order. However, the repair steps within a given procedure are organized in the order the repair must be Performed regardless of the numerical order of the steps. The user must use the contents pages or the index at the back of the manual to locate specific topics when not using the troubleshooting trees. ‘This manual coversall base engine repair procedures and some fuel system repair procedures. Repair procedures and fault code diagnosis for the electronic fuel system is covered in the Fuel System Troubleshooting and Repair Manual listed in section L How to Use the Manual This manual is orgenized to provide an easy flow from problem identification to problem correction. A list of trouble- shooting symptoms containing the most common engine probiems is in the Troubleshooting Symptoms, Section (TS) ‘The manual is designed to use the Troubleshooting Symptoms as a guide to locating the problem and directing the end-user to the correct procedure for making the repair. Complete the following steps to locate and correct the problem. (Step 1) Locate the symptom on the Section Contents pages of Section TS. Reference to the page number where the Troubleshooting Symptom Tree is found is made to the right of the symptom tree titi. (Step 2) ‘The left column of boxes in the Troubleshooting Symptom Charts indicates a probable cause of the problem, starting at the top with the simplest and easiest to repair, and con- tinuing downward to the most difficult. ‘The right column of boxes provides a brief description of the corrective action with a refer- fence number to the correct procedure used to make the repair (Step 3) Locate the probable cause in the left column then turn to the procedure referenced in the right column, (Step 4) The Troubleshooting Symptom Charts are based on the following assumptions: 1. The engine has been installed according to the manufacturer's specifications. 2. The easiest repairs are done first. 3, “Generic” solutions to cover problems with the most common applications and Origi- nal Equipment Manufacturer (OEM),Symbols Page i-2 ism Section i Introduction Symbols The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below: @ § ®OKFOHOGS P 92 (tym) WARNING - Serious personal injury or extensive property damage can result ifthe warning instructions, are not folowed. ‘CAUTION.- Minor personal injury can result or a part, an assembly, or the engine can be damaged it the caution instructions are not followed. Indicates a REMOVAL or DISASSEMBLY step, Indicates an INSTALLATION or ASSEMBLY step. INSPECTION is required. CLEAN the part or assembly. PERFORM a mechanical or time MEASUREMENT. LUBRICATE tho part or assembly. Indicates that a WRENCH or TOOL SIZE will be givan. TIGHTEN to a specific torque. PERFORM an olectrical MEASUREMENT. Refer to another location in this manual or another publication for additional information. ‘The component weighs 23 kg [50 Ib] or more. To avoid personal injury, use a hoist or get assistance to litt the component.ism Section i - Introduction Illustrations ‘Some of the illustrations throughout this manual are ge- neric and will not Icok exactly like the engine or parts used in your application, The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition The illustrations are intended to show repair or replace- ment procedures. The procedure will be the same for all applications, although the illustration can differ. Mlustrations: Page I3 ora)General Safety Instructions ism Page Section i - Introduction General Safety Instructions Important Safety Notice A WARNING A Improper practices or carelessness can cause burn, cuts, mutilation, asphyxiation or other body injury or death, Read and understand all of the safety precautions and warnings before performing any rapair This list contains the general safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures when they apply. ‘+ Make sure the work area surrounding the product is dry, well it, ventilated, free from cluter, loose tools, parts, ignition sources and hazardous substances. Be aware of hazardous conditions that can exist. Always wear protective glasses and protective shoes when working. Rotating parts can cause cuts, mutilation or strangulation. Do not wear loose-iting or torn clothing. Remove all jawelry when working, Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work. Disconnect the ar starting motor if equipped to prevent accidental engine starting. Put a “Do Not Operate” tag in the operator's compartment or on the controls. + Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or damage to the fan blade(s) causing premature fan failure. + Ian engine has been operating and the coolant is hot, allow the engine to coo! before you siowly loosen the filler cap and relieve the pressure from the cooling system. + Do not work on anything that is supported ONLY by lifting jacks or a hoist. Always use blocks or proper stands to support the product before performing any service work. + Relieve all pressure in the ai, ol, fuel and the cooling systems before any lines, fittings, or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that ulizes pressure, Do net check for pressure leaks with your hand. High pressure oll or fuel can cause personal injury + To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect fuel and liquid refrigerant (freon) lines in a well ventilated area. To protect the environment, quid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas (luorocarbons) into the atmo- sphere. Federal law “equires capturing and recyciing refrigerant. + To.avoid personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [60 Ib] or more. Make sure alliting davices such as chains, hooks, or slings are in good condition and are ofthe correct capacity Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be side-loaded. * Corrosion inhibitor, a component of SCA and lubricating ol, contains alkall. Do not get the substance in your eyes. Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and water In case of contact, immediately food eyes with large amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN. + Napthaand Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the manufacturers instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF CHILDREN. * To avoid burns, be alert for hot parts on products that have just been turned off, and hot fluids in lines, tubes, and compartments. + Always use tools that are in good condition. Make sure you understand how to use them before performing any service work. Use ONLY genuine Cummins or Cummins ReCon® replacement parts. + Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of lesser quality if replacements are necessary. +o not periorm any repair when fatigued or after consuming alcohol or drugs that can impair your functioning, * Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil eratism General Repair Instructions Section i - introduction Page [5 General Repair Instructions This engine incorporates the latest technology at the time it was manufactured; yet, itis designed to be repaired using normal repair practices performed to quality standards. ‘* Cummins Engine Company, Inc. does not recommend or authorize any modifications or repairs to engines ‘or components except for those detailed in Cummins Service Information. In particular, unauthorized repair to safety-related components can cause personal injury or death. Below is a partial listing of components classified as safety-related: Air Compressor Flywheel Mounting Capscrews Air Controls Fuel Shutoff Assemblies Air Shutoff Assemblies Supply Tubes Balance Weights Lifting Brackets Cooling Fan Throttle Controls Fan Hub Assembly ‘Turbocharger Compressor Casing Fan Mounting Bracket(s) ‘Turbocharger Oil Drain Line(s) Fan Mounting Capscrews ‘Turbocharger Oil Supply Line(s) Fan Hub Spindle ‘Turbocharger Turbine Casing Flywheel Vibration Bamper Mounting Capscrews Flywheel Crankshaft