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CM850 Electronic Control System – CM850 Electronic Control System – Troubleshooting and Repair Manual

Engine Performance Troubleshooting Tree – ISB, ISBe, and QSB engines without EGR (CM800 and CM850 Electronic Control System)

Symptoms

    • Engine Acceleration or Response Poor
    • Engine Difficult to Start or Will
      Not Start (Exhaust Smoke)
    • Engine Difficult to Start or Will
      Not Start (No Exhaust Smoke)
    • Engine Power Output Low
    • Engine Runs Rough at Idle
    • Engine Runs Rough or Misfires
    • Engine Speed Surges at Low or High Idle
    • Engine Speed Surges Under Load or in Operating Range
    • Smoke, Black – Excessive
    • Smoke, White – Excessive
    • Engine Shuts Off or Dies Unexpectedly or Dies During Deceleration
    • Engine Decelerates Slowly
    • Engine Starts but Will
      Not Keep Running
    • Engine Will
      Not Reach Rated Speed (RPM)
    • Intake Manifold Pressure (Boost) is Below Normal
    • Engine Vibration Excessive

How To Use This Tree

This symptom tree can be used to troubleshoot all performance-based symptoms listed above. Start by performing Step 1 troubleshooting. Step 2 will ask a series of questions and will provide a list of troubleshooting steps to perform, depending on the symptom.

Many steps will reference using INSITE™ electronic service tool to check for fault codes, perform tests, monitor data, and check features and parameters. It is recommended that INSITE™ electronic service tool remain connected while using this troubleshooting tree, to periodically check for fault codes. If any fault codes become active during use of the troubleshooting tree, discontinue using this troubleshooting tree and troubleshoot the active fault code.

This symptom tree often references other procedures and symptom trees. The procedures and symptom trees referenced may
not be located in the same service literature as this symptom tree. Use the following procedure for a listing of the service literature available for the engine being serviced.
Refer to Procedure 205-001 in Section L.

Shop Talk

Driveability is a term that in general describes vehicle performance on the road. Driveability problems for an engine can be caused by several different factors. Some of the factors are engine-related and some are
not. Before troubleshooting, it is important to determine the exact complaint and whether the engine has a real driveability problem or if it simply does
not meet driver expectations.

Low power is a term that is used in the field to describe many different performance problems. Low power is defined as the inability of the engine to produce the power necessary to move the vehicle at a speed that can be reasonably expected under the given conditions of load, grade, wind, and so on. With industrial equipment, low power might relate to the inability of the equipment to pick up or maintain load.

Poor acceleration or response is described as the inability of the vehicle to accelerate satisfactorily from a stop or from the bottom of a grade. It can also be the lag in acceleration during an attempt to pass or overtake another vehicle at conditions less than rated speed and load. Poor acceleration or response is difficult to troubleshoot, since it can be caused by several factors.

