Troubleshooting and Repair Manual

ISB, ISBe2, ISBe3, ISBe4, QSB4.5, QSB5.9,

QSB6.7, ISC, QSC8.3, ISL, ISLe3, ISLe4, and
QSL9, CM850 Electronic Control System
Volume 1
 Troubleshooting and Repair Manual
ISB, ISBe2, ISBe3, ISBe4, QSB4.5, QSB5.9, QSB6.7, ISC,
QSC8.3, ISL, ISLe3, ISLe4, and QSL9, CM850 Electronic Control
System
Volume 1

Copyright© 2014 Bulletin 4021416

Cummins Inc. Printed 01-APRIL-2014
All rights reserved

To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com
 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.

To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com
 Table of Contents
Section

Introduction ........................................................................................................................................................ i

Engine and System Identification .................................................................................................................... E

Familiarization .................................................................................................................................................... F

Troubleshooting Fault Codes (FC0001 - FC) ................................................................................................... TF

Back .................................................................................................................................................................... back

To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com
To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com
ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]
Section i - Introduction Page i-a

Section i - Introduction
Section Contents
Page
About the Manual .........................................................................................................................................................i-1
General Information.....................................................................................................................................................i-1
Acronyms and Abbreviations ...................................................................................................................................i-17
General Information...................................................................................................................................................i-17
General Cleaning Instructions ..................................................................................................................................i-12
Abrasive Pads and Abrasive Paper...........................................................................................................................i-12
Definition of Clean......................................................................................................................................................i-12
Fuel System...............................................................................................................................................................i-15
Gasket Surfaces........................................................................................................................................................ i-13
Plastic Bead Cleaning................................................................................................................................................i-14
Solvent and Acid Cleaning.........................................................................................................................................i-13
Steam Cleaning......................................................................................................................................................... i-14
General Repair Instructions ......................................................................................................................................i-10
General Information...................................................................................................................................................i-10
Welding on a Vehicle with an Electronic Controlled Fuel System..............................................................................i-11
General Safety Instructions ........................................................................................................................................i-8
Important Safety Notice...............................................................................................................................................i-8
How to Use the Manual ................................................................................................................................................i-2
General Information.....................................................................................................................................................i-2
Illustrations ...................................................................................................................................................................i-7
General Information.....................................................................................................................................................i-7
Symbols ........................................................................................................................................................................i-3
General Information.....................................................................................................................................................i-3

To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com
 ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]
Page i-b Section i - Introduction

This Page Left Intentionally Blank

ISB, ISBe2, ISBe3, ISBe4, QSB4 [...] About the Manual
Section i - Introduction Page i-1

About the Manual

General Information
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' filmcard system. Some
sections contain reference numbers and procedure numbers. Reference numbers provide general information,
specifications, diagrams, and service tools where applicable. Procedure numbers are used to identify and reference
specific repair procedures for correcting the problem.
This manual does not contain fuel systems electronic troubleshooting. Use the troubleshooting trees in this manual, if
there are no electronic fault codes.
This manual is designed so the troubleshooting trees are used to locate the cause of an engine problem. The
troubleshooting trees then direct the user to the correct repair procedure. The repair procedures within a section are 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.

To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com
How to Use the Manual ISB, ISBe2, ISBe3, ISBe4, QSB4 [...]
Page i-2 Section i - Introduction

How to Use the Manual

General Information
This manual is organized to provide an easy flow from problem identification to problem correction.
A list of troubleshooting symptoms containing the most common problems 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.
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 title.
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 continuing downward to the most difficult.
• The right column of boxes provides a brief description of the corrective action with a reference number to the
correct procedure used to make the repair.
3 Locate the probable cause in the left column then turn to the procedure referenced in the right column.
4 The Troubleshooting Symptom Charts are based on the following assumptions:
• The components have been installed according to the manufacturer's specifications.
• The easiest repairs are done first.
• All generic solutions are designed for the most common applications and Original Equipment Manufacturer
(OEM).
Refer to the Original Equipment Manufacturer's service manual for their specifications.

To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com