Cummins Troubleshooting And Repair Manual Ism Qsm 11 Volume 2

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Troubleshooting and Repair Manual

ISM, ISMe, and QSM11 Engines Volume 2

Troubleshooting and Repair Manual
Cummins Inc.
Box 3005 e
Columbus, Indiana, U.S.A., 47202 ISM, ISM , and QSM11 Engines
Registered Office Volume 2
Cummins Engine Company, Ltd
Unit 1-B Uniongate, Ridgeway Trading Estate,
Iver,
Buckinghamshire SL0 9HX,
England
Registration 573951 England

Copyright© 2005
Cummins Inc.

Bulletin 3666322
Printed in U.S.A. 15-AUGUST-2005 p63

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 Troubleshooting and Repair Manual
ISM, ISMe, and QSM11 Engines
Volume 2

Copyright© 2005 Bulletin 3666322

Cummins Inc. Printed 15-AUGUST-2005
All rights reserved
 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 identifying and correcting problems
related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment
manufacturer for repair procedures.
A series of specific service manuals (for example: Shop, Specifications, and Alternative Repair) are available and can
be ordered by Contacting your local area Cummins Regional office. A Cummins Regional office listing is located in
Service Literature (Section L).
The repair procedures used in this manual are recommended by Cummins Inc. Some service procedures require the
use of special service tools. Use the correct tools as described.
Cummins 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 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
replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts. These parts
can be identified by the following trademarks:
 Table of Contents
Section

Injectors and Fuel Lines — Group 06 ...................................................................................................... 6

Lubricating Oil System - Group 07 .......................................................................................................... 7

Cooling System - Group 08 ...................................................................................................................... 8

Drive Units - Group 09 .............................................................................................................................. 9

Air Intake System - Group 10 ................................................................................................................... 10

Exhaust System - Group 11 ..................................................................................................................... 11

Compressed Air System - Group 12 ........................................................................................................ 12

Electrical Equipment - Group 13 .............................................................................................................. 13

Engine Testing - Group 14 ....................................................................................................................... 14

Mounting Adaptations - Group 16 ............................................................................................................ 16

Miscellaneous - Group 17 ......................................................................................................................... 17

Vehicle Braking — Group 20 .................................................................................................................... 20

Service Literature ..................................................................................................................................... L

Component Manufacturers ....................................................................................................................... M

Specifications ........................................................................................................................................... V
ISM, ISMe, and QSM11
Section 6- Injectors and Fuel Lines — Group 06 Page 6-a

Section 6- Injectors and Fuel Lines — Group 06

Section Contents
Page
Air in Fuel ..........................................................................................................................................................6-3
Test..................................................................................................................................................................6-3
Sight Glass Method........................................................................................................................................6-3
Gear Pump Drain Method...............................................................................................................................6-4
Cylinder Misfires or Smokes .............................................................................................................................6-6
Automated Cylinder Performance Test..............................................................................................................6-6
ISM................................................................................................................................................................6-6
Cylinder Cutout Test.........................................................................................................................................6-6
ISM................................................................................................................................................................6-6
Exhaust Manifold Temperature Test..................................................................................................................6-7
Exhaust Manifold Tilt-back Method....................................................................................................................6-7
General Information..........................................................................................................................................6-6
ECM Cooling Plate, Fuel Cooled .......................................................................................................................6-8
Inspect for Reuse..............................................................................................................................................6-9
Install................................................................................................................................................................6-9
Remove............................................................................................................................................................6-8
Fuel Drain Line Restriction .............................................................................................................................6-10
Measure..........................................................................................................................................................6-10
ISM..............................................................................................................................................................6-10
Fuel Filter (Spin-On Type) ...............................................................................................................................6-11
Install..............................................................................................................................................................6-12
Remove..........................................................................................................................................................6-11
Fuel Inlet Restriction .......................................................................................................................................6-13
Measure..........................................................................................................................................................6-13
ISM..............................................................................................................................................................6-13
Fuel Supply Lines ............................................................................................................................................6-15
Inspect for Reuse............................................................................................................................................6-15
Install..............................................................................................................................................................6-16
Remove..........................................................................................................................................................6-15
Injector .............................................................................................................................................................6-22
Install..............................................................................................................................................................6-25
ISM..............................................................................................................................................................6-25
Remove..........................................................................................................................................................6-22
ISM..............................................................................................................................................................6-22
Service Tools ....................................................................................................................................................6-1
Injectors and Fuel Lines....................................................................................................................................6-1
Static Injection Timing ....................................................................................................................................6-17
Measure..........................................................................................................................................................6-18
Setup..............................................................................................................................................................6-17
 ISM, ISMe, and QSM11
Page 6-b Section 6- Injectors and Fuel Lines — Group 06

