Cummins ISB, QSB 5.9 24v VP44 Engine Troubleshooting & Repair Manual


Category: Tags: , ,

 Bookmarked, searchable, printable PDF  Instant download

Covers: Cummins ISB 5.9-44 and QSB 5.9-44 (24v with Bosch VP44 fuel injection pump, before 2003)
Format: PDF
File size: 62mb
Compatibility: Windows/Mac/Tablet
Notes: 1999 publication. Digital download only — no printed copy.

This Troubleshooting and Repair Manual is intended to aid in determining the cause of Cummins ISB and QSB 5.9L VP44 engine mechanical-related problems and to provide recommended engine repair procedures. It also includes mechanical repair and overhaul of the engine. This manual is in PDF format and is a fast and affordable way to view the Cummins ISB, QSB 5.9 24v VP44 Engine Troubleshooting & Repair Manual on your computer. Electronic control system troubleshooting/diagnostic manual sold separately.

Topics in the Cummins ISB, QSB 5.9 (24v VP44) Engine Troubleshooting & Repair Manual:


Engine and System Identification
Engine Identification
Engine Diagrams

Complete Engine – Overview
Cylinder Block – Overview
Fuel System – Overview
Flow Diagram, Fuel System
Lubricating Oil System – Overview
Flow Diagram, Lubricating Oil System
Flow Diagram, Cooling System
Air Intake System – Overview
Flow Diagram, Air Intake System
Flow Diagram, Exhaust System
Compressed Air System – Overview
Flow Diagram, Compressed Air System
Electrical Equipment – Overview
Engine Testing – Overview

Troubleshooting Symptoms
Troubleshooting Procedures and Techniques
Troubleshooting Symptoms Charts
Air Compressor Air Pressure Rises Slowly
Air Compressor Cycles Frequently
Air Compressor Noise is Excessive
Air Compressor Pumping Excess Lubricating Oil into the Air System
Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)
Air Compressor Will Not Pump Air
Air Compressor Will Not Stop Pumping
Alternator Not Charging or Insufficient Charging
Alternator Overcharging
Coolant Contamination
Coolant Temperature Above Normal – Gradual Overheat
Coolant Temperature is Above Normal – Sudden Overheat
Coolant Temperature is Below Normal
Coolant in the Lubricating Oil
Crankcase Gases (Blowby) Excessive
Cranking Fuel Pressure is Low
Engine Acceleration or Response Poor
Engine Decelerates Slowly
Engine Difficult to Start or Will Not Start (Exhaust Smoke)
Engine Difficult to Start or Will Not Start (No Exhaust Smoke)
Engine Noise Excessive
Engine Noise Excessive – Combustion Knocks
Engine Noise Excessive – Connecting Rod
Engine Noise Excessive – Main Bearing
Engine Noise Excessive – Piston
Engine Noise Excessive – Turbocharger
Engine Power Output Low
Engine Runs Rough at Idle
Engine Runs Rough or Misfires
Engine Shuts Off Unexpectedly or Dies During Deceleration
Engine Speed Surges at Low or High Idle
Engine Speed Surges Under Load or in Operating Range
Engine Speed Surges in PTO or Cruise Control
Engine Starts But Will Not Keep Running
Engine Will Not Crank – (Electric Starter)
Engine Cranks Slowly – (Electric Starter)
Engine Vibration Excessive
Engine Will Not Crank or Cranks Slowly (Air Starter)
Engine Will Not Reach Rated Speed (RPM)
Engine Will Not Shut Off
Fault Code Warning Lamps Stay On (No Apparent Reason)
Fault Code Warning Lamps Do Not Illuminate
Fuel Consumption Excessive
Fuel in Coolant
Fuel in the Lubricating Oil
Intake Manifold Air Temperature Above Specification
Intake Manifold Pressure (Boost) is Below Normal
Low Idle Adjust Switch Does Not Work
Lubricating Oil Consumption Excessive
Lubricating Oil Contaminated
Lubricating Oil Pressure High
Lubricating Oil Pressure Low
Lubricating Oil Sludge in the Crankcase Excessive
Lubricating Oil Temperature Above Specification
Lubricating or Transmission Oil in the Coolant
PTO or Cruise Control Does Not Operate
Smoke, Black – Excessive
Smoke, White – Excessive
Turbocharger Leaks Engine Oil or Fuel
Troubleshooting Overview

Complete Engine
Service Tools
Engine Removal
Engine Installation
Engine Painting
Engine Mounting Bolts