Troubleshooting Steps

STEPS SPECIFICATIONS
STEP 1. Perform basic troubleshooting procedures.  
  STEP 1A. Check for active fault codes or high counts of inactive fault codes. Active fault codes or high counts of inactive fault codes?
  STEP 1B. Perform basic troubleshooting checks. All steps have been verified to be correct?
STEP 2. Determination of engine symptom.  
  STEP 2A. Engine Difficult to Start or Will Not Start (With or Without Exhaust Smoke), Engine Shuts Off or Dies Unexpectedly or Dies During Deceleration, or Engine Starts but Will Not Keep Running. Is the engine symptom Engine Difficult to Start or Will Not Start (With or Without Exhaust Smoke), Engine Shuts Off or Dies Unexpectedly or Dies During Deceleration, or Engine Starts but Will Not Keep Running?
  STEP 2B. Engine Runs Rough at Idle, Engine Runs Rough or Misfires, Engine Speed Surges at Low or High Idle, Engine Speed Surges under Load or in Operating Range. Is the engine symptom Engine Runs Rough at Idle, Engine Runs Rough or Misfires, Engine Speed Surges at Low or High Idle, Engine Speed Surges under Load or in Operating Range?
  STEP 2C. Smoke, Black – Excessive. Is the engine symptom Smoke, Black – Excessive?
  STEP 2D. Smoke, White – Excessive. Is the engine symptom Smoke, White – Excessive?
  STEP 2D-1. Smoke, White – Excessive.
  STEP 2D-1. Smoke, White – Excessive.
  STEP 2E. Engine Acceleration or Response Poor, Engine Power Output Low, Engine Decelerates Slowly, Intake Manifold Pressure (Boost) is Below Normal or Engine Will Not Reach Rated Speed (RPM). Is the engine symptom – Engine Acceleration or Response Poor, Engine Power Output Low, Engine Decelerates Slowly, Intake Manifold Pressure (Boost)
is Below Normal or Engine Will Not Reach Rated Speed (RPM)?
  STEP 2F. Engine vibration is excessive. Is the engine symptom – Engine Vibration Excessive?
STEP 3. Engine will not start or stalls troubleshooting procedures.  
  STEP 3A. Verify the operation of cold weather starting aids. Are the necessary cold weather starting aids being used and are they operational as required?
  STEP 3B. Check electronic features and programmable parameters. Are electronic features and programmable parameters the cause for the engine shutting down or the no-start complaint?
  STEP 3C. Monitor the engine speed during cranking. Is the engine speed greater than 150 rpm during cranking?
  STEP 3D. Monitor the ECM keyswitch input. Does the User Fueling State indicate cranking or is keyswitch voltage equal to battery voltage?
  STEP 3E. Monitor the ECM battery supply. Is the ECM battery supply voltage greater than +11-VDC for 12 volt systems or +22-VDC for 24 volt systems?
  STEP 3F. Check the load carrying capabilities of the ECM power and ground circuits. Do the headlights illuminate brightly?
  STEP 3G. Check orientation of connector. Is the rail fuel pressure sensor connector installed correctly?
  STEP 3H. Verify rail fuel pressure sensor accuracy. Is the Fuel Rail Pressure (measured) less than 30 bar [435 psi]?
  STEP 3I. Monitor fuel rail pressure while cranking the engine. Did the Fuel Rail Pressure (measured) equal the Fuel Rail Pressure (commanded)?
STEP 4. Fuel system troubleshooting procedures.  
  STEP 4A. Check for air in the fuel supply line. Is air present in the fuel supply?
  STEP 4B. Check for air in the high pressure pump fuel supply. Is the pressure measured within specification?
  STEP 4B-1. Measure the fuel inlet restriction.
  STEP 4C. Measure fuel pressure at the outlet of the on engine fuel filter. Is the pressure drop across the filter greater than the specification?
  STEP 4D. Perform INSITE™ electronic service tool single cylinder cutout test. Can the miss or excessive smoke be attributed to a single cylinder?
  STEP 4E. Perform a manual single cylinder cut-out test. Did the engine start after blocking off a cylinder(s) or can the miss or excessive smoke be attributed to a cylinder(s)?
  STEP 4F. Measure the injector return fuel drain flow from the cylinder head. Is injector fuel drain flow from the cylinder head greater than specification?
  STEP 4G. Determine which cylinder(s) is causing excessive injector fuel drain flow from the cylinder head. Did blocking off a cylinder(s) decrease the flow rate below the maximum specified flow rate?
  STEP 4H. Monitor Commanded Fuel Rail Pressure and Measured Fuel Rail Pressure. Does the Measured Fuel Rail Pressure vary more than ± 35 bar
[± 500 psi] from the Commanded Fuel Rail Pressure?
  STEP 4I. Check the fuel pressure relief valve for excessive leakage. Is the fuel pressure relief valve within specification?
  STEP 4J. Measure the high-pressure fuel supply pump fuel drain flow. Is the high pressure fuel supply pump fuel return flow greater than specification?
  STEP 4K. Measure fuel drain line restriction. Is the drain line restriction less than specification?
STEP 5. Air handling troubleshooting procedures.  
  STEP 5A. Check intake manifold pressure sensor accuracy. Intake manifold pressure reading is less than 102 mm-Hg [4 in-Hg]?
  STEP 5B. Check the air intake system for leaks. Were any air intake system leaks found?
  STEP 5C. Check air intake restriction. Is the air intake restriction greater than the specification?
  STEP 5D. Inspect the turbocharger compressor blades for damage. Damage found on turbocharger blades?
  STEP 5E. Determine if the turbocharger is a wastegated turbocharger. Is the turbocharger a wastegated turbocharger?
  STEP 5F. Inspect the wastegate actuator hose. Holes or cracks found in the wastegate actuator hose?
  STEP 5G. Inspect the turbocharger wastegate capsule for air leaks. Did the wastegate actuator capsule leak air?
  STEP 5G-1. Inspect the turbocharger wastegate for proper operation.
  STEP 5G-2. Inspect the turbocharger wastegate for proper operation.
  STEP 5H. Measure turbocharger axial and radial clearance. Are the axial and radial clearances within specification?
  STEP 5I. Inspect the charge-air cooler. Does the charge-air cooler pass the visual inspection as well as the pressure test and temperature differential test?
STEP 6. Verify electronic features are operating correctly.  
  STEP 6A. Verify accelerator (throttle) pedal travel. Does the accelerator (throttle) position read 0 percent when the accelerator
(throttle) is fully released and 100 percent when the accelerator (throttle)
is fully depressed?
  STEP 6B. Monitor the vehicle speed. Does the vehicle speed read zero when the vehicle is not moving?
  STEP 6C. Verify electronic feature settings are correct. Are electronic features set correctly?
  STEP 6D. Check temperature sensor accuracy. Are all temperature readings within 5.6°C or 10°F of each other?
  STEP 6E. Check ambient air pressure sensor accuracy. INSITE™ electronic service tool reading is within 50.8 mm-Hg [2 in-Hg] of local barometric pressure?
STEP 7. Perform base engine mechanical checks.  
  STEP 7A. Verify overhead adjustments are correct. Are the overhead settings within the lash check limits?
  STEP 7B. Check exhaust restriction. Is the exhaust back pressure greater than the specification?
  STEP 7C. Verify engine crankcase pressure (blowby) is within specification. Is the engine crankcase pressure (blowby) less than specification?
  STEP 7D. Check for internal engine damage. Did cutting the oil filter open reveal evidence of internal engine damage?
STEP 8. Excessive vibration checks.  
  STEP 8A. Check engine idle speed. Is the engine idle speed within specification?
  STEP 8B. Check if the feature Fast Idle Warm Up is available and enabled. Is the feature Fast Idle Warm Up available and enabled?
  STEP 8B-1. Monitor if the Fast Idle Warm Up Status.
  STEP 8C. Check front engine driven accessory(s). Did isolating the front engine driven accessory(s) correct the vibration?
  STEP 8D. Check the vibration damper/crankshaft speed indicator ring. Is the vibration damper/crankshaft speed indicator ring damaged?
  STEP 8E. Check the engine support brackets, mounts, and/or isolators. Are the engine support brackets, mounts, and/or isolators or damaged?
  STEP 8F. Check engine gear driven accessory(s). Does the engine have an engine gear driven/air compressor driven hydraulic pump?
  STEP 8F-1. Isolate engine gear driven accessory(s).
  STEP 8F-2. Check if the engine is equipped with an air compressor.
  STEP 8F-3. Unload the air compressor and operate.
  STEP 8F-4. Check air compressor timing.
  STEP 8G. Check/isolate engine driven components. Did isolating/removing any engine driven component correct the vibration?
  STEP 8H. Check the flywheel housing alignment. Is the flywheel housing bore and face runout within specification?
  STEP 8I. Check if engine is equipped with an internal engine balancer. Is the engine equipped with an internal engine balancer?
  STEP 8I-1. Check the internal engine balancer.