Adapter " Follow all safety instructions noted In the procedures — Follow tne manufacturer's recommendations for cleaning solvents and other substances used during the repair of the engine. Some solvents and used engine oll have been identified by government agencies as toxic or carcinogenic. Avoid excessive breathing, ingestion and contact with such substances. Always use {good safety practices with tools and equipment. Provide a clean environment and follow the cleaning instructions specitied in the procedures — The engine and its components must be kept clean during any repair. Contamination of the engine or components will cause premature Wear. Perform the inspections specified in the procedures Replace all components or assemblies which are damaged or worn beyond the specifications. + Use genuine Cummins new or ReCon® service parts and assemblies — The assembly instructions have been written to use again as many components and assemblies as possible. When it is necessary to replace a component or assembly, the procedure is based on the use of new ‘Cummins or Cummins ReCon® components. All of the repair services described in this manual are available {rom all Cummins Distributors and most Dealer locations. * Follow the specified disassembly and assembly procedures to avoid damage to the components Complete rebuild instructions are available in the shop manual which can be ordered or purchased from a Cummins Authorized Repair Location. Refer to Section L — Service Literature for ordering instructions. Welding on a Vehicle with an Electronic Controlled Fuel System A caution A Disconnect both the positive (+) and negative (-) battery cables from the battery before welding on the vehicle. Attach the welder ground cable no more than 0.61 meters [2 feet] from the part being welded. Do not connect the ground cable of the welder to the ECM cooling plate or ECM. Welding on the engine or engine mounted ‘components is not recommended. 23 gwar)General Cleaning Instructions ism Page I-6 Section | - Introduction General Cleaning Instructions Solvent and Acid Cleaning ‘Several solvent and acid-type cleaners can be used to clean the engine parts. Experience has shown that the best results can be obtained usirg a cleaner that can be heated to 90 to 95 degrees Celsius [180 to 200 degrees Fahrenheit} ‘cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best results. Cummins Engine Company, Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer's instructions Remove all the gasket material, o-ings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before Putting the paris in a cleanng tank. Be careful not to damage any gasket surfaces. When possible, steam clean the parts before putting them in the cleaning tank. A WARNING A Acid is extremely dangerous and can cause personal injury and damage the machinery. Always provide a tank of strong soda water as ¢ neutralizing agent. Rinse all of the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all of the capscrew holes and the oi! drillings. If the parts are not to be used immediately after cleaning, dip them in a suitable rustproofing compound. The rustproofing compound must be removed from the parts before installation on the engine. Steam Cleaning ‘Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. itis a good way to clean the oil drillings. A WARNING A Wear protective clothing to prevent personal injury from the high pressure and extreme heat. Do not steam clean the folowing parts: 1, Electrical Components 5. Belts and Hoses 2. Wiring 6. Bearings 8, Injectors 7. Electronic Control Module (ECM) 4. Fuel Pump 8. ECM Connectors Glass or Plastic Bead Cleaning Glass or plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning process is controlled by the size of the glass or plastic beads, the operating pressure, and the cleaning time. A caution A Do not use glass or plastic bead cleaning on aluminum piston aluminum ring grooves. Small particles of glass or plastic will embed wear. Valves, turbocharger shafts, etc., can also be damaged. Follow the cl procedures. NOTE: Plastic bead blasting media, Part No. 3822735, can be used to clean aluminum ring grooves. Do not use any bead blasting media on pin bores or aluminum skirts, Follow the equipment manufacturer's cleaning instructions. The following guidelines can be used to adapt to manu- facturer's instructions: 1. Bead size: a. Use U.S. size No. 16-20 for piston cleaning with plastic bead media, Part No, 3822735. b. Use U.S. size No. 70 for piston domes with glass media. ©. Use U.S. size No. 60 for general purpose cleaning with glass media. 2. Operating Pressure: a. Glass: Use 620 kPa [90 psi] for general purpose cleaning, Plastic: Use 270 kPa [40 psi] for piston cleaning. 8. Steam clean or wash the parts with solvent to remove all of the foreign material and glass or plastic beads after Cleaning. Rinse with hot water. Dry with compressed air. 4, Do not contaminate the wash tanks with glass or plastic beads. rts. Do not use glass bead cleaning on ‘the aluminum and result in premature 9 directions listed in the ‘09ersSection i - Introduction AFC API ASTM ‘CARB CLD. Acronyms and Abbreviations Page I-7 Acronyms and Abbreviations Air Fuel Control ‘American Petroloum Institute Air Signal Attenuator American Society of Testing and Materials Celsius California Air Resources Board Cubic Inch Displacement Compressed Natural Gas Control Parts List Contistokes Electronic Control Module Emission Control System Environmental Protection Agency Engine Position Sensor Fahrenheit Gross Vehicle Weight Mercury Horsepower Water Igniticn Contro! Module Kilometers per Liter kPa LNG LTA mip MPa mph mpq Nem NG OEM ppm psi PTO rpm SAE SCA sTC vs vss Kilopascal Liquid Natural Gas Low Temperature Aftercooling Mixer Inlet Pressure Megapascal Miles Per Hour Miles Per Quart Newton-meter Natural Gas Original Equipment Manufacturer Parts Per Million Pounds Per Square inch Power Takeoff Revolutions Per Minute Society of Automotive Engineers Supplemental Coolant Additive Step Timing Control Variable Speed Vehicle Speed SensorAeronyes and Abbreviations ism Page 8 Section I Introduction NOTESism Section E - Engine Identification Page Ea Section E - Engine Ideni Section Contents Engine Diagrams gine Views Engine Identification ose ‘Euimmins Engine Nomenclature ECM Dalaplae eons Engine Dataplato Specifications... Air Intake System Batteries (Specitic Gravity) Cooling SystEM ener Electrical System Exhaust System .... Fuel System... : General Specifications =. Lubricating Oil SystemIsM Page E-b Section E - Engine Identification THIS PAGE LEFT INTENTIONALLY BLANK.ism Section - Engine Identification En Engine Dataplate The engine dataplate shows facts about your engine. The Engine Serial Numoer and CPL provide information for ordering parts and service needs. The engine dataplate ‘must not be changed unless approved by Cummins En- gine Company, Inc. The dataplate is loceted on the fuel pump side of the engine fon the rocker housing. Have the following engine data available when communicating with a Cummins Autho- rized Repair Location. The following information on the dataplate is mandatory when sourcing service parts. Engine Identification 1. Engine serial number 2. CPL 3. Mode! 4, Horsepower and rpm rating,Engine Identification ‘= Engle Model Designation «= Interact Syetem ism Section E - Engine Identification ECM Dataplate ‘The ECM dataplate is located on the front of the ECM. ‘The abbreviations on the dataplate are explained as fol- lows: ‘= PIN = part number ‘© SIN = serial number + DIC = date code. Cummins Engine Nomenclature The Cummins engine nomenclature provides the data as illustrated in the graphics.ism Specifications Section E - Engine Identification Page E-3 Specifications General Specifications Horsepower (refer to engine dataplate) Engine Speed @ Maximum Output: Governed Speed (rpm) ‘Automotive 1800 Vocational/Tansit Bus’ 2100 Marine ~ 2300 Bore and Stroke 125 am [4.91 in] x 147 mm [5.787 in Displacement . 