Cylinder Block
Service Tools
Bearings, Connecting Rod
Bearings, Main
Camshaft Bushings
Camshaft Gear (Camshaft Removed)
Connecting Rod
Crankshaft Gear, Front (Crankshaft Installed)
Crankshaft Gear, Front (Crankshaft Removed)
Crankshaft Seal, Front
Crankshaft Seal, Rear
Crankshaft Wear Sleeve, Front
Cylinder Block
Gear Cover, Front
Gear Housing, Front
Piston Rings
Vibration Damper, Rubber
Vibration Damper, Viscous
Piston and Connecting Rod Assembly
Crankshaft Wear Sleeve, Rear
Crankshaft Speed Indicator Ring

Cylinder Head
Service Tools
Cylinder Head
Valve Guide Seal, Cylinder Head
Valve Guide, Cylinder Head
Valve, Cylinder Head
Cylinder Head Gasket
Injector Protrusion

Rocker Levers
Overhead Set
Rocker Lever
Rocker Lever Cover
Crankcase Breather Tube

Cam Followers/Tappets
Service Tools
Push Rods or Tubes
Tappet Cover

Fuel System
Service Tools
Engine Fuel Heater, Electric
Fuel Consumption
Fuel Flow
Fuel Injection Pump, Rotary
Fuel Pump Support Bracket
Fuel Pump Timing
Fuel Lift Pump
Stall Speed Test

Injectors and Fuel Lines
Service Tools
Air in Fuel
Fuel Drain Line Restriction
Fuel Drain Lines
Fuel Filter (Canister Type)
Fuel Filter (Spin-On Type)
Fuel Filter Head Bracket
Fuel Inlet Restriction
Fuel Supply Lines
Fuel Return Overflow Valve
Injector Supply Lines (High Pressure)
Fuel Connector (Head Mounted)

Lubricating Oil System
Service Tools
Engine Oil Heater
Lubricating Oil and Filters
Lubricating Oil Cooler
Lubricating Oil Dipstick
Lubricating Oil Dipstick Tube
Lubricating Oil Filter (Spin-On)
(Lubricating Oil Leaks
Lubricating Oil Pan
Lubricating Oil Pressure Regulator (Main Rifle)
Lubricating Oil Pump
Lubricating Oil Suction Tube (Block-Mounted)
Lubricating Oil Pressure Sensor,
Lubricating Oil and Filter Analysis

Cooling System
Service Tools
Drive Belt, Cooling Fan
Coolant Temperature Gauge
Coolant Heater
Coolant Thermostat
Cooling System Diagnostics
Fan Clutch, On-Off
Fan Hub, Belt Driven
Fan Shroud Assembly
Fan Spacer and Pulley
Fan, Cooling
Radiator Hoses
Radiator Pressure Cap
Radiator Shutter Assembly
Water Pump

Drive Units
Hydraulic Pump Drive
Hydraulic Pump Drive Gear and Shaft

Air Intake System
Service Tools
Air Crossover
Air Inlet Connection
Air Intake Manifold
Air Leaks, Air Intake and Exhaust Systems
Charge-Air Cooler
Cold Starting Aid
Air Intake Restriction
Turbocharger Axial Clearance
Turbocharger Blade Damage
Turbocharger Compressor Seal Leaks
Turbocharger Oil Drain Line
Turbocharger Oil Supply Line
Turbocharger Radial Bearing Clearance
Turbocharger Turbine Seal Leaks
Turbocharger Wastegate Actuator
Turbocharger Wastegate Valve Body
Intake Manifold Pressure

Exhaust System
Service Tools
Exhaust Manifold, Dry
Exhaust Restriction

Compressed Air System
Service Tools
Air Compressor Carbon Buildup
Air Compressor Coolant Lines
Air Compressor Unloader and Valve Assembly
Air Compressor
Air Governor (Air Compressor Pumps Continuously)
Air Leaks, Compressed Air System
Air Compressor Cylinder Head (Holset® QE Models)

Electrical Equipment
Service Tools
Alternator Bracket
Battery Cables and Connections
Starter Magnetic Switch
Starter Switch
Starter Solenoid
Starting Motor
Belt Tensioner, Automatic (Alternator)
Charging System Indicator

Engine Testing
Service Tools
Engine Testing (Chassis Dynamometer)
Engine Run-in (Chassis Dynamometer)
Engine Run-in (Without Dynamometer)
Engine Testing (Engine Dynamometer)
Engine Run-in (Engine Dynamometer)
Engine Testing (In Chassis)
Crankcase Blowby, Measure

Mounting Adaptations
Service Tools
Engine Support Bracket, Front
Engine Support Bracket, Rear
Flywheel Housing
Flywheel Ring Gear

Service Tools
Cup Plug
Pipe Plug
Straight Thread Plug

Vehicle Braking
Engine Exhaust Brake