Cummins ISC, ISCe, QSC8.3, ISL, ISLe3 Troubleshooting Manual

Troubleshooting and Repair Manual
ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and
QSL9 Engines
Volume 1

Troubleshooting and Repair Manual
ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and
QSL9 Engines
Volume 1

Copyright© 2014 Bulletin 4021418
Cummins Inc. Printed 23-JULY-2014
All rights reserved

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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.

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Table of Contents

Section

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

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

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

Troubleshooting Symptoms ............................................................................................................................. TS

Troubleshooting Symptoms (New Format) ..................................................................................................... TT

Product - Group 00 ............................................................................................................................................ 0

Cylinder Block - Group 01 ................................................................................................................................. 1

Cylinder Head - Group 02 .................................................................................................................................. 2

Rocker Levers - Group 03 ................................................................................................................................. 3

Cam Followers/Tappets - Group 04 ................................................................................................................. 4

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

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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

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Page i-b Section i - Introduction

This Page Left Intentionally Blank

ISC, ISCe, QSC8.3, ISL, ISLe3, [...] 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.

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How to Use the Manual ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Symbols
Section i - Introduction Page i-3

Symbols

General Information

The 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.

NOTE: It is possible to have four symbols for each text and graphic combination.

WARNING
Serious personal injury or extensive property damage
can result if the warning instructions are not followed.

CAUTION
Minor personal injury can result or a part, and
assembly, or the engine can be damaged if the
caution instructions are not followed.

Indicates a REMOVAL or Dissassembly step.

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Symbols ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page i-4 Section i - Introduction

Indicates an INSTALLATION or ASSEMBLY step.

INSPECTION is required.

CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Symbols
Section i - Introduction Page i-5

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque.

PERFORM an electrical MEASUREMENT.

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Symbols ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page i-6 Section i - Introduction

Refer to another location in this manual or another
publication for additional information.

The component weighs 23kg [50 lbs] or more. To reduce
the possibility of personal injury, use a hoist or get
assistance to lift the component.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Illustrations
Section i - Introduction Page i-7

Illustrations

General Information

Some of the illustrations throughout this manual are
generic and will not look 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
replacement procedures. The procedure will be the same
for all applications, although the illustration can differ.

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General Safety Instructions ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page i-8 Section i - Introduction

General Safety Instructions

Important Safety Notice

WARNING
Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation or
other personal injury or death.

Read and understand all of the safety precautions and warnings before performing any repair. 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.

• Work in an area surrounding the product that is dry, well lit, ventilated, free from clutter, 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-fitting or torn clothing. Remove all jewelry when working.

• Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work.

Disconnect the air 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.

• If an engine has been operating and the coolant is hot, allow the engine to cool before slowly loosening the filler

cap to relieve the pressure from the cooling system.

• Always use blocks or proper stands to support the product before performing any service work. Do not work on

anything that is supported ONLY by lifting jacks or a hoist.

• Relieve all pressure in the air, oil, fuel, and 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 utilizes
pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.

• To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect liquid

refrigerant (Freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must be
properly emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into the
atmosphere. Federal law requires capturing and recycling refrigerant.

• To reduce the possibility of personal injury, use a hoist or get assistance when lifting components that weigh 23 kg

[50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the
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 oil, contains alkali. Do not get the substance in 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 flood eyes with large amounts of water for a minimum of
15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.

• Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the

manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF
CHILDREN.

• To reduce the possibility of burns, be alert for hot parts on products that have just been turned off, exhaust gas

flow, and hot fluids in lines, tubes, and compartments.

• Always use tools that are in good condition. Make sure you understand how to use the tools 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.

• When necessary, the removal and replacement of any guards covering rotating components, drives, and/or belts

should only be carried out be a trained technician. Before removing any guards the engine must be turned off and
any starting mechanisms must be isolated. All fasteners must be replaced on re-fitting the guards.

• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] General Safety Instructions
Section i - Introduction Page i-9

• 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.

• Do not connect the jumper starting or battery charging cables to any ignition or governor control wiring. This can
cause electrical damage to the ignition or governor.

• Always torque fasteners and fuel connections to the required specifications. Overtightening or undertightening can
allow leakage. This is critical to the natural gas and liquefied petroleum gas fuel and air systems.

• Always test for fuel leaks as instructed, as odorant can fade.

• Close the manual fuel valves prior to performing maintenance and repairs, and when storing the vehicle inside.

• Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations.

• The catalyst reagent contains urea. Do not get the substance in your eyes. In case of contact, immediately flood
eyes with large amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of
contact, immediately wash skin with soap and water. Do not swallow internally. In the event the catalyst reagent is
ingested, contact a physician immediately.

• The catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of
California to cause cancer. Always wear protective gloves and eye protection when handling the catalyst assembly.
Do not get the catalyst material in your eyes. In Case of contact, immediately flood eyes with large amounts of
water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of contact, immediately wash skin
with soap and water.

• The Catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of
California to cause cancer. In the event the catalyst is being replaced, dispose of in accordance with local
regulations.

• California Proposition 65 Warning - Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.

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General Repair Instructions ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page i-10 Section i - Introduction

General Repair Instructions

General Information

This system incorporates the latest technology at the time it was manufactured; yet, it is designed to be repaired using
normal repair practices performed to quality standards.

WARNING
Cummins Inc. does not recommend or authorize any modifications or repairs to 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:

1 Air Compressor

2 Air Controls

3 Air Shutoff Assemblies

4 Balance Weights

5 Cooling Fan

6 Fan Hub Assembly

7 Fan Mounting Bracket(s)

8 Fan Mounting Capscrews

9 Fan Hub Spindle

10 Flywheel

11 Flywheel Crankshaft Adapter

12 Flywheel Mounting Capscrews

13 Fuel Shutoff Assemblies

14 Fuel Supply Tubes

15 Lifting Brackets

16 Throttle Controls

17 Turbocharger Compressor Casing

18 Turbocharger Oil Drain Line(s)

19 Turbocharger Oil Supply Line(s)

20 Turbocharger Turbine Casing

21 Vibration Damper Mounting Capscrews

22 Manual Service Disconnect

23 High Voltage Interlock Loop

24 High Voltage Connectors/Connections and Harnesses

25 High Voltage Battery System

26 Power Inverter

27 Generator Motor

28 Clutch Pressure Plate

• Follow all safety instructions noted in the procedures

• Follow the manufacturer's recommendations for cleaning solvents and other substances used during repairs. Some

solvents 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 specified in the procedures

• All components must be kept clean during any repair. Contamination of the 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

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] General Repair Instructions
Section i - Introduction Page i-11

• 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 from all Cummins
Distributors and most Dealer locations.

• Follow the specified disassembly and assembly procedures to reduce the possibility of damage to the components

Welding on a Vehicle with an Electronic Controlled Fuel System

CAUTION
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 clamp of the welder to any of the sensors, wiring harness, electronic control units or the
components. Direct welding of any electronic components must not be attempted. Sensors, wiring harness,
and electronic control unit should be removed if nearby welding will expose these components to
temperatures beyond normal operation. Additionally, all electronic control unit connectors must be
disconnected

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General Cleaning Instructions ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page i-12 Section i - Introduction

General Cleaning Instructions

Definition of Clean

Parts must be free of debris that can contaminate any engine system. This does not necessarily mean they have to
appear as new.

Sanding gasket surfaces until the factory machining marks are disturbed adds no value and is often harmful to forming
a seal. It is important to maintain surface finish and flatness tolerances to form a quality sealing surface. Gaskets are
designed to fill small voids in the specified surface finish.

Sanding gasket surfaces where edge-molded gaskets are used is most often unnecessary. Edge-molded gaskets are
those metal carriers with sealing material bonded to the edges of the gasket to seal while the metal portion forms a
metal to metal joint for stability. Any of the small amounts of sealing material that can stick to the parts are better
removed with a blunt-edged scraper on the spots rather than spending time polishing the whole surface with an air
sander or disc.

For those gaskets that do not have the edge molding, nearly all have a material that contains release agents to
prevent sticking. Certainly this is not to say that some gaskets are not difficult to remove because the gasket has
been in place a long time, has been overheated or the purpose of the release agent has been defeated by the
application of some sealant. The object however is just to remove the gasket without damaging the surfaces of the
mating parts without contaminating the engine (don't let the little bits fall where they can not be removed).

Bead blasting piston crowns until the dark stain is removed is unnecessary. All that is required is to remove the carbon
build-up above the top ring and in the ring grooves. There is more information on bead blasting and piston cleaning
later in this document.

Cummins Inc. does not recommend sanding or grinding the carbon ring at the top of cylinder liners until clean metal is
visible. The liner will be ruined and any signs of a problem at the top ring reversal point (like a dust-out) will be
destroyed. It is necessary to remove the carbon ring to provide for easier removal of the piston assembly. A medium
bristle, high quality, steel wire wheel that is rated above the rpm of the power tool being used will be just as quick and
there will be less damage. Yes, one must look carefully for broken wires after the piston is removed but the wires are
more visible and can be attracted by a magnet.

Oil on parts that have been removed from the engine will attract dirt in the air. The dirt will adhere to the oil. If possible,
leave the old oil on the part until it is ready to be cleaned, inspected and installed, and then clean it off along with any
attracted dirt. If the part is cleaned then left exposed it can have to be cleaned again before installation. Make sure
parts are lubricated with clean oil before installation. They do not need to be oiled all over but do need oil between
moving parts (or a good lube system priming process conducted before cranking the engine).

Bead blasting parts to remove exterior paint is also usually unnecessary. The part will most likely be painted again so
all that needs happen is remove any loose paint.

Abrasive Pads and Abrasive Paper

The keyword here is "abrasive". There is no part of an engine designed to withstand abrasion. That is they are all
supposed to lock together or slide across each other. Abrasives and dirt particles will degrade both functions.

WARNING
Abrasive material must be kept out of or removed from oil passages and parts wear points. Abrasive material
in oil passages can cause bearing and bushing failures that can progress to major component damage
beyond reuse. This is particularly true of main and rod bearings.

Cummins Inc. does not recommend the use of emery cloth or sand paper on any part of an assembled engine or
component including but not limited to removing the carbon ridge from cylinder liners or to clean block decks or
counterbores.

