Cummins ISC, ISL, QSC8.3, QSL9 Engine Troubleshooting Repair Manual


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Covers: Cummins ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Diesel Engines

  • Equipped w/ CM554 (CAPS) or CM850 (Common Rail) fuel system

Pages: 1,476 – 2 volumes
Format: PDF files (zipped)
File size: 65mb
Compatibility: Windows/Mac computers
Notes: 2014 revision

This manual provides instructions for mechanical troubleshooting and repair of the Cummins ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 engines in the chassis. This manual is designed to aid the mechanic with service and complete disassembly/assembly of the engine, fuel system, cooling system, intake/exhaust system and much more. View the manual on your computer or print off pages as needed.

Electronic control system troubleshooting and wiring diagrams are sold separately.

Topics in the Cummins ISC, ISL, QSC8.3, QSL9 Engine Troubleshooting Repair Manual:


Engine and System Identification
Engine Identification
Engine Diagrams

Complete Engine – Overview
Rocker Levers – Overview
Fuel System – Overview
Flow Diagram – Fuel System
Injectors and Fuel Lines – Overview
Lubricating Oil System – Overview
Flow Diagram, Lubricating Oil System
Cooling System – Overview
Flow Diagram – Cooling System
Air Intake System – Overview
Flow Diagram – Air Intake System
Exhaust System – Overview
Flow Diagram, Exhaust System
Compressed Air System – Overview
Flow Diagram, Compressed Air System
Electrical Equipment – Overview
Engine Testing – Overview
Vehicle Braking – Overview

Troubleshooting Symptoms
Troubleshooting Procedures and Techniques
Troubleshooting Symptom 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 Loss – External
Coolant Loss – Internal
Coolant Temperature Above Normal – Gradual Overheat
Coolant Temperature Above Normal – Sudden Overheat
Coolant Temperature Below Normal
Coolant in the Lubricating Oil
Coolant Temperature Above Normal – Sea Water Cooling System
Crankcase Gases (Blowby Excessive
Engine Brake Does Not Operate
Engine Brake – Low Retarding Power or Slow to Activate
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 Will Not Crank – (Electric Starter
(Engine Cranks Slowly – (Electric Starter
Engine Will Not Crank or Cranks Slowly (Air Starter
Engine Will Not Shut Off
Fuel in the Sea Water
Fuel in Coolant
Fuel in the Lubricating Oil
Intake Manifold Air Temperature Above Specification
Intake Manifold Pressure (Boost is Below Normal
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
Turbocharger Leaks Engine Oil or Fuel
Urea Usage – Abnormal
Engine Noise Excessive – Drive Belt

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

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

Service Tools
Crankcase Breather (External
Crankcase Breather (Internal
Overhead Set
Rocker Lever
Rocker Lever Cover
Rocker Lever Housing
Crankcase Breather Tube
Closed-Crankcase Ventilation System Filter

Service Tools
Engine Fuel Heater, Electric
Fuel Consumption
Fuel Pump
Fuel Pump Delivery Valve
Fuel Pump Gear Pump
Fuel Pump Timing
Fuel Lift Pump
Rotor, CAPS Fuel Injection Pump
Injection Control Valve
Pumping Control Valve
Snubber, Rate Shape
Fuel Pump Distributor Inlet Fitting
Fuel Pump Accumulator Module
Fuel Pump Distributor and Injection Control Valve Module
Fuel Pump Cam Housing Module
Fuel Pump Gear Pump Module
Fuel Pump Rate Shape Tube
Fuel Pump Head Outlet Fitting
Fuel Pump Head
Fuel Pump Actuator Housing
Fuel Injection Pump

Service Tools
Air in Fuel
ECM Cooling Plate, Fuel Cooled
Fuel Drain Line Restriction
Fuel Drain Lines
Fuel Filter (Spin-On Type
Fuel Filter Head
Fuel Filter Head Bracket
Fuel Inlet Restriction
Fuel Supply Lines
Injector Supply Lines (High Pressure
Fuel Connector (Head Mounted
Fuel Pump Air Bleed Line
Fuel Rail
Fuel Pressure Relief Valve
Fuel Cooler
Fuel Rail High Pressure Fitting