Guided Step 1 – Perform basic troubleshooting procedures.

Guided Step 1A – Check for active fault codes or high counts of inactive fault codes.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.

Action

Check for any active fault code.

Active fault codes or high counts of inactive fault codes?
YES NO

Follow the electronic fault code trees for the appropriate troubleshooting procedures.

 No Repair
Repair complete

Guided Step 1B – Perform basic troubleshooting checks.

Action

The following items must be checked or verified before continuing:

  • Verify the fuel level in the tanks.
  • Verify the vehicle is in good working order
  • Check if any recent maintenance or service work has been performed
  • Verify there have
    not been any changes to CPL components on the engine.
  • Verify fuel grade is correct for the application.
  • Verify the engine is operating within the recommended altitude.
  • Verify the engine oil is in good condition and at the correct level.
  • Verify the engine parasitics have
    not changed.
  • Verify the engine duty cycle has
    not changed.
  • Verify the air filter is
    not excessively plugged by checking filter minder.
  • Listen for air and exhaust leaks.
  • Verify there are no visible external fuel leaks.
  • Verify there are no visible coolant leaks.
  • Verify the crankshaft position and the camshaft position sensors are correctly connected to the engine harness.

All steps have been verified to be correct?

YES NO
No Repair

Correct the step and verify complaint is no longer present after repair.

Repair complete

Guided Step 2 – Determination of engine symptom.

Guided Step 2A – Engine Difficult to Start or Will Not Start (With or Without Exhaust Smoke), Engine Shuts Off or Dies Unexpectedly or Dies During Deceleration, or Engine Starts but Will Not Keep Running

Action

Interview the driver and verify the complaint.

Is the engine symptom Engine Difficult to Start or Will
Not
Start (With or Without Exhaust Smoke), Engine Shuts Off or Dies Unexpectedly or Dies During Deceleration, or Engine Starts but Will
Not Keep Running?