This Page Left Intentionally Blank

ISM, ISMe, and QSM11 Service Tools
Section 6- Injectors and Fuel Lines — Group 06 Page 6-1

Service Tools
Injectors and Fuel Lines

The following special tools are recommended to perform procedures in this section. The use of these tools
is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized
Repair Location.

Tool No. Tool Description Tool Illustration

Vacuum Gauge (0 to 30 in. Hg)
Used to check fuel inlet restriction. Fuel restriction adapters, Part
Numbers ST-434-1, 3375845, and 3376922, are required and must
ST-434
be ordered separately.

Hose Adapter
Used with vacuum gauge, Part Number ST-434. Use Part Number
ST-434-1 ST-434-1 with Number 8 hose. Use Part Number ST-434-2 with
ST-434-2 Number 10 hose.

Sight Glass
Used to check for air in the fuel suction line. Use Part Number
ST-998
3375362 with Number 12 hose, and Part Number 3375808 with
3375362
Number 16 hose.
3375808

Mercury-Filled Slack Tube Manometer

Used to measure fuel drain line restriction.
ST-1111-3

Chip Removing Unit

Used to remove carbon from the top of the piston. Refer to capscrew
ST-1272-11
salvage thread kit, Part Number 3376208. Chip unit, Part Number
or
3823461, is a vacuum tool.
3823461

Filter Wrench
Used to remove or tighten spin on fuel filters.
3376807
Service Tools ISM, ISMe, and QSM11
Page 6-2 Section 6- Injectors and Fuel Lines — Group 06

Tool No. Tool Description Tool Illustration

Static Injection Timing Tool
Used to measure static timing.
3823451

CELECT™ Injector Puller and Driver Assembly

Used to remove and install CELECT™ injectors.
3823579
ISM, ISMe, and QSM11 Air in Fuel
Section 6- Injectors and Fuel Lines — Group 06 Page 6-3

Air in Fuel (006-003)

Test
Sight Glass Method
Remove the fuel suction line.
Install a sight glass, Part Number 3375362, in the line.
Operate the engine.
A small air leak will have a milky appearance. A large air
leak will look like bubbles in the fuel.

If an air leak is found, inspect the fuel lines, o-rings, and

fittings for damage. Check for loose connections.
Replace the damaged lines or tighten the loose
connections.

Operate the engine at high idle with no load, and check

the sight glass.

Tighten the hose connections and the fuel filter.

Check the drop tube in the fuel tank for damage.
Air in Fuel ISM, ISMe, and QSM11
Page 6-4 Section 6- Injectors and Fuel Lines — Group 06

Replace any defective parts as required.

Remove the sight glass, and install the suction hose.
Test the engine again for other air leaks.

Gear Pump Drain Method

Remove the gear pump cooling drain line from the check
valve, and install a plug in the line.
Install a hose on the check valve and place the other end
of the hose in a container.

Operate the engine at high idle with no load.

If air is entering the fuel pump suction line, bubbles will be

visible in the container of fuel.
ISM, ISMe, and QSM11 Air in Fuel
Section 6- Injectors and Fuel Lines — Group 06 Page 6-5

If bubbles are visible, tighten the fuel supply pump inlet

fitting.
Tighten the cooling plate inlet and outlet fittings.

Tighten the hose connections and the fuel filter.

Check the drop tube in the fuel tank for damage.

Correct the air leak and test again for other leaks.