10.8 liters [661 C.1.D] Firing Order . 153624 Enging Weight (wih standard accessories Dry Weight 940 kg [2070 Ib} ‘Wet Weight : £996 kg [2193 Ib} Crankshalt Rotation (viewed from the font ofthe engine) . Clockwise 7 FOQOOOOO) Firing Order 1-5-3-6-2-4 Cylinder Location and Firing Order Intake and Exhaust Valve LocationsSpecifications ism Page E-4 Section E - Engine Identification Fuel System For performance and fuel rate values, refer to the engine data sheet or the fuel pump code for the particular model Involved. Engine Idle Speed Fuel Inlet Maximum Restriction: Clean Fuel Filter Dirty Fucl Filter Fuel Drain Minimum Fuel Pressure: During Cranking . 600 to 800 rpm 152 mm Hg [6 in Hg] 254 mm Hg [10 in Hol 89 mm Hg [3.5 in Hg} 1@ Maximum Restriction 172 kPa [25 psi] 1200 rpm 827 kPa [120 psi] Governed rpm "4084 to 1241 kPa [150 to 180 psi} Fuel Inlet Maximum Temperature . 71°C [160°F] Engine Minimum Cranking Speed 150 1pm ‘Shutoff Valve Solenoid Ccil Resistance 12.VOC ... 7.0 to 8.0 ohms Lubricating Oil System Oil Pressure: Low Idle (minimum allowable) 70 kPa [10 psi] ‘At 1200 rpm or Torque Peak (minimur “207 kPa [30 psi] il Capacity of Standard Engine: ‘Combination Filter: LF8000 LF9001 3.0 liters [0.8 gal] liters [0.7 gal] Cl Pan (highviow) $4 to 26.5 liters [9 to 7 gal] ‘Transit Bus Oil Pan (high-low) . 34 10 30.3 liters [9 to 8 gal} Cooling System Coolant Capacity (engine only) ‘Standard Modulating Thermostat Range Cylinder Block Coolant Pressure (pressure cap removed) Minimum Closed Thermostat - 1800 rpm - No Load Maximum Closed Thermostat ... 9.5 liters [10 qt] 82 to 93°C [180 to 20°F) 188 kPa [20 psi] 275 kPa [40 psi] Maximum Allowable Operating Coolant Temperature... 100°C [212°F] Minimum Recommended Operating Coolant Temperature 70°C [160°F] Minimum Recommended Pressure Cap : . sone 48 KPA (7 psi] Maximum Allowable Coolant Flow to Accessories (iters/minute [goml) 7.7 Liters (20 gall Coslant Sensing Fan Control longemess off 96°C [205°F] 91°C [195°F]ism Specifications Section E - Engine Identification Page E-5 Air Intake System Maximum intake Restritio Clean Air Filter Element Diny Air Filter Element Maximum Temperature Rise Between Ambient Alr and Engine Inlet 254 mm H,0 [10 in H.0] (635 mm H,0 [25 in H,C] (ambient above C° (32°F) son 17°C [20°F] Maximum Allowable Pressure Drop From Turbocharger to Intake Manifold 12 mm Hg [6 in Hg} Maximum Allowable Pressure Drop Across Charge Alt C00I@F nnn 162 mm Hg [6 in He] Exhaust System Maximum Back Pressure From Piping and Silencer (combined): Winout Cast s_76 mm [3 in] 27016 min [40 in] «152 mm [6 in} ” as 082 mm [62 in} Exhaust Pipe Size normally acceptable inside diameter) «127 mm [5 in} Electrical System Minimum recommended battery capacity: System Voltage ‘Ambient Temperature 18°C [0°F] 0°C [32°F] Cold Cranking Reserve Capacity ' Cold Cranking Reserve Capacity * ‘Amperes ‘Amperes ‘Amperes, ‘Amperes s2voc 1800 640 1280 480 24 VDC * 900 320 640, 240 1. The number of plates within a given battery size determines reserve capacity. Reserve capacity deter- mines the length of time during that sustained cranking can occur. 2. Cold Cranking Amperes ratings are based on two 12-VDC batteries in series. ‘A minimum of 6.5 VOC at the power connector is required to power up the ECM. Batteries (Specific Gravity) ‘Specific Gravity at State of Charge 27°C [80°F] 1.260 to 1.280 O08, 1.230 101.250. 75% 4.200 101.220 50% 1.170 t0-1.190- 25% 1.110 to 1.130 DischargedEngine Diagrams ism Page E-6 Section E - Engine Identification Engine Diagrams Engine Views The following illustrations contain information about engine components, filter locations, drain points, and access locations for instrumentation and engine controls. The information and configuration of components shown in these drawings are of a general nature. Some component locations will vary depending on applications and installations. Exhaust Side 4. Ether Hookup 14, Water Pump Pressure 2. Before Charge Air Ccoler 48, Coolant inlet 3. Boost Temperature Sensor 16. Gil Drain 4. Intake Manifold Pressure Sensor 17, Oil Pan Sump Heater 5. After Charge Air Cooler 418, Filter Out Pressure 6. Shutter Stat 19. Engine Brake Oil Supply 7. Engine Vent Coolant 20, Filter Inlet Pressure 8. Shutter Stat 21. Block Coolant Pressure 9. Fan Sensor 22. Coolant Heater 10. Coolant Temperature Sensor 23. Heater Supply ‘1, Heater Return 24, Coolant Temperature Pickup 42. Coolant Inlet Pressure 25. Wastegate Controller 18. Makeup line from Radiatorism Engine Diagrams Section E - Engine Identification Page ET 1 2 45 6 19. a 1 ° 18 3 0600 7 2 lob ge ° 2" Q | 6, 10 4 we 8 a a ECM Cooling Piate . Electronic Control Module (ECM) Compressor Air Discharge Blowby Measurement ‘Ambient Air Pressure Sensor Fuel Return to Tank Engine Data Tag Engine Serial Number Starter Flywheel Ring Gear Sensor Seenomsens Fuel Pump Side 11. Side Oil Drain 12. Centine!™ (optional) 18. Fuel inlet to Pump 14. Fuel Filter 15. Rail Pressure 16. Power Steering Pump Mounting Location 17. Oil Pressure and Temperature Sensor 18. Engine Position Sensor 19. Freon Compressor Mounting Locationms sm Paes Section E - Engine Identification NOTESism Section TS - Troubleshooting Symptoms Page TS-a Section TS - Troubleshooting Symptoms Section Contents Troubleshooting Procedures and Techniques Air Compressor A\r Pressure Rises Slowly Air Compressor Cycles Frequently ‘Air Compressor Noise is Excessive eee ‘Ar Compressor Pumping Excess Lubricating Oi into the Ar System ‘Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continucusiy)... ‘Air Compressor Will Not Pump Air... nnn ‘Air Compressor Will Not Stop Pumping 2 Alternator Not Charging or Insufficient Charging... ‘Alternator Overcharging a Communication Error ~ Electronic Service Connecting Rod Bearing NOIS@ «nn Coolant in the Lubricating Oil. Coolant Loss ~ External Goolant Loss ~ Internal a oon Coolant Temperature Above Normal ~ Gradual Overheat... Coolant Temperature is Above Normal - Sudden Overheat. Coolant Temperature is Below Normal... Crankcase Gases (Blowby) Excessive .. Cranking Fuel Pressure is Low. Driveability — General Information Driveability/Low Power — Customer Gompiaint Form Driveability/Low PowerlExcessive Fuel Consumption — Checkiist Engine Acceleration or Response Poor. = Engine Brake Does Not Operate... : Engine Brake — One or More Cylinders Braking with Power Switch Off Engine Brake ~ Low Retarding Power or Slow t0 ACtiVat®w..rnn Engine Decelerates Siowly. cetera Engine Difficult to Start or Will Not Start (Exhaust Smoke) Engine Difficult to Start or Will Not Start (No Exhaust Smoke). Engine Noise Diagnostic Procedures — General Information Engine Noise Excessive. : . Engine Noise Excessive — Combustion Knocks. Engine Noise Excassive — Connecting Rod. Engine Noise Exoassive — Main Bearing... Engine Noise Excessive — Piston Engine Noise Excassive — Turbocharger . Engine Power Output Low ....nnen Engine Runs Rough at Idle Engine Runs Rough or Misfires... Engine Shuts Off Unexpectedly or Dies During Deceleration.. Engine Speed Surges at Low of High Ide... Engine Speed Surges Under Load or in Operating Range. Engine Starts But Will Not Keep Running. Engine Vibration Excessive... Engine Will Not C-ank or Cranks Siowiy (Air Starter). Engine Will Not Crank or Cranks Slowly (Electric Starter). Engine Will Not Shut Off, . = Fuel Consumption Excessive. Tae Fuel Consumption — Customer Gompiaint Form Fuel Consumption — General Information Fuel in Coolant aoe Fuel in the Lubricating Oii Intake Manifold Air Temperature Abave Specification... Intake Manifold Pressure (Boost) is Below Normal Low Idle Adjust Switch Does Not Work rrr Lubricating Oil Consumption Excessive... Lubricating Oil Contaminated «0 Lubricating Oil Degradation (Gentine) Lubricating Oil Pressure High Lubricating Oil Pressure Low. : Lubricating Oil Sludge in the Grankcase Excessive... Lubricating Oil Temperature Above Specification .. “Woo! or Control Geviceism Page TS-b Section TS - Troubleshooting Symptoms Page Lubricating or Transmission Oil in the Cootant Main Bearing Noise il Consumption Fi i] Pan Level Incorrect ~ High (Centinei) Oil Pan Level Incorrect - Low (Centine)) Operating Fuel Pressure is Low. Piston Noise Response Test ‘Smoke, Black — Excessive. Smoke, White — Excessive. ‘Turbocharger Leaks Engine Oil or Fuel... ‘Troubleshooting Symptoms Charts......ism ‘Troubleshooting Symptoms Charts Section TS - Troubleshooting Symptoms Page TS-1 Troubleshooting Symptoms Charts Use the charts on the following pages of this section to aid in diagnosing specific engine symptoms. Read each row Of blocks from top tc bottom. Follow through the chart to identify the corrective action, A WARNING A ‘Troubleshooting presents the risk of equipment damage, personal injury or death. Troubleshooting must be performed by trained experienced technicians. 