YES NO

Perform the troubleshooting steps in the recommended order listed below:

Step 3 – Engine will
Not Start or Stalls Troubleshooting Procedures

Step 4 – Fuel System Checks

Step 5 –
Air Handling Checks

Step 6 – Electronics Checks

 No Repair
Perform the troubleshooting steps suggested in the repair procedure.

Guided Step 2B – Engine Runs Rough at Idle, Engine Runs Rough or Misfires, Engine Speed Surges at Low or High Idle, Engine Speed Surges under Load or in Operating Range.

Action

Interview the driver and verify the complaint.

Is the engine symptom Engine Runs Rough at Idle, Engine Runs Rough or Misfires, Engine Speed Surges at Low or High Idle, Engine Speed Surges under Load or in Operating Range?

YES NO

Perform the troubleshooting steps in the recommended order listed below:

Step 4 – Fuel System Checks

Step 6 – Electronic Checks

Step 5 – Air Handling Checks

Step 7 – Base Engine Checks

No Repair
Perform the troubleshooting steps suggested in the repair procedure.

Guided Step 2C – Smoke, Black – Excessive.

Action

Interview the driver and verify the complaint.

Is the engine symptom Smoke, Black – Excessive?

YES NO

Perform the troubleshooting steps in the recommended order listed below:

Step 5 – Air Handling Checks

Step 4 – Fuel System Checks

Step 6 – Electronics Checks

Step 7 – Base Engine Checks

 No Repair
Perform the troubleshooting steps suggested in the repair procedure.

Guided Step 2D – Smoke, White – Excessive

Action

Interview the driver and verify the complaint.

Is the engine symptom Smoke, White – Excessive?

YES NO
No Repair No Repair

Guided Step 2D-1 – Smoke, White – Excessive

Action

Interview the driver and verify the complaint. Verify if, along with the white smoke complaint, coolant is being used.

Check the coolant level.

Is the engine using coolant?
YES NO
No Repair No Repair
See the Coolant Loss – Internal Troubleshooting Symptom (TS) Tree.

Guided Step 2D-2 – Smoke, White – Excessive

Action

Interview the driver and verify the complaint.

Check if the white smoke excessive complaint is only occurring when the engine is cold and during cold ambient conditions?

Some white smoke after a cold start in cold ambient conditions is
not uncommon. If white smoke persists once the engine has reached the minimum operating coolant temperature, troubleshoot the white smoke complaint.

Minimum Operating Coolant Temperature: 60°C [140°F].

Is the white smoke excessive complaint only occurring when the engine is cold and during cold ambient conditions?
YES NO

Perform the checks in Step 3A only.

Step 4 – Fuel System Checks

Step 6 – Electronics Checks

Perform the troubleshooting steps in the recommended order listed below:

Step 4 – Fuel System Checks

Step 7 – Electronics Checks
Perform the troubleshooting steps suggested in the repair procedure.

Guided Step 2E – Engine Acceleration or Response Poor, Engine Power Output Low, Engine Decelerates Slowly, Intake Manifold Pressure (Boost)
is Below Normal or Engine Will Not Reach Rated Speed (RPM).

Action

Interview the driver and verify the complaint.

Is the engine symptom Engine Acceleration or Response Poor, Engine Power Output Low, Engine Decelerates Slowly, Intake Manifold Pressure (Boost) is Below Normal or Engine Will
Not Reach Rated Speed (RPM)?
YES NO

Perform the troubleshooting steps in the recommended order listed below:

Step 5 – Air Handling Checks

Step 4 – Fuel Systems Checks

Step 6 – Electronic Checks

Step 7 – Base Engine Checks

 No Repair
Perform the troubleshooting steps suggested in the repair procedure.

Guided Step 2F – Engine Vibration – Excessive

Action

Interview the driver and verify the complaint.

Is the engine symptom Engine Vibration Excessive?

YES NO

Perform the troubleshooting steps in the recommended order listed below:

Perform Step 4E of the Fuel System Checks

Step 8
– Excessive Vibration Checks

Step 7 – Base Engine Checks

Is the engine symptom Engine Vibration Excessive?

No Repair
Perform the troubleshooting steps suggested in the repair procedure.

For engine related symptoms, see the correct troubleshooting symptom
(TS) tree.

Guided Step 3 – Engine will Not Start or Stalls Troubleshooting Procedures

Guided Step 3A – Verify the operation of cold weather aids.

Conditions

  • Engine and Ambient Conditions Cold
  • Turn keyswitch ON.

Action

Make sure that necessary cold weather starting aids are operational as required:

Note: Minimum Ambient Air Temperature for Unaided Cold Start is minus 12.2°C [10°F].