Great care must be taken when using abrasive products to clean engine parts, particularly on partially assembled
engines. Abrasive cleaning products come in many forms and sizes. All of them contain aluminum oxide particles,
silicon carbide, or sand or some other similar hard material. These particles are harder than most of the parts in the
engine. Since they are harder, if they are pressed against softer material they will either damage the material or
become embedded in it. These materials fall off the holding media as the product is used. If the products are used with
power equipment the particles are thrown about the engine. If the particles fall between two moving parts, damage to
the moving parts is likely.

If particles that are smaller than the clearance between the parts while they are at rest (engine stopped), but larger
than the running clearance then damage will occur when the parts move relative to each other (engine started). While
the engine is running and there is oil pressure, particles that are smaller than the bearing clearance are likely to pass
between the parts without damage and be trapped in the oil filter. However, particles larger than the bearing clearance
will remove material from one part and can become embedded in one of the parts. Once embedded in one part it will

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] General Cleaning Instructions
Section i - Introduction Page i-13

abrade the other part until contact is no longer being made between the two parts. If the damage sufficiently degrades
the oil film, the two parts will come into contact resulting in early wear-out or failure from lack of effective lubrication.

Abrasive particles can fly about during cleaning it is very important to block these particles from entering the engine as
much as possible. This is particularly true of lubricating oil ports and oil drilling holes, especially those located
downstream of the lubricating oil filters. Plug the holes instead of trying to blow the abrasive particles and debris with
compressed air because the debris is often simply blown further into the oil drilling.

All old gasket material must be removed from the parts gasket surfaces. However, it is not necessary to clean and
polish the gasket surface until the machining marks are erased. Excessive sanding or buffing can damage the gasket
surface. Many newer gaskets are of the edge molded type (a steel carrier with a sealing member bonded to the steel).
What little sealing material that can adhere is best removed with a blunt-edged scraper or putty knife. Cleaning gasket
surfaces where an edge-molded gasket is used with abrasive pads or paper is usually a waste of time.

WARNING
Excessive sanding or grinding the carbon ring from the top of the cylinder liners can damage the liner beyond
reuse. The surface finish will be damaged and abrasive particles can be forced into the liner material which
can cause early cylinder wear-out or piston ring failures.

Tape off or plug all openings to any component interior before using abrasive pads or wire brushes. If really necessary
because of time to use a power tool with abrasive pads, tape the oil drillings closed or use plug and clean as much of
the surface as possible with the tool but clean around the oil hole/opening by hand so as to prevent contamination of
the drilling. Then remove the tape or plug and clean the remaining area carefully and without the tool. DO NOT use
compressed air to blow the debris out of oil drilling on an assembled engine! More likely than not, the debris can be
blown further into the drilling. Using compressed air is fine if both ends of the drilling are open but that is rarely the
case when dealing with an assembled engine.

Gasket Surfaces

The object of cleaning gasket surfaces is to remove any gasket material, not refinish the gasket surface of the part.

Cummins Inc. does not recommend any specific brand of liquid gasket remover. If a liquid gasket remover is used,
check the directions to make sure the material being cleaned will not be harmed.

Air powered gasket scrapers can save time but care must be taken to not damage the surface. The angled part of the
scraper must be against the gasket surface to prevent the blade from digging into the surface. Using air powered
gasket scrapers on parts made of soft materials takes skill and care to prevent damage.

Do not scrape or brush across the gasket surface if at all possible.

Solvent and Acid Cleaning

Several solvent and acid-type cleaners can be used to clean the disassembled engine parts (other than pistons. See
Below). Experience has shown that the best results can be obtained using a cleaner that can be heated to 90° to 95°
Celsius (180° to 200° Fahrenheit). Kerosene emulsion based cleaners have different temperature specifications, see
below. A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best results.
Cummins Inc. does not recommend any specific cleaners. Always follow the cleaner manufacturer's instructions.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before
putting the parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible, steam clean the
parts before putting them in the cleaning tank.

WARNING
When using solvents, acids, or alkaline materials for cleaning, follow the manufacturers recommendations for
use. Wear goggles and protective clothing to reduce the possibility of personal injury.

Experience has shown that kerosene emulsion based cleaners perform the best to clean pistons. These cleaners
should not be heated to temperature in excess of 77°C (170°F). The solution begins to break down at temperatures in
excess of 82°C (180°F) and will be less effective.

Do not use solutions composed mainly of chlorinated hydrocarbons with cresols, phenols and/or cresylic components.
They often do not do a good job of removing deposits from the ring groove and are costly to dispose of properly.

Solutions with a pH above approximately 9.5 will cause aluminum to turn black; therefore do not use high alkaline
solutions.

Chemicals with a pH above 7.0 are considered alkaline and those below 7.0 are acidic. As you move further away
from the neutral 7.0, the chemicals become highly alkaline or highly acidic.

Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before
putting the parts in a cleaning tank. Be careful to not damage any gasket surfaces. When possible use hot high

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General Cleaning Instructions ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page i-14 Section i - Introduction

pressure water or steam clean the parts before putting them in the cleaning tank. Removing the heaviest dirt before
placing in the tank will allow the cleaner to work more effectively and the cleaning agent will last longer.

Rinse all the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all the
capscrew holes and the oil drillings.

If the parts are not to be used immediately after cleaning, dip them in a suitable rust proofing compound. The rust
proofing compound must be removed from the parts before assembly or installation on the engine.

Steam Cleaning

Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good method for
cleaning the oil drillings and coolant passages

WARNING
When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam
can cause serious personal injury.

Do not steam clean the following components:

• Electrical Components

• Wiring Harnesses

• Belts and Hoses

• Bearings (ball or taper roller)

• Electronic Control Module (ECM)

• ECM Connectors

• Capacitive Coil Driver Module (CCD)

• Ignition Coils and Leads

• NOx Sensor

• Fuel Control Valve

• Throttle Driver and Actuator.

Plastic Bead Cleaning

Cummins Inc. does not recommend the use of glass bead blast or walnut shell media on any engine part. Cummins
Inc. recommends using only plastic bead media, Part Number 3822735 or equivalent on any engine part. Never use
sand as a blast media to clean engine parts. Glass and walnut shell media when not used to the media
manufacturer's recommendations can cause excess dust and can embed in engine parts that can result in premature
failure of components through abrasive wear.

Plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning process is
controlled by the use of plastic beads, the operating pressure and cleaning time.

CAUTION
Do not use bead blasting cleaning methods on aluminum pistons skirts or the pin bores in any piston, piston
skirt or piston crown. Small particles of the media will embed in the aluminum or other soft metal and result in
premature wear of the cylinder liner, piston rings, pins and pin bores. Valves, turbocharger shafts, etc., can
also be damaged. Follow the cleaning directions listed in the procedures.

CAUTION
Do not contaminate wash tanks and tank type solvent cleaners with the foreign material and plastic beads.
Remove the foreign material and plastic beads with compressed air, hot high pressure water or steam before
placing them in tanks or cleaners. The foreign material and plastic beads can contaminate the tank and any
other engine parts cleaned in the tank. Contaminated parts may cause failures from abrasive wear.

Plastic bead blasting media, Part Number 3822735, can be used to clean all piston ring grooves. Do not sure any
bead blasting media on piston pin bores or aluminum skirts.

Follow the equipment manufacturer's cleaning instructions. Make sure to adjust the air pressure in the blasting
machine to the bead manufacturer's recommendations. Turning up the pressure can move material on the part and
cause the plastic bead media to wear out more quickly. The following guidelines can be used to adapt to
manufacturer's instructions:

1 Bead size: U.S. size Number 16 — 20 for piston cleaning with plastic bead media, Part Number 3822735

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] General Cleaning Instructions
Section i - Introduction Page i-15

2 Operating Pressure — 270 kPa (40 psi) for piston cleaning. Pressure should not cause beads to break.

3 Steam clean or wash the parts with solvent to remove all of the foreign material and plastic beads after cleaning.

Rinse with hot water. Dry with compressed air.

CAUTION
The bead blasting operation must not disturb the metal surface. If the metal surface is disturbed the engine
can be damaged due to increased parts clearance or inadequate surface finish on parts that move against
other parts.

When cleaning pistons, it is not necessary to remove all the dark stain from the piston. All that is necessary is to
remove the carbon on the rim and in the ring grooves. This is best done by directing the blast across the part as
opposed to straight at the part. If the machining marks are disturbed by the blasting process, then the pressure is too
high or the blast is being held on one spot too long. The blast operation must not disturb the metal surface.

Walnut shell bead blast material is sometimes used to clean ferrous metals (iron and steel). Walnut shell blasting
produces a great amount of dust particularly when the pressure if the air pressure on the blasting machine is
increased above media manufacturer's recommendation. Cummins Inc. recommends not using walnut shell media to
clean engine parts due to the risk media embedment and subsequent contamination of the engine.

Cummins Inc. now recommends glass bead media NOT used to clean any engine parts. Glass media is too easily
embedded into the material particularly in soft materials and when air pressures greater than media manufacturer's
recommend are used. The glass is an abrasive so when it is in a moving part, that part is abrading all the parts in
contact with it. When higher pressures are used the media is broken and forms a dust of a very small size that floats
easily in the air. This dust is very hard to control in the shop, particularly if only compressed air (and not hot water) is
used to blow the media after it is removed from the blasting cabinet (blowing the part off inside the cabinet may
remove large accumulations but never removes all the media).

Bead blasting is best used on stubborn dirt/carbon build-up that has not been removed by first steam/higher pressure
washing then washing in a heated wash tank. This is particularly true of pistons. Steam and soak the pistons first then
use the plastic bead method to safely remove the carbon remaining in the grooves (instead of running the risk of
damaging the surface finish of the groove with a wire wheel or end of a broken piston ring. Make sure the parts are dry
and oil free before bead blasting to prevent clogging the return on the blasting machine.

Always direct the bead blaster nozzle "across" rather than directly at the part. This allows the bead to get under the
unwanted material. Keep the nozzle moving rather than hold on one place. Keeping the nozzle directed at one-place
too long causes the metal to heat up and be moved around. Remember that the spray is not just hitting the dirt or
carbon. If the machining marks on the piston groove or rim have been disturbed then there has not been enough
movement of the nozzle and/or the air pressure is too high.