10 0.0029Troubleshooting Procedures and Techniques ism Page TS-2 Section TS - Troubleshooting Symptoms Troubleshooting Procedures and Techniques A thorough analysis of the customer's complaint s the key to successful troubleshooting. The more information known about a complaint, the faster and easier the problem can be solved. ‘The Troubleshooting Symptom Charts are organized so that a problem can be located and corrected by doing the easiest and most logical things first. Complete all steps in the sequence shown fram top to bottom. Itis not possible to include all the solutions to problems that can occur; however, these charts are designed to stimulate ‘a thought process that will lead to the cause and correction of the problem. Follow these basic troubleshooting steps: * Get all the facts corcerning the complaint Analyze the problem thoroughly Relate the symptoms to the basic engine systems and components Consider any recent maintenance or repair action that can relate to the complaint Double-check before beginning any disassembly Solve the problem by using the symptom charts and doing the easiest things first + Determine the cause of the problem and make a thorough repair + After repairs have been made, operate the engine to make sure the cause of the complaint has been corrected (9000-00-49ism Section TS - Troubleshooting Symptoms Troubleshooting Procedures and Techniques Page 1S:3 Air Compressor Air Pressure Rises Slowly This is symptom tree T004. Cause Air intake systom restriction to air compressor Correction Replace the air compressor air cleaner (if installed). Check the air intake piping. Check fengine air intake restriction ifthe alt compres: | Air system leaks Is excessive ‘sof inlet is plumbed to the vehicle or equip- Tent intake system. Refer to Procedure 010-031 — - Block the vehicle wheels and check the air system for leaks with spring brakes applied and released. Check for leaks from the air ‘compressor gaskets and the air system hoses, fittings, and valves. Refer to Procedure 012-019 and the OEM service manuals. OK Air governor is malfunctioning or not set correctly Check the air governor for correct operation. Refer to Procedure 012.017. OK Carbon buildup is excessive in the air dis- charge line, check vaive, or cylinder head Check for carbon buildup. Replace the alr ‘compressor discharge line if necessary. Refer to Procedure 012-003. Check the turbocharger for oll leaks. Check the intake tube for oil, Refer to Procedures 010-040 and 010-049. OK E-type system is not plumbed correctly } Install an Econ valve, check valve, and system hoses. Refer to the Master Repair Manual, Air system component is malfunctioning OK (Holset” only) Holset® Air Compressors, Bulletin No. 3666121 ‘OK — — Check the operation of check valves, alcohol evaporators, air dryers, and other OEM- installed air system components. Refer to the ‘manufacturer's instructions, Unloader valve is malfunctioning ‘Check the unloader valve and unloader body seal. Refer to Procedure 012-013. OK (Continued)‘Troubleshooting Procedures and Techniques Page TS-4 IsM Section TS - Troubleshooting Symptoms Air Compressor Air Pressure Rises Slowly (Continued) Cause Air compressor intake or exhaust valve leaks | alr Correction Ingpect the air compressor intake and exhaust valve assemblies. Refer to Procedure(s) (012-103, 012-104, or 012-106. ‘OK Air instalation issues Refer to the Automotive and Bus Installation Recommendations - Air Compressor Systems, Bulletin No. 3884946.ism Section TS - Troubleshooting Symptoms Troubleshooting Procedures and Tech 9 Air Compressor Cycles Frequently This is symptom tree TO0S. - cause conection Bikini wet and he Boss een acer te a on apse ers wit ao ale ope compressor gaskets and the air system hoses, mee Seas oe x Air governor is malfunctioning or not set correctly Check the air governor for correct operation. Refer to Procedure 012-017. OK Air system component is malfunctioning Check the operation of check valves, alcohol ‘evaporators, air dryers, and other OEM- installed air system components. Refer to the manufacturer's instructions. OK E-type system is not plumbed correctly {Install an Econ valve, check valve, and system hoses. Refer to the Master Repair Manual, (Holset™ oniy) Holset® Air Compressors, Bulletin No. 9666121, | OK ‘Carbon buildup is excessive in the alr dis- charge line, check valve, or cylinder head Check for carbon buildup. Replace the air ‘compressor discharge line if ne Refer to Procedure 012.003. Check the turbocharger for oil leaks. Check the intake tube for oi Refer to Procedures 010-040 and 010-049, OK Air dryer desiccant cartridge needs replaced Replace the desiccant cartridge on the ‘Turbo/CR2000 air dryer (if equipped). Refer to the OEM service manual OK Air dryer outlet check valve is sticking Lubricate or replace the air dryer outlet check valve assembly. Refer to the manufacturer's instructions. OK * (Continued)Troubleshooting Procedures and Techniques Page TS-6 IsM Section TS - Troubleshooting Symptoms Air Compressor Cycles Frequently (Continued) Cause Correction Air installation issues Refer to the Automotive and Bus Installation Recommendations - Air Compressor Systems, Bulletin No. 3884946, ‘OK Air compressor not designed for application Check the air compressor duty cycle. Install a larger air compressor, if necessary. Refer to Section G in the Master Repair Manual, Holset® Air Compressors, Bulletin No. 3666121.ism Section TS - Troubleshooting Symptoms Troubleshooting Procedures and Techni Page Air Compressor Noise is Excessive This is symptom tree T006. Cause Correction Carbon buildup is excessive in the air dis- charge line, check vaive, or cylinder head OK Check for carbon buildup. Replace the alr ‘compressor discharge line if necessary. Refer to Procedure 012-003. Check the turbocharger | {or oil leaks. Check the intake tube for oil Refer to Procedures 010-040 and 010-049, | Air compressor is sending air pulses into the air tanks, Install a ping tank between the air dryer and the wet tank. Refer to the manufacturer's instructions, OK Accessory drive is worn (axial end play is out of specification) Check the accessory drive axial end play. Inspect the shaft for wear. Refer to Procedure 008-001, OK Air compressor timing is not correct, OK Check the air compressor timing, Refer to Procedure 012-014, Air compressor drive gear or engine gear train isworn or damaged Inspect the accessory drive gears and gear train, Refer to Procedure 008-001, 001-036, 001-039, and 001-040. OK Ice buildup in the air system components For all models, check for ice in low spots of the air discharge line, dryer inet, and elbow fittings. On Holset” models also check the Econ valve (if equipped) OK bore wear is excessive OK Air compressor is excessively worn or internally ‘damaged. Check for pin bore wear. Refer to Procedure 12.010, Replace or rebuild