Remove the hose from the check valve elbow and the plug
from the cooling drain line.
Install the drain line on the check valve.
Cylinder Misfires or Smokes ISM, ISMe, and QSM11
Page 6-6 Section 6- Injectors and Fuel Lines — Group 06

Cylinder Misfires or Smokes (006-005)

General Information

WARNING
Due to the stroke of the injectors on M series engines,
do not use the mechanical method to perform a
cylinder cutout test. When an injector on an engine is
mechanically shorted (barred), the push rods can be
thrown free, causing personal injury. Refer to the
Automated Cylinder Performance Test to perform the
test on M series engines.
The following methods can be used to find the cylinder(s)
causing misfire/white smoke:
• Exhaust manifold temperature
• Tilting back exhaust manifold
• Automated cylinder performance test.

Automated Cylinder Performance Test

ISM
Do not run the automated cylinder performance test on
engines that are smoking at idle.
Perform the automated cylinder performance test at least
twice.
Refer to the appropriate electronic service tool manual.
Minimum cylinder contribution is 71 percent.

Cylinder Cutout Test

ISM
The following methods can be used to find the cylinder(s)
causing misfire/white smoke:
• Exhaust manifold temperature
• Tilting back exhaust manifold
• Automated cylinder performance test.
ISM, ISMe, and QSM11 Cylinder Misfires or Smokes
Section 6- Injectors and Fuel Lines — Group 06 Page 6-7

Cut out each cylinder while watching the exhaust smoke.

Refer to the appropriate electronic service tool manual.
Replace the injector in the cylinder that causes a reduction
in smoke when cut out.

Exhaust Manifold Temperature Test

To locate a smoking cylinder, use a pyrometer or infrared
temperature gun to measure the exhaust manifold surface
temperature at each cylinder port.
The maximum exhaust manifold surface temperature at
idle is 143°C [290°F].
A cylinder is smoking if:
• The exhaust manifold surface temperature at that
exhaust port exceeds the above specification.
• The exhaust manifold surface temperature at that
port is significantly higher than that for the other
cylinder ports.
If this test is inconclusive, tilt back the exhaust manifold
to locate the smoking cylinder.

WARNING
To avoid personal injury, do not place hand on the
exhaust manifold if the engine is hot or emitting thick
black smoke.
An alternative method is to place your hand on the exhaust
manifold at each cylinder port. A smoking cylinder will feel
hot.
Replace the injector in the cylinder that is producing the
smoke. Refer to Procedure 006-026.

Exhaust Manifold Tilt-back Method

Loosen the exhaust manifold capscrews, and tilt the
exhaust manifold back.
ECM Cooling Plate, Fuel Cooled ISM, ISMe, and QSM11
Page 6-8 Section 6- Injectors and Fuel Lines — Group 06

Idle the engine.

Observe the smoking cylinder.
Replace the injector in the cylinder that is producing the
smoke. Refer to Procedure 006-026.

ECM Cooling Plate, Fuel Cooled (006-

006)
Remove
Disconnect the engine wiring harness from the electronic
control module (ECM).
Remove the six ECM mounting capscrews. Remove the
ECM from the cooling plate.

Remove the inlet and outlet fuel plumbing from the cooling
plate.

Remove the four cooling plate mounting capscrews.

Do not lose any of the heat-resistant grommets. They are
on both sides of the cooling plate.
One of the mounting locations has heat-resistant star
washer grommets on both sides of the cooling plate.
Remove the cooling plate.
ISM, ISMe, and QSM11 ECM Cooling Plate, Fuel Cooled
Section 6- Injectors and Fuel Lines — Group 06 Page 6-9

Inspect for Reuse

Inspect the cooling plate for cracks or damage. Replace
the cooling plate if damaged.

Install
Install a new cooling plate.
Install the heat-resistant grommets on both sides of the
cooling plate.
Install the two heat-resistant star washer grommets at the
same mounting location.
Tighten the four capscrews.
Torque Value: 40 N•m [ 30 ft-lb ]

Connect and tighten the inlet and outlet plumbing to the

cooling plate.
Inspect for paint or grease on the cooling plate.