Never bead blast valve stems. Tape or use a sleeve to protect the stems during bead blasting. Direct the nozzle
across the seat surface and radius rather than straight at them. The object is to remove any carbon build up and
continuing to blast to remove the stain is a waste of time.

Fuel System

When servicing any fuel system components, which can be exposed to potential contaminants, prior to disassembly,
clean the fittings, mounting hardware, and the area around the component to be removed. If the surrounding areas are
not cleaned, dirt or contaminants can be introduced into the fuel system.

The internal drillings of some injectors are extremely small and susceptible to plugging from contamination. Some fuel
injection systems can operate at very high pressures. High pressure fuel can convert simple particles of dirt and rust
into a highly abrasive contaminant that can damage the high pressure pumping components and fuel injectors.

Electrical contact cleaner can be used if steam cleaning tools are not available. Use electrical contact cleaner rather
than compressed air, to wash dirt and debris away from fuel system fittings. Diesel fuel on exposed fuel system parts
attracts airborne contaminants.

Choose lint free towels for fuel system work.

Cap and plug fuel lines, fittings, and ports whenever the fuel system is opened. Rust, dirt, and paint can enter the fuel
system whenever a fuel line or other component is loosened or removed from the engine. In many instances, a good
practice is to loosen a line or fitting to break the rust and paint loose, and then clean off the loosened material.

When removing fuel lines or fittings from a new or newly-painted engine, make sure to remove loose paint flakes/chips
that can be created when a wrench contacts painted line nuts or fittings, or when quick disconnect fittings are
removed.

Fuel filters are rated in microns. The word micron is the abbreviation for a micrometer, or one millionth of a meter. The
micron rating is the size of the smallest particles that will be captured by the filter media. As a reference, a human hair

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General Cleaning Instructions ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page i-16 Section i - Introduction

is 76 microns [0.003 in] in diameter. One micron measures 0.001 mm [0.00004 in.]. The contaminants being filtered
out are smaller than can be seen with the human eye, a magnifying glass, or a low powered microscope.

The tools used for fuel system troubleshooting and repair are to be cleaned regularly to avoid contamination. Like fuel
system parts, tools that are coated with oil or fuel attract airborne contaminants. Remember the following points
regarding your fuel system tools:

• Fuel system tools are to be kept as clean as possible.

• Clean and dry the tools before returning them to the tool box.

• If possible, store fuel system tools in sealed containers.

• Make sure fuel system tools are clean before use.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Acronyms and Abbreviations
Section i - Introduction Page i-17

Acronyms and Abbreviations

General Information

The following list contains some of the acronyms and abbreviations used in this manual.

ANSI American National Standards Institute

API American Petroleum Institute
ASTM American Society of Testing and Materials
ATDC After Top Dead Center

BTU British Thermal Unit

BTDC Before Top Dead Center

°C Celsius

CAN Controller Area Network

CO Carbon Monoxide

CCA Cold Cranking Amperes

CARB California Air Resources Board

C.I.B. Customer Interface Box
C.I.D. Cubic Inch Displacement

CNG Compressed Natural Gas

CPL Control Parts List

cSt Centistokes

DEF Diesel Exhaust Fluid

DOC Diesel Oxidation Catalyst

DPF Diesel Particulate Filter

ECM Engine Control Module

EFC Electronic Fuel Control

EGR Exhaust Gas Recirculation

EPA Environmental Protection Agency

°F Fahrenheit

ft-lb Foot-Pound Force

FMI Failure Mode Indentifier

GVW Gross Vehicle Weight

Hg Mercury
hp Horsepower

H2O Water

inHg Inches of Mercury

in H20 Inches of Water

ICM Ignition Control Module

IEC International Electrotechnical Commission

km/l Kilometers per Liter

kPa Kilopascal

LNG Liquid Natural Gas

LPG Liquified Petroleum Gas
LTA Low Temperature Aftercooling

MCRS Modular Common Rail System

MIL Malfunction Indicator Lamp

MPa Megapascal
mph Miles Per Hour
mpq Miles Per Quart

N•m Newton-meter

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Acronyms and Abbreviations ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page i-18 Section i - Introduction

NOx Mono-Nitrogen Oxides

NG Natural Gas

O2 Oxygen
OBD On-Board Diagnostics
OEM Original Equipment Manufacturer

OSHA Occupational Safety and Health Administration

PID Parameter Identification Descriptions

ppm Parts Per Million

psi Pounds Per Square Inch

PTO Power Takeoff

REPTO Rear Power Take Off

RGT Rear Gear Train

rpm Revolutions Per Minute

SAE Society of Automotive Engineers
SCA Supplemental Coolant Additive
SCR Selective Catalytic Reduction

STC Step Timing Control

SID Subsystem Identification Descriptions

TDC Top Dead Center
VDC Volts of Direct Current

VGT Variable Geometry Turbocharger

VS Variable Speed

VSS Vehicle Speed Sensor

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Section E - Engine and System Identification Page E-a

Section E - Engine and System Identification

Section Contents

Page

Cummins® Service Engine Model Product Identification ....................................................................................E-38

General Information..................................................................................................................................................E-38

Engine Diagrams ........................................................................................................................................................E-6

Engine Views..............................................................................................................................................................E-6

Engine Identification ..................................................................................................................................................E-1

Cummins® Engine Nomenclature..............................................................................................................................E-3

Dosing Control Unit Dataplate....................................................................................................................................E-5

ECM Dataplate...........................................................................................................................................................E-4

Engine Dataplate........................................................................................................................................................E-1

Fuel Injection Pump Dataplate...................................................................................................................................E-3

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Page E-b Section E - Engine and System Identification

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Identification
Section E - Engine and System Identification Page E-1

Engine Identification

Engine Dataplate

All Applications Except Marine

The engine dataplate provides important information about the engine. The engine serial number (ESN) and control
part list (CPL) provide information for service and for ordering parts. The engine dataplate must not be changed
unless approved by Cummins Inc.

Have the following engine data available when communicating with a Cummins® Authorized Repair Location:

1 Engine serial number (ESN)

2 Control parts list (CPL)

3 Model

4 Horsepower and rpm rating.

NOTE: Depending on the manufacturing plant, calibration data may also be be found on the engine dataplate.

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Engine Identification ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-2 Section E - Engine and System Identification

If the engine dataplate (1) is not legible, the engine serial
number (ESN) (2) can be found on the engine block, on
top of the lubricating oil cooler housing. Additional engine
information is on the ECM dataplate.

Marine Applications

The engine dataplate provides important facts about the
engine. The engine serial number (ESN) and control parts
list (CPL) provide information for service and ordering
parts. The engine dataplate must not be changed unless
approved by Cummins Inc.

The dataplate for marine engines is located on the top
front of the valve cover for both the QSC and QSL
engines.

If the engine dataplate (1) is not legible, the engine serial
number (ESN) (2) can be found on the engine block, on
top of the lubricating oil cooler housing. Additional engine
information is on the electronic control module (ECM)
dataplate.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Identification
Section E - Engine and System Identification Page E-3

Have the following engine data available when communicating with a Cummins® Authorized Repair Location:

1 Control parts list (CPL)

2 Model

3 Engine serial number (ESN)

4 Horsepower and rpm rating.

Cummins® Engine Nomenclature

The Cummins® engine nomenclature provides the engine
model and horsepower rating.

Fuel Injection Pump Dataplate

The Cummins® Accumulator Pump System (CAPS) fuel
injection pump dataplate is located on the side of the
injection pump. The dataplate contains the following
information:

1 Cummins® part number

2 Pump serial number

3 Factory code.

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Engine Identification ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-4 Section E - Engine and System Identification

The Cummins® Common Rail Fuel System dataplate is
located on the side of the high-pressure pump. The
dataplate contains the following information:

1 Cummins® part number

2 Pump serial number

3 Factory code.

ECM Dataplate

All Applications Except Marine

The ECM dataplate is located on the front of the ECM.

The following information is found on the ECM dataplate:

• ECM part number (PN)

• ECM serial number (SN)

• ECM date code (DC)

• Engine serial number (ESN)

• ECM Code (identifies the software in the ECM).

NOTE: The presence of an ECM dataplate depends on
the manufacturing plant and the date the engine was
manufactured. If an ECM dataplate was not installed by
the manufacturing plant, calibration data can be found on
the engine dataplate.

Marine Applications

The ECM dataplate is located on the front of the ECM.

The following information is found on the ECM dataplate:

• ECM part number (PN)

• ECM serial number (SN)

• ECM date code (DC)

• Engine serial number (ESN)

• ECM Code (identifies the software in the ECM).

NOTE: The presence of an ECM dataplate depends on
the manufacturing plant and the date the engine was
manufactured. If an ECM dataplate was not installed by
the manufacturing plant, calibration data can be found on
the engine dataplate.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Identification
Section E - Engine and System Identification Page E-5

Dosing Control Unit Dataplate

ISLe4 engines are fitted with a dosing control unit which is
part of the aftertreatment system. The dosing control unit
dataplate is located on the front edge of the dosing control
unit, as shown (1). The dataplate contains the following
information:

• Type

• Ref.

• S/N.

• Cummins® part number.

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Engine Diagrams ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-6 Section E - Engine and System Identification

Engine Diagrams

Engine Views

All Applications Except Marine

The following illustrations provide the locations of the major external engine components, filters, and other service and
maintenance points. Some external components will be different locations for different engine models.