the air compressor. Refer to 012.014,‘Troubleshooting Procedures and Techniques Page TS-8 ism Section TS - Troubleshooting Symptoms Air Compressor Pumping Excess Lubricating Oil into the Air System This is symptom tree T007. Cause Correction Lubricating oil drain interval is excessive Verify the correct lubricating oil drain interval, Refer to Section 2 in the correct Operation and Maintenance Manual. ‘OK Air intake system restriction to air compressor Replace the air compressor air cleaner (if installed). Check the air intake piping. Check engine air intake restriction if the air compres is excessive oF inlet is plumbed to the vehicle or equip ent intake system. Refer to Procedure 010-031, | ‘OK : Contaminants aro building up in the system reservoirs Drain the reservoirs daily. Refer to the Opera- tion and Maintenance Manual. OK Exype system is not plumbed correctly (Holset only) OK Install an Econ valve, check valve, and system hoses. Refer to the Master Repair Manual, Holset® Air Compressors, Bulletin No. 3666121. Air dryer desiccant cartridge needs replaced Replace the desiccant cartridge on the ‘Turbo/CR2000 air dryer (it equipped). Refer to the OEM service manual. ‘OK Carbon buildup is excessive in the alr dis- Charge line, check valve, or cylinder head Check for carbon buildup. Replace the air compressor discharge line if necessary. Refer to Procedure 012-003, Check the turbocharger for ol leaks. Check the intake tube for ol Refer to Procedures 010-040 and 010-049. OK Engine angularity during operation exceeds | ‘specification ‘OK Air compressor pumping too high air pressure ~ ‘OK > Continued) Refer to the Engine Specification data sheet. Check the air governor for correct operation. Refer to Procedure 012-017. |ism Section TS - Troubleshooting Symptoms Troubleshooting Procedures and Techniques Page Air Compressor Pumping Excess Lubricating Oil into the Air System (Continued) Cause Crankcase pressure is excessive u - Correction Check for excessive blowby. Refer to Section 14. Refer to the Crankcase Gases (Blowby) Excessive symptom tree, OK Lubricating oi pressure is above specification | Check the oil pressure. Refer to Procedure 007-028. OK ‘Air compressor runs hot If coolant temperature is above normal, refer to the Coolant Temperature Above Normal- Gradual Overheat symptom tree. OK | Lubricating oil drain line is restricted Remove the air compressor, and check the oil drain holes in the air compressor and the accessory drive. Refer to Procedure 012-014. ‘OK Air compressor not designed for application Check the air compressor duty cycle. Install a larger ei compressor if necessary. Refer to Section G in the Master Repair Manual, Holset® Air Compressors, Bulletin No. 3666121 Air installation issues OK Refer to the Automotive and Bus Installation Recommendations - Air Compressor Systems, Bulletin No. 3884946. l a Air compressor is excessively worn or internally damaged. Replace or rebuild the air compressor. Refer to Procedure 012-014, Replace the desiccant ‘element on the Turbo/GR 2000 air dryer (if equipped). Refer to the manufacturer's instructions.Troubleshooting Procedures and Techniques Page TS-10 ism Section TS - Troubleshooting Symptoms Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously) This is symptom tree T008. Cause Correction Block the vehicle wheels and check the air systom for leaks with sping brakes appiod ‘and released. Check for leaks from the air | eee ‘compressor gaskets and the air system hoses, fittings, and valves. Refer to Procedure 012-019 | and the OEM service manuals. OK Air governor is maitunctioning or not set correctly Check the alr governor for correct operation. Refer to Procedure 012-017. OK ‘Air compressor intake or exhaust valve leaks ar Inspect the air compressor intake and exhaust valve assemblies. Fefer to Procedures) 012-103, 012-104, or 012-106. OK Cover gasket is leaking internally (Holset™ SS models only) Check the torque on the unloader screws. Refer to Procedure 012-013. OK Ar installation issues Refer to the Automotive and Bus Installation Recommendations - Air Compressor Systems, Bulletin No. 3884946,IsM Section TS - Troubleshooting Symptoms Troubleshooting Procedures and Techniques Page TS-11 Air Compressor Will Not Pump Air This is symptom tree TO09. Cause Correction Air governcr is malfunctioning or not set correctly Check the air governor for correct operation Refer to Procedure 012-017. OK Unloader valve is malfunctioning Check the unloader valve and unloader body seal. Refer to Procedure 012-013, OK A Air compressor intake or exhaust valve leaks air Inspect the air compressor intake and exhaust valve assemblies. Refer to Procedure(s) 012-103, 012-104, or 012-108. OK Cover gasket is ruptured (Holset™ SS models, only) OK Check the discharge line for blockage. Refer to Procedure 012-003. Check the cover gasket for flatness. Replace the cover gasket. Air compressor is excessively worn or internally damaged Replace or rebuild the air compressor. Refer to Procedure 012-014,‘Troubleshooting Procedures and Techniques Page TS-12 ism Section TS - Troubleshooting Symptoms Air Compressor Will Not Stop Pumping This Is symptom tree T010. Cause Correction Ar system leaks. Block the vehicle wheels and check the air system for leaks with spring brakes applied and released. Check for leaks from the air Compressor gaskets and the air system hoses, fitiings, and valves. Refer to Procedure 012-019 | and the OEM service manuals. OK Air governor is malfunctioning or not set correctly ‘Check the air governor for correct operation. Refer to Procedure 012.017. ‘OK Air governor signal line or actuator line is plugged Inspect the signal line and actuator line. Refer to the manufacturer's instructions. : J OK Air system component is malfunctioning Check the operation of check valves, alcohol evaporators, air dryers, and other OEM- installed air system components, Refer to the ‘manufacturer's instructions. OK Unioader valve is malfunctioning ‘Check the unloader valve and unloader body seal. Refer to Procedure 012-013. OK ‘Air compressor intake or exhaust valve leaks air Ingpect the air compressor intake and exhaust valve assemblies. Refer to Procedure(s) (012-103, 012-104, or 012-106.ism Section TS - Troubleshooting Symptoms ‘Troubleshooting Procedures and Techniques Page TS-13 Alternator Not Charging or Insufficient Charging This is symptom tree TO13. Cause Correction Vehicle gauge is malfunctioning Check the vehicle gauge. Refer to the OEM service manual ‘OK Alternator belt is loose Check the alternator belt tension. Adjust as necessaty, Refer to Procedure 15-008 Tighten the pulley. Refer to manufacturer's instructions. Alternator drive pulley is loose on the water pump shaft ‘OK Battery cables or connections are loose, broken, or corroded (excessive resistance) z ‘OK ‘Make sure the drive pulley is tight on the shaft Refer to Procedure 009-010. Check the battery cables and connections. Refer to Procedure 013-009. | Batteries have failed OK Check the condition of the batteries. Refer to Procedure 013-007. Replace the batteries if necessary. Refer to the OEM service manual Alternator or yoltage regulator is malfunction ‘Test the alternator output. Refer to Procedure 013-001. Replace the alternator or voltage ing regulator if necessary. Refer to the OEI service manual. = oo — Electrical system is “open” (blown fuses, broken wires, or loose connections) Check the fuses, wires, and connections. Refer to the OEM service manual and the manufac- | turer’s wiring diagrams. OK Alternator is cverloaded or alternator capacity is below specification Install an alternator with higher capacity. Refer to Procedure 013-001 and the OE! service manual OK (Continued)‘Troubleshooting Procedures and Techniques Page TS-14 IsM Section TS - Troubleshooting Symptoms Alternator Not Charging or Insufficient Charging (Continued) Cause Correction Battery temperature is