CAUTION
Do not paint the cooling plate. Make sure there is no
grease or dirt between the ECM and the cooling plate.
Install the ECM on the cooling plate.
Install the six capscrews.
Install the star washer under one of the capscrews.
Fuel Drain Line Restriction ISM, ISMe, and QSM11
Page 6-10 Section 6- Injectors and Fuel Lines — Group 06

Tighten the six capscrews.

Torque Value: 20 N•m [ 177 in-lb ]
Connect the engine harness and OEM harness
connectors to the ECM.
Refer to Procedure 019-031 in the Troubleshooting and
Repair Manual, Came Electronic Control System, ISM
Engines, Bulletin 4021381 or Troubleshooting and Repair
Manual, Electronic Control System, ISM and Gismo
Series Engines, Bulletin 3666266.

Close the valve on the inlet side of the manometer. Open

the valve on the outlet side of the manometer. Record the
vacuum reading on the manometer.

Cooling Plate Restriction

mm Hg in Hg
25 MAX 1
If the restriction is greater than the value given, clean or
replace the cooling plate.

Fuel Drain Line Restriction (006-012)

Measure
ISM
Inspect the drain lines, and make sure the lines do not
have any loops and are not kinked.
Remove the fuel drain line, and install the mercury
manometer, Part Number ST-1111-3

Operate the engine at rated speed and no load.

ISM, ISMe, and QSM11 Fuel Filter (Spin-On Type)
Section 6- Injectors and Fuel Lines — Group 06 Page 6-11

Observe the reading on the manometer. Hold the

manometer at the same level as the connection.

Fuel Drain Line Restriction

mm Hg in Hg
89 MAX 3.5

If the restriction is above the maximum specifications,

remove the fuel tank fill cap and check again.

If the restriction is below the specifications when the cap

is removed, replace the tank vents.
If the restriction is still above the specifications, inspect
the drain lines for restrictions.

Fuel Filter (Spin-On Type) (006-015)

Remove
Clean the area around the fuel filter and fuel filter head.
Remove the fuel filter with filter wrench, Part Number
3376807, or equivalent.
Fuel Filter (Spin-On Type) ISM, ISMe, and QSM11
Page 6-12 Section 6- Injectors and Fuel Lines — Group 06

Remove the thread adapter sealing ring (1).

Use a clean, lint-free towel to clean the gasket surface on
the fuel filter head.

Install
Cummins Inc., requires a fuel water separator be installed
in the fuel supply system.
Use correct filters for the engine. Refer to Procedure 018-
024 (Cummins/Fleetguard® Filter Specifications) in
Section V in the Operation and Maintenance Manual, ISM
and ISMe Engines, Bulletin 3666319.

Efficiency Water Removed

98.7% at 10 microns Free = 95%
96% at 8 microns Emulsified = 95%
86% at 5 microns

NOTE: A 10-micron fuel filter is required with Centinel™

equipped engines.
Install the new thread adapter sealing ring (1) supplied
with the new filter.

Install the filter on the filter head.

Turn the filter until the gasket contacts the filter head
surface.
Cummins Troubleshooting And Repair Manual Ism Qsm 11 Volume 2
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ISM, ISMe, and QSM11 Fuel Inlet Restriction

Section 6- Injectors and Fuel Lines — Group 06 Page 6-13

CAUTION
Mechanical overtightening of the filter can distort the
threads and damage the fuel filter seal.
Tighten the filter an additional ½ to ¾ of a turn after the
gasket contacts the filter head surface, or as specified by
the filter manufacturer.

Fuel Inlet Restriction (006-020)

Measure
ISM
Remove the fuel supply hose to the gear pump, and install
the manometer, Part Number ST-1111-3. Use the
appropriate hose adapter for the specific engine as
described in the Service Tools list.
NOTE: If the gear pump inlet fitting has a Compuchek®
fitting, the manometer can be installed there.

Hold the manometer at the same level as the gear pump

connection.

Operate the engine at rated speed and no load.

Observe the reading on the manometer.

Fuel Inlet Restriction

mm Hg in Hg
Clean Filter 152 MAX 6
Dirty Filter 254 MAX 10
Correct the restriction, or replace the fuel filter.
NOTE: The cooling plate on M Series engines has about
25.4-mm Hg [1-in Hg] restriction.

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