The illustrations are only a reference to show a typical engine.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-7

Engine Views

All Applications Except Marine

Engine Diagrams

Front Engine View (Cummins® Common Rail Fuel System)

1 Engine lifting bracket

2 Crankcase breather

3 Air intake connection

4 Engine oil fill

5 Front gear cover

6 Fan pulley

7 Vibration Damper

8 Starter

9 Engine oil pan drain plug

10 Automatic belt tensioner

11 Coolant inlet connection

12 Water pump

13 Turbocharger (variable geometry turbocharger shown).

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Engine Diagrams ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-8 Section E - Engine and System Identification

Engine Views

All Applications Except Marine

Engine Diagrams

Exhaust Side Engine View (Cummins® Common Rail Fuel System)

1 Exhaust manifold

2 Turbocharger (variable geometry turbocharger shown)

3 Variable geometry turbocharger actuator (variable geometry turbocharger only)

4 Crankcase breather

5 Rocker lever cover

6 Engine oil fill

7 Rocker lever housing

8 Coolant outlet connection

9 Coolant heater port

10 Coolant inlet connection

11 Lubricating oil cooler

12 Lubricating oil filter

13 Dipstick location

14 Flywheel housing.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-9

Engine Views

All Applications Except Marine

Engine Diagrams

Intake Side Engine View (Cummins® Common Rail Fuel System)

1 Air intake connection

2 Crankcase breather

3 Intake air heater

4 Intake manifold pressure and temperature sensor

5 Turbocharger control valve

6 Fuel rail

7 Fuel drain manifold

8 Fuel filter

9 Crankcase breather draft tube

10 Crankcase breather oil drain tube

11 Crankshaft speed sensor

12 Starter

13 Lubricating oil pressure sensor

14 Engine oil drain plug

15 Fuel lift pump (behind ECM)

16 Electronic control module (ECM)

17 Air compressor

18 Camshaft speed sensor

19 Engine data plate

20 High-pressure fuel pump

21 Ambient air pressure sensor

22 Fuel rail pressure sensor.

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Engine Diagrams ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-10 Section E - Engine and System Identification

Engine Views

All Applications Except Marine

Engine Diagrams

Rear Engine View (Cummins® Common Rail Fuel System)

1 Engine lifting bracket

2 Crankcase breather

3 Turbocharger (VGT shown)

4 Injector drain line connection

5 Flywheel housing

6 Flywheel

7 Engine oil drain plug

8 OEM fuel supply line connection

9 OEM fuel drain line connection

10 Air intake connection.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-11

Engine Views

All Applications Except Marine

Engine Diagrams

Top Engine View (Cummins® Common Rail Fuel System)

1 Coolant inlet connection

2 Turbocharger air inlet

3 Turbocharger air outlet

4 Turbocharger exhaust outlet

5 Turbocharger actuator air line (variable geometry turbocharger only)

6 Crankcase breather

7 Flywheel housing

8 Crankcase breather oil drain tube

9 Crankcase breather draft tube

10 Turbocharger control valve (variable geometry turbocharger only)

11 Fuel filter bracket

12 Air inlet connection

13 High-pressure pump

14 Engine oil fill

15 Coolant outlet connection.

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Page E-12 Section E - Engine and System Identification

Engine Views

All Applications Except Marine

Engine Diagrams

1 Fan pulley

2 Top dead center (TDC) mark

3 Front gear cover

4 Vibration damper

5 Engine oil pan drain plug

6 Automatic belt tensioner

7 Water inlet

8 Water pump

9 Alternator

10 Water outlet

11 Turbocharger air outlet

12 Turbocharger air inlet

13 Engine oil fill.

Front View (CAPS Fuel System)

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-13

Engine Views

All Applications Except Marine

Engine Diagrams

1 1/2-inch (NPTF) coolant taps

2 Turbocharger wastegate actuator

3 Engine oil fill

4 Coolant outlet

5 Front engine lifting bracket

6 Coolant temperature sensor

7 Coolant heater port

8 Coolant inlet

9 Lubricating oil cooler

10 Engine oil pan drain plug

11 Lubricating oil filter

12 Dipstick location

13 Coolant filter

14 Injector drain fuel outlet connection.

Exhaust Side View (CAPS Fuel System)

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Engine Diagrams ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-14 Section E - Engine and System Identification

Engine Views

All Applications Except Marine

Engine Diagrams

Fuel Pump Side View (CAPS Fuel System)

1 Engine air inlet

2 Intake manifold pressure sensor

3 Intake manifold temperature sensor

4 M10 (STOR) fuel pressure after-lift pump

5 M10 (STOR) fuel pressure before-lift pump

6 Magnetic pickup location 3/4-16 UNF

7 Fuel return connection

8 Fuel inlet connection

9 Fuel lift pump

10 Starter mounting flange

11 Oil pressure sensor

12 Fuel filter/water separator

13 Electronic control module (ECM)

14 Dipstick location

15 M10 (STOR) oil pressure port

16 Engine position sensor (EPS) - (inboard)

17 Engine speed sensor (ESS) - (outboard)

18 Engine dataplate

19 High-pressure fuel lines

20 Cummins® Accumulator Pump System (CAPS) injection pump

21 Intake air heater.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-15

Engine Views

All Applications Except Marine

Engine Diagrams

1 Rear engine lifting bracket

2 Turbocharger exhaust outlet

3 Clutch mounting holes

4 Flywheel housing

5 Flywheel.

Rear View (CAPS Fuel System)

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Engine Diagrams ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-16 Section E - Engine and System Identification

Engine Views

All Applications Except Marine

Engine Diagrams

1 Engine lifting bracket

2 Crankcase breather

3 Air intake connection

4 Engine oil fill

5 Front gear cover

6 Fan pulley

7 Vibration Damper

8 Starter

9 Engine oil pan drain plug

10 Automatic belt tensioner

11 Coolant inlet connection

12 Water pump

13 Turbocharger.

Front - ISLe3 and ISLe4 - (CM850 Electronic Control Module)

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-17

Engine Views

All Applications Except Marine

Engine Diagrams

Left - ISLe3 and ISLe4 - (CM850 Electronic Control Module)

1 Air intake connection

2 Crankcase breather

3 Intake air heater

4 Fuel rail pressure sensor

5 Fuel rail

6 Fuel drain manifold

7 Fuel filter

8 Crankcase breather draft tube

9 Crankcase breather oil drain tube

10 Starter

11 Engine oil drain plug

12 Aftertreatment interface connection (ISLe4)

13 Fuel lift pump

14 Electronic control module (ECM)

15 Air compressor

16 Engine data plate

17 High-pressure pump.

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Engine Diagrams ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-18 Section E - Engine and System Identification

Engine Views

All Applications Except Marine

Engine Diagrams

Rear - ISLe3 and ISLe4 - (CM850 Electronic Control Module)

1 Engine lifting bracket

2 Crankcase breather

3 Turbocharger

4 Injector drain line connection

5 Flywheel housing

6 Flywheel

7 Engine oil drain plug

8 OEM fuel supply line connection

9 OEM fuel drain line connection

10 Air intake connection.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-19

Engine Views

All Applications Except Marine

Engine Diagrams

1 Exhaust manifold

2 Turbocharger

3 Turbocharger air inlet

4 Crankcase breather

5 Rocker lever cover

6 Engine oil fill

7 Rocker lever housing

8 Coolant outlet connection

9 Coolant heater port

10 Coolant inlet connection

11 Lubricating oil cooler

12 Lubricating oil filter

13 Dipstick location

14 Flywheel housing.

Right - ISLe3 and ISLe4 - (CM850 Electronic Control Module)

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Engine Diagrams ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-20 Section E - Engine and System Identification

Engine Views

All Applications Except Marine

Engine Diagrams

Top - ISLe3 and ISLe4 - (CM850 Electronic Control Module)

1 Coolant inlet connection

2 Turbocharger air inlet

3 Turbocharger air outlet

4 Turbocharger exhaust outlet

5 Exhaust manifold

6 Crankcase breather

7 Flywheel housing

8 Crankcase breather oil drain tube

9 Crankcase breather draft tube

10 Starter motor location

11 Fuel filter bracket

12 Air inlet connection

13 High-pressure pump

14 Engine oil fill

15 Coolant outlet connection.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-21

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Engine Diagrams ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-22 Section E - Engine and System Identification

Marine Applications

1 Heat exchanger

2 Coolant fill cap

3 Expansion tank

4 Timing case cover

5 Engine mounting bracket

6 Oil pan

7 Oil pan drain plug

8 Belt and pulley guard.

Front View QSL9 Marine (Sea water cooled)

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-23

Marine Applications

1 Keel cooler thermostat housing

2 Coolant fill cap

3 Expansion tank

4 Timing case cover

5 Engine mounting bracket

6 Oil pan drain plug

7 Belt and pulley guard.

Front View QSL9 Marine (Keel Cooled)

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Engine Diagrams ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-24 Section E - Engine and System Identification

Marine Applications

Left View (Port) QSL9 Marine (Sea Water Cooled)

1 Expansion tank

2 Aftercooler air outlet

3 Intake manifold temperature sensor

4 Intake manifold pressure sensor

5 Aftercooler sea water outlet

6 Zinc anode

7 Air cleaner or filter

8 Aftercooler air inlet

9 Aftercooler housing

10 Flywheel housing

11 Zinc anode

12 Crankshaft speed sensor

13 Fuel inlet from fuel tank

14 Oil pressure sensor

15 Aftercooler sea water inlet

16 Electronic control module (ECM)

17 Fuel return from engine to fuel cooler

18 Fuel lift pump (behind ECM)

19 SIM module (mounted on ECM bracket)

20 Fuel return to fuel tank

21 Sea water pump inlet

22 Sea water pump

23 Camshaft position sensor

24 Fuel filter

25 Fuel rail pressure sensor (behind aftercooler air outlet).

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-25

Marine Applications

Left View (Port) QSL9 Marine (Keel Cooled)

1 Expansion tank

2 Aftercooler air outlet

3 Intake manifold temperature sensor

4 Intake manifold pressure sensor

5 Zinc anode

6 Aftercooler coolant inlet

7 Air cleaner or filter

8 Aftercooler air inlet

9 Aftercooler housing

10 Flywheel housing

11 Crankshaft speed sensor

12 Aftercooler coolant outlet

13 Fuel inlet from fuel tank

14 Fuel lift pump (behind ECM)

15 Engine oil dipstick

16 SIM module (mounted on ECM bracket)

17 Electronic control module (ECM)

18 Camshaft position sensor

19 Fuel filter

20 Fuel rail pressure sensor (behind aftercooler air outlet).

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Engine Diagrams ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-26 Section E - Engine and System Identification

Marine Applications

Rear View QSL9 Marine (Sea Water Cooled)