above specification Position batteries away from heat sources. Refer to the OEM service manualism Section TS - Troubleshooting Symptoms Troubleshooting Procedures and Techniques Page TS-15 Alternator Overcharging This is symptom tree TO14. Cause Correction Voltage regulator is malfunction Check the voltage regulator. Replace the Vollage regulator I necessary. Refer to the GEM service manual. OK Battory cell is damaged (open circuit) Check the condition of the batteries. Replace the batteries if necessary. Refer to the OEM service manual.Troubleshooting Procedures and Techniques Page TS-16 ism Section TS - Troubleshooting Symptoms Communication Error - Electronic Service Tool or Control Device This is symptom tree TO16. Cause Correction Keyswitch Is in the OFF position ‘Tur on the Keyswitch OK Datalink is locked up ‘Tum off the keyswitch and the electronic service tool and disconnect the battery cables for a least § minutes. Connect the battery cables and turn on the keyswitch and the electronic service tool to establish communica ion. INLINE adapter (detalink adapter) is not connected to the battery voltage supply ‘the appropriate INSITE™ user's manual. —— | Electronic service tool cartidge or software is wot corac ‘othe system OK Electronic control module (ECM) is not Verify that the electronic service tool cartridge or software is correct for thi Calibrate the ECM. Refer to the appropriate | Papen lectronic service tol manual and Procedure ‘OK Moisture in the wiring harness connectors OK Dry the connectors with Cummins electronic cleaner, Part No. 3824510. Keyswitch circuit is malfunctioning Check the vehicle keyswitch circuit. Refer to Procedure 019-064 of the ISM Fuel System Troubleshooting and Repair Manual, Bulletin | No. 3666266. ‘OK * Continued)ism Secti ion TS - Troubleshooting Symptoms Troubleshooting Procedures and Techniques Page Communication Error - Electronic Service Tool or Control Device (Continued) Cause Correction Battery voltage supply to the vlectronic contiol ‘module (ECM) has been lost, ‘Check the battery connections. Refer to | Procedure 013-009 in the base engine Trouble- | shooting and Repair Manual. Check the fuses and the unswitched battery supply circuit. || Refer to Procedures 019-188 and 019-087 of | the ISM Fuel System Troubleshooting and Repair Manual, Bullatin No. 3666: Electronic control module (ECM) is not grounded correctly Check the ECM for correct placement of star washers. Refer to Procedure 019-031 of the ISM Fuel System Troubleshooting and Repair Manual, Bulletin No. 3666266. OK Electronic service tool is malfunctioning Check the electronic service tool by trying it on another engine OK Monitor devices are connected to the data link ‘Tum off or disconnect the monitor devices while using the electronic service tool. OK Dataliné circuit is malfunctioning Check the datalink circuit, Refer to Procedure 019-028 of the ISM Fuel System Troubleshoot ing and Repair Manual, Bulletin No. 3666266. OK Datalink is locked up ‘Tum off the keyswitch and the electronic service tool and disconnect the battery cables {or a least 5 minutes. Connect the battery cables and turn on the keyswitch and the electronic service tool to establish communica. tion. Electronic ccntro! module (ECM) is malfunc- tioning Replace the ECM. Refer to Procedure 019-031 Of the ISM Fuel System Troubleshooting and | Repair Manual, Bulletin No, 3666266.Troubleshooting Procedures and Techniques Page TS-18 Section TS - Troubleshooting Symptoms Coolant Loss - External This is symptom tree TO20. Cause Correction Coolant level is above specification Check the coolant level. Refer to the OEM service manual OK External coolant leak Inspect the engine for coolant leaking from hoses, drain cocks, water manifold, jumper tubes, expansion and pipe plugs, fittings, radiator core, air compressor and cylinder head gaskets, lubricating oll cooler, water pump seal, and OEM-mounted components that have coolant flow. If necessary, pressure-test the cooling system. Refer to Procedure 008-018 and OK Radiator cap is not correct, is malfunctioning, or has low-pressure rating Check the radiator pressure cap. Refer to Procedure 008-047. OK 1e oF vent lines are restricted, obstructed, (F not routed correctly Check the vent lines and the fill ine for correct routing and for restriction. Refer to Procedure 008-017 or the OEM specifications. OK Air or combustion gases are entering the cooling system Check for air or combustion gases in the cooling system. Refer to Procedure 008-019. OK Engine is overheating Refer to the Coolant Temperature Above Normal symptom tree.ism Section TS - Troubleshooting Symptoms Coolant Loss ‘Troubleshooting Procedures and Techniques Page TS-19 Internal This is symptom tree TO21. Correction Air compressor cylinder head is cracked or porous, or has a leaking gasket Inspect the air compressor cylinder head and gasket. Refer to Procedure 012-103, 012-104, ‘6r 012.106. Check the lubricating oil cooler for coolant leaks. Refer to Procedure 007-003, Air or combustion gases are entering the cooling system Check for air or combustion gases in the cooling system. Refer to Procedure 008-019. OK Cylinder head gasket is leaking Check the cylinder head gasket. Refer to Procedure 002-004, ‘OK Cylinder head is cracked or porous, or an injector sleeve is leaking OK Pressure-test the cylinder head and inspect the injector sleeves. Refer to Procedure 002-004. Fuel heater is malfunctioning (if equipped) OK Check the fuel heater and replace if necessary. Refer to the manufacturer's instructions. ‘Transmission oil cooler of torque converter cooler is leaking Check the transmission oil cooler and torque converter cooler for coolant leaks. Refer to the manufacturer's Instructions. Cylinder liner is corroded or cracked, or the cylinder block is cracked or porous Remove the oil pan. Prossure-test the cooling system to check for leaks. Refer to Procedure 001-027 .‘Troubleshooting Procedures and Technique Page TS-20 ism Section TS - Troubleshooting Symptoms Coolant Temperature Above Normal - Gradual Overheat This Is symptom tree T022. Cause Correction Electronic fault codes active or hich counts of View and troubleshoot the fault codes with INSITE™. Refer to View and troubleshoot the fault codes with Insite. Refer to Section T in inactive fault codes. the Troubleshooting and Repair Manual, Bulletin No. 3666266 for fault code trouble- shooting, OK a Coolant temperature gauge is malfunctioning ‘Test the temperature gauge. Repair or replace the gauge if necessary. Refer to Procedure (008-004 and the OEM service manual. OK Cold weather radiator cover or winterfront is Open the cold weather radiator cover or the winterfront. Maintain a minimum of 784 cm chsed [120 in*] or approximately 28 cm x 28 cm [11 in X 1f in] of opening at al times. OK 7 Coolant level is below specification OK Inspect the engine and cooling system for external coolant leaks. Repair if necessary. ‘Add coolant. Refer to Procedure 008-018. {Charge air cooler (CAC) tins, radiator tins, or air conditioner condenser fins are damaged or obstructed with debris OK Inspect the CAC, air conditioner condenser, and radiator fins. Clean if necessary. Refer 10 Procedures 010-027 and 008-042 and the OEM service manual, Cooling system hose is collapsed, restcted, or aking Inspect the radiator hoses. Refer to Procedure 008-045, OK Fan drive belt is loose Check the belt tension and tighten if neces- sary, Refer to Procedure 008-002. OK Lubricating oil level is above or below specifi- cation Check the oil level. Add or drain oll it neces sary, Refer to Procedure 007-025. Check the dipstick calibration. Refer to Procedure 007-008. OK * Continued)ism Section TS - Troubleshooting Symptoms ‘Troubleshooting Procedures and Techniques Page TS-21 Coolant Temperature Above Normal - Gradual Overheat (Continued) Cause Fan shroud is damaged or missing, or the air recirculation