Service Tools
Engine Oil Heater
Lubricating Oil Cooler
Lubricating Oil Dipstick
Lubricating Oil Dipstick Tube
Lubricating Oil Filter (Spin-On
Lubricating Oil Filter Bypass Valve
Lubricating Oil Filter Head
Lubricating Oil Filter Head (Remote-Mounted
Lubricating Oil Filter Head Adapter
Lubricating Oil High Pressure Relief Valve
Lubricating Oil Leaks
Lubricating Oil Pan
Lubricating Oil Pressure Regulator (Main Rifle
Lubricating Oil Pump
Lubricating Oil Suction Tube (Block-Mounted
Lubricating Oil System
Lubricating Oil and Filter Analysis
Lubricating Oil Lines

Service Tools
Belt Guard
Drive Belt, Cooling Fan
Coolant Filter
Coolant Filter Head
Coolant Filter Valve
Coolant Heater
Coolant Thermostat
Coolant Thermostat Housing
Coolant Thermostat Housing Support
Coolant Thermostat Seal
Coolant Vent Lines
Cooling System
Cooling System Diagnostics
Fan Clutch, On-Off
Fan Shroud Assembly
Fan Spacer and Pulley
Fan, Cooling
Marine Gear Oil Cooler
Radiator Hoses
Radiator Pressure Cap
Radiator Shutter Assembly
Expansion Tank
Heat Exchanger
Sea Water Pump
Zinc Anode
Water Pump
Sea Water Strainer
Belt Tensioner, Automatic (Water Pump
Water Inlet Connection
Keel Cooler
Sea Water System Diagnostics
Sea Water Hoses
Pulley, Fan Idler
Bracket, Fan Idler Pulley
Coolant Return Junction Block
Marine Gear Oil and Fuel Cooler Assembly

Hydraulic Pump Drive
Refrigerant Compressor
Drive Belt, Refrigerant Compressor
Belt Tensioner, Refrigerant Compressor, Automatic
Refrigerant Compressor Mounting Bracket

Service Tools
Aftercooler Assembly (Sea Water
Air Cleaner Assembly (Engine-Mounted
Air Crossover
Air Inlet Connection
Air Leaks, Air Intake and Exhaust Systems
Charge-Air Cooler
Cold Starting Aid
Air Intake Restriction
Turbocharger Coolant Hoses
Turbocharger Oil Drain Line
Turbocharger Oil Supply Line
Turbocharger Wastegate Actuator
Turbocharger Wastegate Valve Body
Intake Manifold Pressure
Air Intake Connection
Air Intake Manifold Cover
Turbocharger, Variable Geometry Actuator
Turbocharger Actuator Air Line
Air Intake Connection Adapter
Inline Air Filter
Turbocharger Exhaust Connection Adapter

Service Tools
Exhaust Manifold, Dry
Exhaust Restriction
Exhaust Outlet Connection
Exhaust Gas Pressure Sensor Adapter
Exhaust Gas Treatment Monitor Unit
Exhaust Catalyst
Exhaust Gas Temperature Sensor
Exhaust Gas Treatment Monitor Harness
Exhaust Gas Pressure Sensor
Aftertreatment Nozzle

Service Tools
Engine Support Bracket, Front
Engine Support Bracket, Rear
Flywheel Housing
Flywheel Housing, REPTO
Flywheel Ring Gear
Engine Mounts
Propeller Shaft
Marine Vibration Isolator
Engine Drive Shaft

Cup Plug
Pipe Plug
Straight Thread Plug
Expansion Plug

Vehicle Braking
Engine Brake Assembly
Engine Brake Housing Spacer
Engine Brake Solenoid Valve
Engine Brake Wiring Harness




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