1 Air cleaner and filter

2 Air cleaner restriction indicator

3 Turbocharger compressor side

4 Turbocharger turbine side

5 Sea water from heat exchanger to exhaust elbow

6 Water cooled exhaust elbow

7 Sea water discharge

8 Sea water to heat exchanger

9 Flywheel housing

10 Flywheel

11 Aftercooler zinc anode

12 Marine gear oil cooler

13 Aftercooler air inlet

14 Aftercooler.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-27

Marine Applications

Rear View QSL9 Marine (Keel Cooled)

1 Air cleaner and filter

2 Air cleaner restriction indicator

3 Coolant outlet from thermostat housing to aftercooler

4 Turbocharger compressor side

5 Turbocharger turbine side

6 Exhaust elbow

7 Coolant return from marine gear oil cooler to water pump

8 Flywheel housing

9 Zinc anode

10 Marine gear oil cooler

11 Aftercooler air inlet

12 Aftercooler

13 Fuel return to fuel tank.

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Engine Diagrams ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-28 Section E - Engine and System Identification

Marine Applications

Right View (Starboard) QSL9 Marine (Sea Water Cooled)

1 Water cooled exhaust elbow

2 Sea water from heat exchanger to exhaust elbow

3 Heat exchanger

4 Crankcase breather

5 Heat exchanger coolant inlet

6 Expansion tank

7 Coolant level sensor

8 Zinc anode

9 Alternator

10 Coolant temperature sensor

11 Lubricating oil cooler

12 Coolant filter

13 Lubricating oil filter

14 Oil pan drain plug

15 Heat exchanger coolant outlet

16 Starter motor

17 Flywheel housing

18 Heat exchanger sea water inlet

19 Intake air from turbocharger to aftercooler.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-29

Marine Applications

Right View (Starboard) QSL9 Marine (Keel Cooled)

1 Exhaust elbow

2 Coolant return from marine gear oil cooler to water pump

3 Coolant outlet from thermostat housing to aftercooler

4 Keel cooler thermostat housing

5 Coolant from keel cooler to engine

6 Coolant from engine to keel cooler

7 Coolant return from engine to keel cooler thermostat housing

8 Expansion tank

9 Coolant level sensor

10 Alternator

11 Coolant return from exhaust manifold to water pump

12 Coolant temperature sensor

13 Lubricating oil cooler

14 Oil pan drain plug

15 Lubricating oil filter

16 Starter motor

17 Flywheel housing

18 Intake air from turbocharger to aftercooler.

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Engine Diagrams ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-30 Section E - Engine and System Identification

Marine Applications

1 Heat exchanger

2 Exhaust manifold

3 Exhaust outlet

4 Turbocharger

5 Air inlet restriction indicator

6 Air filter

7 High-pressure injector supply line

8 Aftercooler

9 Fuel rail

10 Crankcase breather

11 Fuel pump

12 Front engine mount

13 Expansion tank coolant fill cap

14 Oil fill cap.

Top View QSL9 Marine (Sea Water Cooled)

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-31

Marine Applications

1 Thermostat housing (keel cooled)

2 Exhaust manifold

3 Exhaust outlet

4 Turbocharger

5 Air inlet restriction indicator

6 Air filter

7 Aftercooler

8 Fuel rail

9 Crankcase breather

10 High pressure injector supply line

11 Fuel pump

12 Front engine mount

13 Expansion tank coolant fill cap

14 Oil fill cap.

Top View QSL9 Marine (Keel Cooled)

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Engine Diagrams ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-32 Section E - Engine and System Identification

Marine Applications

1 Heat exchanger

2 Engine coolant to heat exchanger

3 Coolant fill cap

4 Expansion tank

5 Intake air inlet from aftercooler

6 Timing case cover

7 Sea water pump discharge

8 Engine mounting bracket

9 Oil pan drain plug

10 Oil pan

11 Belt and pulley guard.

Front View QSC8.3 Marine (Sea Water Cooled)

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-33

Marine Applications

Left View (Port) QSC8.3 Marine (Sea Water Cooled)

1 Expansion tank

2 Intake manifold temperature sensor (behind aftercooler air outlet)

3 Intake manifold pressure sensor (behind aftercooler air outlet

4 Crankcase breather

5 Aftercooler air outlet

6 Air cleaner or filter

7 Aftercooler sea water outlet

8 Aftercooler sea water inlet

9 Aftercooler housing

10 Zinc anodes

11 Fuel cooler

12 Fuel outlet to fuel tank

13 Marine gear oil cooler connection (behind gear oil cooler x 2)

14 Flywheel housing

15 Zinc anode

16 Crankshaft speed sensor

17 Marine gear oil cooler

18 Oil pressure sensor (behind marine gear oil cooler)

19 Fuel inlet from fuel tank

20 Electronic control module (ECM)

21 Lubricating oil dipstick

22 Fuel lift pump (behind ECM)

23 Sea water inlet

24 Sea water pump

25 SIM module (mounted on ECM bracket)

26 Camshaft position sensor

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Engine Diagrams ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-34 Section E - Engine and System Identification

27 Fuel filter

28 Fuel rail pressure sensor.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-35

Marine Applications

Rear View QSC8.3 Marine (Sea Water Cooled)

1 Air cleaner or filter

2 Closed crankcase ventilation canister/filter

3 Intake air restriction indicator

4 Turbocharger compressor side

5 Turbocharger oil supply

6 Turbocharger exhaust side

7 Heat exchanger sea water outlet

8 Sea water cooled exhaust elbow

9 Sea water discharge

10 Heat exchanger sea water inlet

11 Turbocharger oil drain tube

12 Marine gear oil cooler connection

13 Marine gear oil cooler connection

14 Aftercooler air inlet

15 Fuel cooler inlet from engine

16 Aftercooler drain valve

17 Aftercooler sea water inlet.

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Engine Diagrams ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-36 Section E - Engine and System Identification

Marine Applications

Right View (Starboard) QSC8.3 Marine (Sea Water Cooled)

1 Sea water outlet from heat exchanger

2 Vacuum regulator for air filter

3 Coolant level sensor

4 Expansion tank

5 Coolant fill cap

6 Heat exchanger

7 Coolant outlet from heat exchanger

8 Coolant inlet to heat exchanger

9 Zinc anode

10 Coolant temperature sensor

11 Alternator

12 Lubricating oil cooler

13 Lubricating oil filter

14 Starter motor

15 Turbocharger oil drain

16 Flywheel housing

17 Zinc anode

18 Sea water inlet to aftercooler

19 Sea water inlet to heat exchanger

20 Exhaust elbow/sea water discharge

21 Turbocharger.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Engine Diagrams
Section E - Engine and System Identification Page E-37

Marine Applications

1 Heat exchanger

2 Exhaust manifold

3 Exhaust outlet

4 Turbocharger

5 Air inlet restriction indicator

6 Air filter

7 Crankcase breather

8 Aftercooler

9 Electronic control module (ECM)

10 High pressure injector supply line

11 Fuel pump

12 Front engine mount

13 Injector

14 Expansion tank coolant fill cap

15 Oil fill cap.

Top View QSC8.3 Marine (Sea Water Cooled)

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Cummins® Service Engine Model Product Identification ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-38 Section E - Engine and System Identification

Cummins® Service Engine Model
Product Identification

General Information

The Cummins® Service Engine Model Nomenclature
procedure describes how engines are identified within
Cummins service organization. This method was
introduced for models after and including manufacture
year 2007.

Electronic engines are identified by the first two letters,
either an "IS" for On-Highway automotive or "QS" for Off­Highway industrial market applications.

The third letter is the engine platform designation followed
by the engine liter size.

If the engine operates on a fuel type other than diesel, the
type will be identified after the liter size.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cummins® Service Engine Model Product Identification
Section E - Engine and System Identification Page E-39

The control system is identified with the letters "CM"
followed by the control system model number.

The technology identifier after the control system
designates the prevailing technology used with the
engine. (See table in this procedure for letter
designations.)

Example:

1 On-Highway automotive "X" 15 liter engine

2 Control system number 871

3 Technology supported; Electric EGR and Diesel

Particulate Filter

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Cummins® Service Engine Model Product Identification ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page E-40 Section E - Engine and System Identification

Technology Name Suffix

Exhaust Gas Recirculation Not used None

Pneumatic P

Electric E

Diesel Particulate Filter (DPF) Not used None

Full Flow DPF F

Partial Flow DPF F2

Diesel Oxidation Catalyst Not used None

DOC C

3-Way Oxidation Catalytic Converter Not used None

3-Way Catalyst J

Selective Catalytic Reduction System Not used None

Air Driven S

Airless A

Nox Sensor Not used None

Nox Sensor N

Modular Common Rail System Used only on QSK19, 38, 50 , 60

MCRS

HHP Engines

Integrated Dosing Control Unit Not Used None

Integrated I

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Section F - Familiarization Page F-a

Section F - Familiarization

Section Contents

Page

Air Intake System - Overview ..................................................................................................................................F-33

General Information..................................................................................................................................................F-33

Complete Engine - Overview .....................................................................................................................................F-1

General Information....................................................................................................................................................F-1

Compressed Air System - Overview .......................................................................................................................F-48

General Information..................................................................................................................................................F-48

Cooling System - Overview ..................................................................................................................................... F-23

General Information..................................................................................................................................................F-23

Electrical Equipment - Overview .............................................................................................................................F-52

General Information..................................................................................................................................................F-52

Engine Testing - Overview .......................................................................................................................................F-52

General Information..................................................................................................................................................F-52

Exhaust System - Overview .....................................................................................................................................F-40

General Information..................................................................................................................................................F-40

Flow Diagram, Air Intake System ............................................................................................................................F-38

General Information..................................................................................................................................................F-38

Flow Diagram, Compressed Air System ................................................................................................................ F-51

General Information..................................................................................................................................................F-51

Flow Diagram, Cooling System ...............................................................................................................................F-26

General Information..................................................................................................................................................F-26

Flow Diagram, Exhaust System ..............................................................................................................................F-43

General Information..................................................................................................................................................F-43

Flow Diagram, Fuel System .......................................................................................................................................F-6

General Information....................................................................................................................................................F-6

Flow Diagram, Lubricating Oil System ...................................................................................................................F-15

General Information..................................................................................................................................................F-15

Fuel System - Overview .............................................................................................................................................F-1

General Information....................................................................................................................................................F-1

Injectors and Fuel Lines - Overview .......................................................................................................................F-11

General Information..................................................................................................................................................F-11

Lubricating Oil System - Overview .........................................................................................................................F-14

General Information..................................................................................................................................................F-14

Lubricating Oil Filters.............................................................................................................................................F-14

Rocker Levers - Overview ..........................................................................................................................................F-1

General Information....................................................................................................................................................F-1

Vehicle Braking - Overview ..................................................................................................................................... F-52

General Information..................................................................................................................................................F-52

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...]