baffles are damaged or missing OK Radiator cap is not correct, is malfunctioning, | oF has low-pressure rating OK Correction Inspect the shroud and the recirculation baffies. Repair, replace, or install if necessary. Refer to Procedure 008-038 and the OEM service manual. Check the radiator pressure cap. Refer to Procedure 008-047. ‘Supplemental coolant additive (SCA) level is above specification or the coolant is overcon- certrated with antifreeze Check the SCA level. Verify the antifreeze concentration. Refer to Cooling System ‘Specifications in Section 8. OK Fill line or ven: lines are restricted, obstructed, oF nat routed correctly OK Intake manifold air temperature is above | specification Radiator shutters are not opening completely ‘or the shutterstat setting is wrong ‘OK Fan drive or fan controls are malfunctioning Thermostat is not correct or is malfunctioning OK (Continued) OK Check the vent lines and the fil line for correct, routing and for restriction. Refer to Procedure 008-017 or the OEM specifications. Refer to the Intake Manifold Air Temperature ‘Above Specification symptom tree. —————————— Inspect the radiator shutters. Repair or replace if necessary. Refer to the manufacturer's instructions. Check the shutterstat setting. Refer to Procedure 008-020 or 008-049, Check the fan drive and controls. Refer to Procedures) 008-024, 008-025, 008-026, | 008-027, or 008-028. Check the thermostat for the correct part ‘umber and for correct operation. Refer to Procedure 008-013,‘Troubleshooting Procedures and Techniques Page TS-22 IsM Section TS - Troubleshooting Symptoms Coolant Temperature Above Normal - Gradual Overheat (Continued) Cause Correction Air or combustion gases are entering the cooling system Check for air or combustion gases in the cooling system. Refer to Procedure 008-019. OK Cooling system component is malfunctioning Perform the Cooling System Diagnostics Test. Refer to Procedure 008-020. OK | Radiator core is internally obstructed or damaged, or the check valve or Jtube is | matfunetioning Inspect the radiator and clean i necessary. Refer to. OK Check vaive is damaged (with remote mounted ‘engine coolant heater) OK Inspect the check valve. Replace if necessary. Refer to the manufacturer's instructions. Torque converter is malfunctioning Check the torque converter. Refer to the OEM service manual. Vehicle cooling system is not adequate Verify that the engine and vehicle cooling systems are using the correct components. jefer to the OEM specifications.Is Section TS - Troubleshooting Symptoms Troubleshooting Procedures and Techn 9 Coolant Temperature is Above Normal - Sudden Overheat This Is symptom tree T023. Cause Correction 23 Electronic fault codes active or high counts of inactive fault codes View and troubleshoot the fault codes with INSITE™. Refer to Section T in the Trouble- shooting and Repair Manual, Bulletin No. 3666266 for fault code troubleshooting, Far drive belt is broken OK Check the fan drive belt. Replace the belt if necessary. Refer to Procedure 008-002. Coolant level is below specification Inspect the engine and cooling system for external coolant leaks. Repair if necessary. ‘Add coolant. Refer to Procedure 008-018. OK Cooling system hose is collapsed, restricted, or leaking OK Inspect the radiator hoses. Refer to Procedure 008-045, Radiator shutters are not opening completely or the shutterstat setting is wrong ‘OK Inspect the radiator shutters. Repair or replace If necessary. Refer to the manufacturer's Instructions. Check the shutterstat setting Refer to Procedure 008-020 or 008-049, Fan drive or fan controls are malfunctioning Check the fan drive and controls. Refer to Procedure(s) 008-024, 008-025, 008-026, (008-027, or 008-028, OK Cooling systen component is malfunctioning OK Perform the Cooling System Diagnostics Test. Refer to Procedure 008-020. ‘Thermostat is not correct or is malfunctioning Check the thermostat for the correct part ‘number and for correct operation. Refer to Procedure 008-013.‘Troubleshooting Procedures and Techniques Page TS-24 IsM Section TS - Troubleshooting Symptoms Coolant Temperature is Below Normal This Is symptom tree T024, Coolant temperature gauge is malfunctioning Correction Test the temperature gauge. Repair or replace the gauge if necessary. Fefer to Procedure (008-004 and the OEM service manual. OK Engine is operating at low ambient temperature Check the winterfront, shutters, and underhood ait. Refer to Cold Weather Operation, Bulletin No. 3387266, and the Operation and Mainte- nance Manual. Use intake air from under the hood in cold weather. Coolant fill ine is not routed correctly Check the routing of the coolant fil line. Refer to the OEM service manual. OK Radiator shutters are stuck open or opening Check the shutter operation. Repair or replace the shutters if necessary. Refer to the OEM early service manual and Procedure 008-020 or 008-049 019-019 In Bulletin No. 2666130-02. OK 7 Fan drive or fan cortrols are malfunctioning Check the fan drive and controls. Refer to Procedure(s) 008-024, 008-025, 008-026, 008-027, or 008-028. ‘OK Cooling system component is malfunctioning Perform the Cooling System Diagnostics Test. Refer to Procedure 008-020. OK ‘Thermostat is not correct or is malfunctioning OK Check the thermostat for the correct part ‘umber and for correct operation. Refer to Procedure 008-013. ‘Thermostat seal is damaged, missing, or not installed correctly [ | l ‘OK * Continues) Check the thermostat seal. Check the thermo- stat for correct seating. Refer to Procedure 008-013 or 008-016,ism ‘Troubleshooting Procedures and Techniques Section TS - Troubleshooting Symptoms Page T: Coolant Temperature is Below Normal (Continued) Cause Correction Check for correct coolant flow through the Coolant flow through the radiator is not correct |......| Check for correct coolant flow throust‘Troubleshooting Procedures and Techniques. Page TS-26 ism Section TS - Troubleshooting Symptoms Coolant in the Lubricating Oi This is symptom tree TO25. Cause Correction Lubricating oll cooler is leaking OK Check the lubricating oil cooler for coolant leaks. Refer to Procedure 007-003 ‘Air compressor cylinder head is cracked or porous, or has a leaking gasket Inspect the air compressor cylinder head and gasket, Refer to Procedure 012-103, 012-104, and 012-108. OK Cylinder head gasket is leaking Check the cylinder head gasket. Refer to Procedure 002-004 or 003-021 OK Cylinder head is c’acked or porous, or an injector slaeve is leaking Pressure-test the cylinder head and inspect the Injector sleeves. Refer to Procedure 002-004. OKaeeanet Cylinder block is cracked or porous Remove the oil pan. Pressure-test the cooling stem to check for leaks. Refer to Procedure 1-027IsM Section TS - Troubleshooting Symptoms ‘Troubleshooting Procedures and Techni Pi Crankease Gases (Blowby) Excessive Thi Cause is symptom tree T027. Correction Crankcase ventilation system is plugged OK Check and clean the crankcase breather and vent tube, Refer to 003-002 Centrifugal bypass filter is malfunctioning OK ‘Turbocharger oil seal is leaking Disconnect and plug the air supply line to the filer. Refer to Procedure 0007-012. Check for blowby again. If blowby is within specifications, fepat he liter. Reler tthe OEM service Check the turbocharger compressor and turbine seals. Refer to Procedure 010-040 or 010-049, OK Air compressor is malfunctioning Rocker lever housing or rocker lever housing | gasket is leaking intake air into the crankcase [ Isolate the alr compressor by disconnecting the air inlet and outlet lines. Refer to Proce- dure 012-003. Check biowby. If blowby is within specifications, rebuild or repiace the air compressor. Inspect the rocker lever housing for cracks. Inspect the gasket for tears and breaks. Inspect the gasket sealing surface for scratches and cracks. Refer to Procedure 003-013. OK Cylinder head vaive guides