Page F-b Section F - Familiarization

This Page Left Intentionally Blank

ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel System - Overview
Section F - Familiarization Page F-1

Complete Engine - Overview (000-999)

General Information

The procedures required to replace an engine will vary
with different engine models, the type of equipment,
optional equipment, and the shop facilities. Use the
following procedures as a guide.

All replacement steps will not apply to all types of
equipment. Complete only the steps that apply to the
equipment involved. Use the equipment manufacturer's
recommendations and precautions for removal of chassis
parts to gain access to the engine.

Rocker Levers - Overview (003-999)

General Information

A rocker housing spacer is required on the engines
covered by this manual to accommodate a pass-through
location for the injector wiring harness. The rocker
housing utilizes a press-in-place gasket to form a seal
with the cylinder head. The valve cover is mounted to the
rocker housing by capscrews, isolators, and a press-in­place gasket.

Fuel System - Overview (005-999)

General Information

CAPS Fuel System

The Cummins accumulator pump system (CAPS) fuel
system is a distributor-type injection system. An
accumulator is used to store pressurized fuel for the
injection event. There are four components that provide or
receive input to the electronic control module (ECM).
There are two pumping control valves (1) that are
controlled by the ECM. These valves control the pressure
in the accumulator. The accumulator fuel pressure/
temperature (2) sensor is located on the accumulator and
provides the ECM with pressure and temperature
information. The injection control valve (3) is also
controlled by the ECM and regulates fuel injected into the
cylinder.

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Fuel System - Overview ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page F-2 Section F - Familiarization

The CAPS injection pump can be divided into six distinct
units/modules. They are the gear pump, cam housing,
accumulator, rate shape tube, injection control valve
(ICV), and distributor. Fuel flows through the modules in
the following order:

• Gear pump - 5

• Cam housing - 6

• Accumulator - 1

• Rate shape tube - 2

• Injector control valve (ICV) - 3

• Distributor - 4.

A lift pump is used for priming the pump at start-up. The
lift pump runs for approximately 30 seconds after key-on.
Once the engine is started, the gear pump is able to
maintain prime without any assistance from the lift pump.

The gear pump supplies fuel to the pumping plungers
through internal drillings in the cam housing. The gear
pump also supplies fuel to the distributor for lubrication.
The fuel pressure is regulated to approximately 160 psi at
rated engine rpm. The gear pump has an internal filter to
catch any debris generated downstream of the main,
external fuel filter. The pump camshaft is driven off the
engine camshaft; therefore, pump rpm is one-half engine
rpm. The gear pump is driven by the pump camshaft
through an internal coupling. The gear pump shaft then
turns the distributor rotor through a second internal
coupling.

Each of the two pumping plungers is driven by a three
lobed camshaft (3). The camshaft is located in the cam
housing module by tapered roller bearings. The bearings
that support the camshaft, as well as the tappets (2),
rollers (1), and camshaft itself are lubricated with engine
oil. These are the only components in the pump
lubricated with engine oil.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel System - Overview
Section F - Familiarization Page F-3

A pumping control valve (2) is located above each
pumping plunger (1). The supply fuel from the gear pump
flows around the plunger of this normally open valve into
the chamber above the plunger. The volume above each
pumping plunger is filled, by the gear pump, as the
plungers travel downward. As the plunger starts to move
upward, the fuel is pushed backward into the gear pump.
When the pumping control valve closes, the fuel is pushed
into the accumulator and then held by check valves. The
time when the pumping control valve is energized (closed)
is based on engine speed, accumulator pressure, and
throttle position. A 0- to 24,000-psi pressure sensor is
located in the accumulator. The pressure sensor provides
direct feedback to the ECM, so the desired accumulator
pressure is maintained. This pressure sensor also has
temperature sensing capabilities built into it. Fuel moves
from the accumulator to the distributor and through the
rate shape tube (3).

Fuel is delivered to the injection control valve (1) by the
rate shape tube and through a drilling in the distributor (2).
The ICV controls both fueling and timing. The injection
control valve contains an inner pin and outer valve. The
outer valve is moved by magnetic force generated inside
the ICV by a current from the ECM. The inner pin is
moved by spring force and fuel pressure. When the two
pins are in the closed position, no fuel flows through the
control valve. The position of these internal parts controls
fuel flow to the distributor rotor (3) and to the drain (4).
The injection control valve opens and closes once for
each injection event.

The distributor (1) directs the fuel to the correct injector
using the rotor. The drain fuel from the ICV is routed
through the ICV pressure regulator (4) and is returned to
the tank.

The position of the rotor directs the fuel to one of six
drillings in the distributor housing. These drillings
communicate the fuel to six fuel pump delivery valves (3).
There is one injector line per delivery valve. The injection
line carries the fuel to the injector.

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Fuel System - Overview ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page F-4 Section F - Familiarization

Cummins® Common Rail Fuel System

The Cummins Common Rail Fuel System is a high­pressure common rail injection system. A fuel rail is used
to store pressurized fuel for fuel injection. There are four
components that provide or receive input to the electronic
control module (ECM). The ECM powers the electric fuel
lift pump (located behind the ECM) for approximately 30
seconds at key-on to prime the fuel system. The normally
open fuel pump actuator receives a pulse width
modulated (PWM) signal from the ECM to open or close
in response to the signal from the fuel rail pressure
sensor. The injectors have individual solenoids. The ECM
powers each injector individually to provide fueling to each
cylinder.

The high-pressure fuel pump can be divided into four
distinct assemblies. They are the fuel gear pump, fuel
pump actuator housing, cam housing, and high-pressure
fuel pump head. Fuel flows through the gear pump to a 2­micron pressure-side filter. After the pressure-side filter,
fuel enters the fuel pump actuator housing. The fuel pump
actuator housing includes an air-bleed fitting and the fuel
pump actuator. Some fuel continuously returns to drain
through the air-bleed orifice fitting. Fuel that is metered
through the fuel pump actuator enters the high-pressure
fuel pump head where it is pumped to fuel rail pressure
and exits at the high-pressure outlet fitting.

A lift pump is used for priming the gear pump at start-up.
The lift pump runs for approximately 30 seconds after key­on. Once the engine is started, the gear pump is able to
maintain prime without any assistance from the lift pump.

The ECM and ECM cooling plate must be removed to
access the lift pump and lift pump fuel lines. This is
accomplished by disconnecting the engine harnesses and
the quick disconnect style fuel lines first. Removal of the
ECM cooling plate capscrews allows the ECM, cooling
plate, lift pump and lift pump plumbing to be removed as
one assembly.

The gear pump output is routed to a 2-micron fuel filter.
The filtered fuel returns to the fuel pump actuator housing.

The high-pressure pump is driven by the engine camshaft.
The gear pump is driven by the pump camshaft through
an internal coupling.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Fuel System - Overview
Section F - Familiarization Page F-5

Each of the two pumping plungers is driven by a three
lobed camshaft. The camshaft is located in the cam
housing module by tapered roller bearings. The bearings
that support the camshaft, as well as the tappets, rollers
and camshaft itself are lubricated with engine oil. These
are the only components in the pump lubricated with
engine oil.

Engine oil to the high-pressure pump is supplied through
a drilling in the engine gear housing. The oil passes from
the engine gear housing to the high-pressure pump cam
housing. A small o-ring in a recess on the back of the
engine gear housing seals this passage.

Pressurized fuel from the gear pump is supplied to the
fuel pump actuator. The fuel pump actuator is opened or
closed by the ECM to maintain the appropriate fuel rail
pressure.

An air-bleed orifice fitting in the fuel pump actuator
housing aids in purging air from the fuel supply. Because
of the air-bleed orifice fitting, some fuel that is supplied by
the gear pump will return to drain at all times.

Fuel that is metered past the fuel pump actuator enters
the high-pressure fuel pump inlet drilling, past the inlet
check valve and fills the pumping chamber by pressing
the pumping plunger downward. When the camshaft
pushes the pumping plunger upward, fuel reaches rail
pressure and causes the outlet check valve to lift. Fuel
then enters the outlet drilling of the fuel pump and exits
the high pressure fuel line to the fuel rail.

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Flow Diagram, Fuel System ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page F-6 Section F - Familiarization

General Information

© Cummins Inc.

© Cummins Inc.

© Cummins Inc.

© Cummins Inc.

© Cummins Inc.

Flow Diagram, Fuel System (200-001)

7

5

4

6

3

1 Fuel from supply tank

2 Electronic lift pump

3 Suction side fuel filter and water separator

4 Fuel drain line

5 CAPS injection pump

6 Distributor outlet fitting

7 High-pressure supply lines

8 Fuel connector

9 Injectors

10 Fuel return to supply tank

9

8

10

1

2

05900495

CAPS Fuel System

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Flow Diagram, Fuel System
Section F - Familiarization Page F-7

General Information

© Cummins Inc.

© Cummins Inc.

© Cummins Inc.

© Cummins Inc.

© Cummins Inc.

16

14

Flow Diagram, Fuel System (200-001)

15

19

18

17

13

12

11

7
8
9

5

4

7

1 Fuel from supply tank

2 Fuel filter and water separator

3 OEM fuel supply connection

4 Fuel supply to ECM mounted fuel lift pump

5 ECM cooling plate

6 ECM mounted fuel lift pump

7 Fuel outlet from ECM mounted fuel lift pump

8 Fuel gear pump

9 Fuel from gear pump to fuel filter

10 Pressure side fuel filter

11 Fuel inlet to fuel pump actuator

12 High-pressure fuel pump

13 Fuel outlet from high-pressure pump

14 High-pressure pump drain flow connection

15 Fuel rail

16 High-pressure injector supply lines

17 High-pressure fuel connector

18 Fuel injector

19 Fuel pressure relief valve

20 Fuel injector drain flow line

21 Fuel return to supply tanks

18

20

21

6

10 11

Cummins® Common Rail Fuel System

4

3

1

2

05d00978

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Flow Diagram, Fuel System ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page F-8 Section F - Familiarization

General Information

© Cummins Inc.

© Cummins Inc.

© Cummins Inc.

© Cummins Inc.

© Cummins Inc.

Flow Diagram, Fuel System (200-001)

15

13

12

11

18

16

14

10

9

8

7

22

6

4

3

21

5

6

QSL9 Marine Applications, Cummins® Common Rail Fuel System

1 Fuel from supply tank

2 Fuel filter and water separator

3 Fuel supply to ECM mounted fuel lift pump

4 ECM cooling plate

5 ECM mounted fuel lift pump

6 Fuel outlet from ECM mounted fuel lift pump

7 Fuel gear pump

8 Fuel from gear pump to fuel filter

9 Pressure side fuel filter

10 Fuel inlet to fuel pump actuator

11 High-pressure fuel pump

12 Fuel outlet from high-pressure pump

20

17

19

20

3

2

13 High-pressure pump drain flow connection

14 Fuel rail

15 High-pressure injector supply lines

16 High-pressure fuel connector

17 Fuel injector

18 Fuel pressure relief valve

19 Fuel injector drain flow line

20 Fuel return to fuel cooler on sea water cooled engines

only; fuel return to tank on keel cooled engines

21 Fuel cooler (sea water cooled engines only)

22 Fuel return to fuel tank (sea water cooled engines

only).

1

05d00857

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Flow Diagram, Fuel System
Section F - Familiarization Page F-9

General Information

© Cummins Inc.

© Cummins Inc.

© Cummins Inc.

© Cummins Inc.

© Cummins Inc.

10

9

Flow Diagram, Fuel System (200-001)

15

13

12

11

7

18

16

14

17

8

19

6

6

21

5

3

QSC8.3 Marine Applications (Sea Water Cooled), Cummins® Common Rail Fuel System With ECM Fuel Cooling

1 Fuel from supply tank

2 Fuel filter and water separator

3 Fuel supply to ECM mounted fuel lift pump

4 ECM cooling plate

5 ECM mounted fuel lift pump

6 Fuel outlet from ECM mounted fuel lift pump

7 Fuel gear pump

8 Fuel from gear pump to fuel filter

9 Pressure side fuel filter

10 Fuel inlet to fuel pump actuator

11 High-pressure fuel pump

4

2

1

22

12 Fuel outlet from high-pressure pump

13 High-pressure pump drain flow connection

14 Fuel rail

15 High-pressure injector supply lines

16 High-pressure fuel connector

17 Fuel injector

18 Fuel pressure relief valve

19 Fuel injector drain flow line

20 Fuel return to fuel cooler

21 Fuel cooler

22 Fuel return to fuel tank.

20

3

05d00910

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General Information

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9

Flow Diagram, Fuel System (200-001)

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12

11

7

18

16

14

17

8

19

6

6

21

5

3

QSC8.3 Marine Applications (Sea Water Cooled), Cummins® Common Rail Fuel System Without ECM Fuel Cooling

1 Fuel from supply tank

2 Fuel filter and water separator

3 Fuel supply to ECM mounted fuel lift pump

4 ECM plate

5 ECM mounted fuel lift pump

6 Fuel outlet from ECM mounted fuel lift pump

7 Fuel gear pump

8 Fuel from gear pump to fuel filter

9 Pressure side fuel filter

10 Fuel inlet to fuel pump actuator

11 High-pressure fuel pump

4

2

1

22

12 Fuel outlet from high-pressure pump

13 High-pressure pump drain flow connection

14 Fuel rail

15 High-pressure injector supply lines

16 High-pressure fuel connector

17 Fuel injector

18 Fuel pressure relief valve

19 Fuel injector drain flow line

20 Fuel return to fuel cooler

21 Fuel cooler

22 Fuel return to fuel tank.

20

3

05d01058

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Injectors and Fuel Lines - Overview
Section F - Familiarization Page F-11

Injectors and Fuel Lines - Overview
(006-999)

General Information

CAPS Fuel System

WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot
lights, arcing equipment, and switches out of the
work area and areas sharing ventilation to reduce the
possibility of severe personal injury or death when
working on the fuel system.

Injectors used in the ISC and ISL engines have hole type
nozzles. High pressure fuel flows into the side of the
injector and causes the needle to lift and fuel to be
injected. The clearances in the nozzle bore are extremely
small and any sort of dirt or contaminants will cause the
injector needle valve to stick. This is why it is important to
clean the area around any fuel connection before
servicing it. Also, cap or cover any open fuel connections
before a fuel system repair is performed.

High pressure fuel is supplied to the injector (1) from the
fuel pump via an injector supply line (2) and a fuel
connector (3). The end ferrule on the injector supply line
pushes against the fuel connector when the fuel line nut is
torqued in the cylinder head. This force provides the
sealing pressure between both the injector supply line to
the fuel connector and the connector to the injector.

The torque on this line is critical. If the nut is under
torqued, the surfaces will not seal and a high pressure
fuel leak will result. If the nut is over torqued, the
connector and injector will deform and also cause a high
pressure leak. The leak may result in an injector misfire
and low power.

Always lubricate the threads of the high pressure line nuts
with engine oil before tightening. Always make sure the
proper torque is used on the high pressure line nuts.

The fuel connector contains an edge filter that breaks up
small contaminants that enter the fuel system. The edge
filter uses the pulsating high pressure to break up most
particles so they are small enough to pass through the
injector.

NOTE: The edge filters are not a substitute for cleaning
and covering all fuel system connections during repair.
Edge filters are not a substitute for maintaining the
recommended engine mounted fuel filter.

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Injectors and Fuel Lines - Overview ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page F-12 Section F - Familiarization

The fuel filter is a spin-on type.

Fuel flows around the outside of the filter and back up
through the middle. The filtering media is a 10 micron
Stratapore™ design for efficient debris removal. The filter
also strips the water and collects it at the bottom of the
filter to be drained daily.

The ISC and ISL lift pump will run for 30 seconds after the
key is switched on to assist with fuel priming. The lift
pump will run during cranking and while the engine is
running until the 30 seconds has lapsed. The lift pump will
shut off anytime the key is switched “OFF”. The 30
second timer is reset after each key switch cycle and
ECM power down.

Once the engine is started, additional fuel is drawn
through the lift pump head via the gear pump. A valve in
the head opens when the gear pump requires more flow
than the lift pump can provide or when the lift pump is
shut off.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Injectors and Fuel Lines - Overview
Section F - Familiarization Page F-13

Cummins® Common Rail Fuel System

WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot
lights, arcing equipment, and switches out of the
work area and areas sharing ventilation to reduce the
possibility of severe personal injury or death when
working on the fuel system.

High-pressure common rail fuel systems use solenoid­actuated injectors. High-pressure fuel flows into the side
of the injector. When the solenoid is activated, an internal
needle lifts and fuel is injected. The clearances in the
nozzle bore are extremely small and any dirt or
contaminants can cause the injector to stick. This is why it
is important to clean around all fuel connections before
servicing the fuel system. Also, cap or cover any open fuel
connections before a fuel system repair is performed.

CAUTION
To reduce the possibility of engine damage, always
use the proper torque value and the proper torquing
sequence on the high-pressure line nuts.

High-pressure fuel is supplied to the injector from the fuel
rail by an injector supply line and a fuel connector. The
fuel connector pushes against the injector body when the
fuel connector nut is tightened. The injector supply line is
then connected to the fuel connector.

The torque and sequence for this joint is critical. If the nut
or line is undertightened, the surfaces may not seal and a
high-pressure fuel leak will result. If the nut is
overtightened, the connector and injector will deform and
can cause a high-pressure fuel leak. This leak will be
inside the head and will not be visible. The result will be a
fault code, low power, or no-start.

If the injector is not fully seated prior to the installation of
the high-pressure connector, the joint will not seal.

The fuel connector contains an edge filter that breaks up
small contaminants that enter the fuel system.

The edge filters are not a substitute for cleaning and
covering all fuel system connections during repair.

Be sure to cap or cover all fuel fittings and ports.

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Page F-14 Section F - Familiarization

All injectors feed into a common return drilling contained
within the cylinder head. Any excess fuel is returned to the
tank via this drilling and return line attached to the rear of
the cylinder head. A back-pressure valve is located on the
back of the cylinder head where the drain line attaches.

The electronic control module (ECM) controls the fueling
and timing of the engine by actuating the injector
solenoids. An electronic pulse is sent to the solenoids to
lift the needle and start the injection event. By
electronically controlling the injectors, there is a more
precise and accurate control of fueling quantity and
timing. Also, multiple injection events can be achieved by
electronically controlling the injectors.

Fuel Filters

The engines covered in this manual require original
equipment manufacturers (OEM's) to mount a 10-micron
suction filter prior to the OEM fuel supply connection at
the rear of the engine block. The 10-micron filter performs
water stripping and includes a water-in-fuel sensor. The
water-in-fuel sensor must be installed. If not, a fault code
warning lamp will be active.

The engines covered in this manual also include a 2­micron pressure-side fuel filter. The pressure-side filter
will be located downstream of the gear pump before the
high-pressure fuel pump inlet. If a water-in-fuel fault is
experienced, drain the water stripping filter and replace
the pressure side fuel filter.