are excessively | worn t OK Piston, piston tings, or oylinder liner is worn or damaged Check the valve guides for wear. Replace the cylinder head if necessary. Refer to Procedure 002-004 Check the pistons, piston rings, and cylinder liner. Refer to Procedures 007-043, 001-047, and 001-028,Troubleshooting Procedures and Techniques Page TS-28 ism Section TS - Troubleshooting Symptoms Cranking Fuel Pressure is Low This is symptom tree 7029. ‘cause Fuel inlet restriction excessive OK Correction | Check for fuel inlet restriction. Refer to Procedure 006-020, Fuel leak is causing fuel to drain back in the ‘suciion line ‘Check for fuel drain back. Refer to Procedure 005-011 ‘OK the fuel system Check for air in the fuel system. Refer to Procedure 006-003. ‘OK Fuel pump (gear or shaft) is not rotating Check the fue! pump for shatt rotation and fuel flow, Refer to Procedure 005-016. ‘OK Inline check valve(s) are installed backwards ‘or have incorrect part number Check the in-line check valves for the correct part number. Check the arrow on the check Valve(s) for the correct orient OK Fuel pump gear pump check valve is stuck | open ‘OK Fuel pump pressure regulator is stuck Replace the check valve. Refer to Procedure | 005-026. Check the fuel pump pressure regulator. Refer to Procedure 005-060. Injector o-rings are damaged or missing Remove and check the injectors. Replace the injector o-rings. Refer to Procedure 006-026,Isw Section TS - Troubleshooting Symptoms Troubleshooting Procedures and Techniques Engine Acceleration or Response Poor This is symptom tree TO33, Cause Correction Electronic fault codes active or high counts of inactive fault codes. OK Read the fault codes with an electronic service tool. Refer to Section TF for fault code trouble- shooting View the fault codes and the engine protection data with an electronic service tool. Refer to the appropriate electronic service tool manual. Refer to the corresponding fault code in Electronic control module (ECM) calibration is Compare the calibration stored in the ECM with the engine rating and the Control Parts List (CPL), Bulletin No, 3379133. If necessary, calibrate the ECM, Refer to the appropriate not correct electronic service tool manual and Procedure 019-032 or Section 018-078 in the ISM Trouble- | shooting and Repair Manual, Bulletin No. | 3666266 : OK Section TF. OK Test the engine operation while under load. Perform an engine acceleration tet, Perform Verify the complaint an engine load test. Observe the percent load with an electronic service tool. Refer to the Operability/Low Power form. J OK Programmable parameters or selected features. ‘are not correct, Check the programmable parameters and the selected features with an electronic service tool. Set the parameters and features again if necessary. Refer to the appropriate electronic service too! manual or Section 019-078 in the ISM Troubleshooting and Repair Manual, Bulletin No, 3666266. ‘Turbocharger is not correct, (Continued) Check the turbocharger part number and ‘compare it to the Control Parts List (CPL), Bulletin No. 3379133. Replace the turbo- charger if necessary. Refer to Procedure 010-633.‘Troubleshooting Procedures and Techniques Page TS-30 ism Section TS - Troubleshooting Symptoms Engine Acceleration or Response Poor (Continued) Cause Fuel grade is not correct for the application, or the fuel quality is poor OK Accelerator pedal is restricted or malfunction- Correction Operate the engine from a tank of good fuel. Refer to Fuel Recommendations and Specifica- tions, Check the percent throttle reading on an electronic service tool. Verify that It reads 100 percent with the accelerator pedal depressed and zero percent when released. Calibrate the .J1939 control device causing engine to derate a accelerator if possible. Replace the accelerator pedal if necessary. Refer to the OEM service manual, | _ x — Check the 1939 history using electronic service tool OK Fuel inlet restriction Check for fuel inlet restriction. Refer to Procedure 008-020 OK Fuel drain line restriction Check the fuel drain lines for restriction. Clear oF replace the fuel lines, check valves, or tank vents as necessary. Refer to Procedure 006-012. OK Air in the fuel system Check for air in the fuel system. Bleed air from the system. Refer to Procedure 006-003. ‘OK Injector is matfunctioning Perform the automated cylinder performance test. Replace injectors as necessary. Refer to Procedure 006-026 or 014-008, ‘OK Ambient air pressure sensor is malfunctioning check the ambiont air pressure sensor. Refer to Procedure 019-004. (Continued)ism Section TS - Troubleshooting Symptoms Troubleshooting Procedures and Techniques Page TS-31 Engine Acceleration or Response Poor (Continued) Cause Correction Fuel inlet temperature to pump is above ‘Specification Fill the fuel tank, turn off or bypass the fuel heaters, and check the fuel cooler. Refer to the OEM service manuals. — Charge air cooler (CAC) is restricted or leaking Inspect the CAC for air restriction or leaks. Refer to Procedure 010-027. Intake manifold pressure (boost) is below specification — 2 Refer to the Intake Manifold Pressure (Boost) is. Bolow Normal symptom tree. ‘OK Intake manifold pressure (boost) sensor or Circuit is malfunctioning ‘OK Air insake or exhaust leaks OK Check the boost sensor and circuit. Refer to Procedure 019-061 in the ISM Troubleshooting and Repair Manual, Bulletin No, 3686286. Inspect the air intake and exhaust systems for air leaks, Refer to Procedure 010-024. | Air intake system restriction is above specifica- tion UL OK Check the air intake system for restriction. Clean or replace the air filter and inlet piping as necessary. Refer to Procedure 010-031 Exhaust system restriction is above specifica- tion ‘OK Fuel pump is malfunctioning OK * Continued) Check the exaust system for restrictions, | Refer to Procedure 011-009 | | Check the fuel pump output pressure, pulsa- tion damper, and pressure regulator. Replace the fuel pump if necessary. Refer to Proce- dures 005-011, 005-016, and 005.031Troubleshooting Procedures and Techniques. Page TS-32 ism Section TS - Troubleshooting Symptoms Engine Acceleration or Response Poor (Continued) Cause Correction Drivetrain is net correctly matched to the engine Cueckeecomagwogad sven | ‘components. Refer to the OEM vehicle | specifications. OK Vehicle speed sensor (VSS) or circuit is Check the vehicle speed sensor and circult. Refer to Procedures 019-090 and 019-091 in| maltunetioning the ISM Troubleshooting and Repair Manual, Bulletin No, 3666266, — OK Vehicle parasitics are excessive Check the vehicle brakes for geogns transmission malfunction, cooling fan operation cycle time, and engine-driven units. Refer to the OEM service manual. OK Engine brake acjustment is not correct ‘Adjust the engine brakes. Refer to Procedure 020-001. Overhead adjustments are not correct Measure and adjust the overhead settings. Refer to 003-00 Fuel supply line restriction between the fuel ‘pump and the injectors Check the fuel supply line from the fuel pump to the cylinder head for sharp bends that can cause restrictions. Refer to Procedure 005-024 ‘Turbocharger wastegate actuator is malfunc- tioning (if equipped) Check the ran wastegate actuator for correct operation. Refer to Procedure 010-050. ‘OK ‘Turbocharger wastegate controller is malfunc- tioning (i equipped) eae “OK (Continued) Inspect the wastegate controller components. Refer to Procedure 010-050.Is Troubleshooting Procedures and Techniques Section TS - Troubleshooting Symptoms Page TS-33 Engine Acceleration or Response Poor (Continued) Cause Correction Remove the injectors and compare the part Injectors are not correct sooo) Bulletio No, 3878158 Replace the injectors it necessary Reler to Procedure 006 OK ‘Analyze the oil and inspect the filters to locate Internal engine damage an area of probable damage. Refer to Proce- dure 007-002.