Lubricating Oil System - Overview
(007-999)

General Information

Lubricating Oil Filters

The LF9009 oil filter is used on all ISC, QSC8.3, ISL, and
QSL9 with CM850 engines. This filter is a spin-on element
and contains an internal venturi that provides filter bypass
oil flow through a stacked disk section of the filter.
Lubricating oil filters must be of the venturi style. Using a
lubricating oil filter without a venturi will result in
premature engine wear.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Flow Diagram, Lubricating Oil System
Section F - Familiarization Page F-15

Flow Diagram, Lubricating Oil System (200-002)

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General Information

2

1 Gerotor lubricating oil pump

2 Lubricating oil cooler

3 Bypass oil to lubricating oil pan

4 Full flow lubricating oil filter

5 Filter bypass valve

6 From lubricating oil filter to main oil rifle

7 Oil thermostat

6

5

1

4

Lubricating Oil Cooler Flow

7

2

1

3

07d00183

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Flow Diagram, Lubricating Oil System (200-002)

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General Information

4

1

5

3

1 From lubricating oil filter

2 Main lubricating oil rifle

3 To camshaft

4 To piston cooling nozzle

5 From main lubricating oil rifle

6 To connecting rod bearing.

6

Lubrication for Power Components

2

07d00185

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Section F - Familiarization Page F-17

Flow Diagram, Lubricating Oil System (200-002)

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General Information

4

1

5

3

6

Lubrication for Power Components (All ISL engines and ISC engines with CM850 Electronic Control Module)

1 From lubricating oil filter

2 Main lubricating oil rifle

3 To camshaft

4 To piston cooling nozzle

5 From main lubricating oil rifle

6 To connecting rod bearing.

2

07d00185

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Flow Diagram, Lubricating Oil System ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page F-18 Section F - Familiarization

Flow Diagram, Lubricating Oil System (200-002)

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General Information

1

3

Lubrication for Power Components (ISC engines without CM850 Electronic Control Module)

1 From lubricating oil cooler

2 Main lubricating oil rifle

3 To camshaft

4 To piston cooling nozzle

5 From main lubricating oil rifle

6 To connecting rod bearing.

5

6

2

4

07d00001

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Flow Diagram, Lubricating Oil System
Section F - Familiarization Page F-19

Flow Diagram, Lubricating Oil System (200-002)

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General Information

2

3

1

07d00184

1 Lubricating oil supply from filter

2 Turbocharger lubricating oil supply

3 Turbocharger lubricating oil drain

Lubrication for Turbocharger (All Applications Except Marine)

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Page F-20 Section F - Familiarization

Flow Diagram, Lubricating Oil System (200-002)

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General Information

2

3

1

07d00184

1 Lubricating oil supply from filter

2 Turbocharger lubricating oil supply

3 Turbocharger lubricating oil drain

Lubrication for Turbocharger

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Section F - Familiarization Page F-21

Flow Diagram, Lubricating Oil System (200-002)

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General Information

4

Lubrication for Turbocharger (Marine Applications)

1 Lubricating oil cooler

2 Lubricating oil filter

3 Turbocharger lubricating oil supply

4 Turbocharger

5 Turbocharger lubricating oil drain.

1

2

3

5

07d00189

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Flow Diagram, Lubricating Oil System ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
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Flow Diagram, Lubricating Oil System (200-002)

© Cummins Inc.

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General Information

1

6

4

5

3

2

07d00002

1 From cam bushings

2 Transfer slot

3 Rocker lever support

4 Rocker lever shaft

5 Rocker lever bore

6 Rocker lever.

Lubrication for the Overhead

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cooling System - Overview
Section F - Familiarization Page F-23

Cooling System - Overview (008-999)

General Information

The function of the cooling system is to maintain a
specified operating temperature for the engine. Some of
the heat generated by the engine is absorbed by the
coolant flowing through the passages in the cylinder block
and head. Then, heat is removed from the coolant as it
flows through the radiator.

Conventionally cooled engines with automatic
transmissions typically use oil-to-water transmission
torque converter coolers plumbed between the radiator
and the engine water pump.

A torque converter cooling system with a remote bypass
allows the torque converter to receive coolant flow when
the thermostat is closed (engine cold).

The following publications, available through Cummins
Distributors or Cummins Dealers, provide cooling system
installation recommendations and specifications approved
by Cummins Inc.:

•

Automotive Installation Recommendations (Cooling
System), Bulletin 3382413

•

Construction, Mining, Logging and Agriculture
Installation Recommendations (Cooling System),
Bulletin 3382171

•

Data Sheets for specific engine models

•

Operation of Diesel Engines in Cold Climates,
Bulletin 3379009

•

Heavy-Duty Coolant/SCA Maintenance
Requirements, Bulletin 3387910.

Open the petcocks at the bottom of the radiator and at the
bottom of the oil cooler housing. Remove the lower
radiator hose. A 20 liter [4 gal] drain pan will contain the
coolant in most applications.

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Cooling System - Overview ISC, ISCe, QSC8.3, ISL, ISLe3, [...]
Page F-24 Section F - Familiarization

When troubleshooting overheating, remember that too
much oil in the oil pan can cause additional heat from
friction when the rod journals are submerged in oil.
Overfilling with oil raises the oil temperature that is
transferred to the cooling system at the oil cooler.

The system is designed to use a specific quantity of
coolant. If the coolant level is low, the engine will run hot.

NOTE: The engine or system has a leak if frequent
addition of coolant is necessary. find and repair the leak.

During operation, entrapped air mixes with the coolant
which results in cavitation corrosion and poor heat
transfer. Highly areated coolant can cause localized
overheating of the cylinder head and block which can
result in a cracked head, scored cylinder liner, or blown
head gasket.

Obstructions in the coolant passages will reduce coolant
flow, which can lead to overheating.

NOTE: The small holes in the head gasket are especially
susceptible to plugging. Their size is critical. Do not
enlarge the size of the orifices. Doing so will disturb the
coolant flow and will not solve an overheating problem.

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ISC, ISCe, QSC8.3, ISL, ISLe3, [...] Cooling System - Overview
Section F - Familiarization Page F-25

Water will cause rust formation, reducing the flow in the
smaller coolant passages.

Also, water used as a coolant for even a relatively short
period can result in the expansion plugs rusting through,
which will allow the coolant to leak.

NOTE: A sudden loss of coolant from a heavily loaded
engine can result in severe damage to the pistons and
cylinder bore.

Overfueling and Loading

Overfueling can cause the engine to overheat. Make sure
that the correct engine electronic control module (ECM)
calibration is being used.

Constant overloading (lugging) can cause the engine to
run hot.

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Page F-26 Section F - Familiarization

General Information

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Flow Diagram, Cooling System (200-003)

6

9

8

7

5

4

3

11

2

10

2

2

1

1

08900119

Internal Engine Coolant Flow, All Applications

CAUTION
Never operate the engine without a thermostat. Without a thermostat, the coolant will not flow to the radiator,
and the engine will overheat.

NOTE: The thermostat flow shown is not for QSL9 keel cooled engines. On QSL9 keel cooled marine engines, the

thermostat is located in the keel cooled thermostat housing. See flow diagram below.

1 Coolant inlet from radiator

2 Water pump suction

3 Coolant flow through lubricating oil cooler

4 Block lower water manifold (to cylinders)

5 Coolant filter inlet (optional)

6 Coolant filter outlet (optional)

7 Coolant supply to cylinder head

8 Coolant return from cylinder head

9 Block upper water manifold

10 Thermostat bypass

11 Coolant return to radiator

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Section F - Familiarization Page F-27

General Information

© Cummins Inc.

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© Cummins Inc.

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© Cummins Inc.

2

Flow Diagram, Cooling System (200-003)

1 Turbocharger coolant supply

2 Turbocharger coolant drain

1

All Applications

08d00157

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General Information

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© Cummins Inc.

4

Flow Diagram, Cooling System (200-003)

9

3

2

13

10

7

8

5

6

12

11

QSL9 with Keel Cooled (Engine Coolant)

1 Engine coolant return from keel cooler

2 Keel cooler thermostat housing

3 Engine coolant to aftercooler

4 Aftercooler

5 Engine coolant through marine gear oil cooler

6 Engine coolant to water pump

7 Engine discharge to keel cooler thermostat

8 Engine coolant to keel cooler

9 Cooling system housing vent line

10 Expansion tank

11 Engine coolant from engine to turbocharger

12 Turbocharger turbine housing

13 Exhaust manifold

14 Engine coolant return from exhaust manifold to water pump.

1

14

6

08d00228

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Section F - Familiarization Page F-29

General Information

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© Cummins Inc.

Flow Diagram, Cooling System (200-003)

5

4

2

3

12

3

QSL9 with Heat Exchanger (Engine Coolant)

1 Coolant from thermostat to heat exchanger

2 Heat exchanger

3 Coolant return from heat exchanger to water pump

4 Turbocharger coolant supply from cylinder block

5 Turbocharger with water cooled turbine housing

6 Water cooled exhaust manifold

7 Coolant return from exhaust manifold to water pump

8 Turbocharger coolant vent line

9 Exhaust manifold coolant vent line

10 Cylinder head coolant vent line

11 Expansion tank

12 Coolant makeup to water pump from expansion tank.

8

6

9

1

10

11

7

08d00328

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General Information

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© Cummins Inc.

Flow Diagram, Cooling System (200-003)

11 12

10

QSC8.3 Engine Coolant

1 Coolant from thermostat

2 Heat exchanger coolant inlet

3 Heat exchanger coolant outlet

4 Water pump coolant inlet from heat exchanger

5 Water pump coolant inlet from exhaust manifold

6 Expansion tank

7 Coolant vent line from cylinder head to expansion tank

8 Coolant vent line from exhaust manifold to expansion tank

9 Coolant vent line from turbocharger to expansion tank

10 Turbocharger coolant inlet from cylinder block

11 Coolant from turbocharger to exhaust manifold

12 Expansion tank fill cap.

23

6 789

1

5

4

08d00317

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Section F - Familiarization Page F-31

General Information

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© Cummins Inc.

Flow Diagram, Cooling System (200-003)

12

9

3

2

1

4

5

67

QSL9 Sea Water Cooled (Heat Exchanger), Marine Applications

1 Sea water pump inlet

2 Sea water pump

3 Sea water pump discharge to fuel cooler

4 Fuel cooler

5 Aftercooler sea water inlet

6 Aftercooler

7 Aftercooler lower zinc anode

8 Aftercooler upper zinc anode

9 Aftercooler sea water outlet to marine gear oil cooler

10 Marine gear oil cooler sea water outlet to heat exchanger

11 Heat exchanger

12 Heat exchanger zinc anode

13 Exhaust elbow

14 Sea water discharge.

8

11

13

14

10

08d00159

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