Note: The INSITE™ electronic service tool Intake Air Heater Override test can be used to diagnose intake air heater problems. For engines equipped with air intake heaters, the air intake heaters should begin to function at 19°C [66°F].

Are the necessary cold weather starting aids being used and are they operational as required?
YES NO
No Repair

Install or repair cold weather starting aids.

Use the following procedures in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System), Bulletin 4021271.
Refer to Procedure 008-011 in Section 8.
Refer to Procedure 007-001 in Section 7. For any OEM installed cold starting aids (radiator shutters, etc.), refer to the OEM service manual.

Repair complete

Guided Step 3B – Check electronic features and programmable parameters.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.

Action

Check if the electronic features and programmable parameters are the cause for the engine shutting down or the no-start complaint.

The electronic features and programmable parameters include: Idle Shutdown, Engine Protection Shutdown, and Vehicle Anti-theft Protection.

Are electronic features and programmable parameters the cause for the engine shutting down or the no-start complaint?

YES NO

Program the electronic features per the customer or OEM requirements.

No Repair
Repair Complete

Guided Step 3C – Monitor the engine speed during cranking.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.
  • INSITE™ Monitor

Action

Monitor the engine speed during cranking.

Use INSITE™ electronic service tool.

Attempt to start the engine; engage the engine starter for at least 30 continuous seconds.

Note: Do
not overheat the starter.

Note: Attempting to start the engine for 30 continuous seconds also allows the fault code logic time to run. If any fault codes become active, stop using this troubleshooting tree and reference the corresponding fault code troubleshooting tree.

Is the engine speed greater than 150 rpm during cranking?
YES NO

Find and correct the cause for low cranking speed. Consider the batteries, engine starting motor, drive units, and accessory loads.

See the Engine Will
not Crank or Cranks Slowly (Electric or Air Starter) troubleshooting symptom (TS) tree.

Guided Step 3D – Monitor the ECM Keyswitch Input.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.
  • Engine
    not running

Action

Monitor User Fueling State and key switch while cranking the engine.

Use INSITE™ electronic service tool.

Note: If the engine is intermittently shutting down, User Fueling State can also be monitored during engine shut down.

If INSITE™ electronic service tool is
not available:

Disconnect the OEM harness from the ECM.

Turn keyswitch ON.

Measure the signal voltage from the keyswitch input signal wire of the OEM harness to the engine block ground.

Measure the keyswitch voltage with the keyswitch in the ON position and also with the keyswitch in the cranking position.

Consult the corresponding wiring diagram for the engine being serviced for connector pin identification.

Does the User Fueling State indicate cranking or is keyswitch voltage equal to battery voltage?
YES NO
No Repair

Check the keyswitch battery supply circuit. Use the following procedure in the Electronic Control System Troubleshooting and Repair manual.
Refer to Procedure 019-064 in Section 19. Repair or replace the OEM harness or keyswitch, or check the battery connections. Refer to the OEM service manual for the proper procedures.

Repair Complete

Guided Step 3E – Monitor the ECM Battery Supply.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.
  • Engine
    not running

Action

Monitor Battery Voltage while cranking the engine.

Use INSITE™ electronic service tool.

If INSITE™
electronic service tool is
not available:

  • Disconnect the ECM power supply connection.
  • Turn keyswitch ON.

Measure the voltage from the ECM battery SUPPLY (-) pin(s) to the ECM battery SUPPLY (+) pin(s) in the ECM connector.

Measure the ECM voltage with the keyswitch in the ON position and also with the keyswitch in the cranking position.

See to the corresponding wiring diagram for the engine being serviced for connector pin identification.

Is the ECM battery supply voltage greater than +11-VDC for 12 volt systems or +22-VDC for 24 volt systems?
YES NO
No Repair

Repair or replace the ECM power and ground connections. Check the battery connections and fuse terminals.

Repair complete

Guided Step 3F – Check the load carrying capabilities of the ECM power and ground circuits.

Conditions

  • Turn keyswitch OFF.
  • Disconnect the ECM power supply connector from the ECM.

Action

Connect a headlight (12 volt or 24 volt systems).

Note: A headlight
must be used to make sure that the wattage rating will put enough of a load on the circuit.

Use the ECM battery SUPPLY (+) pin in the ECM power supply connection for the battery positive (+) and the ECM battery SUPPLY (-) pin in the ECM power harness connector for the battery negative (-).

Consult the corresponding wiring diagram for the engine being serviced for connector pin identification.

Do the headlights illuminate brightly?
YES NO
No Repair

Repair or replace the ECM power and ground connections. Check the battery connections and fuse terminals.

Repair complete

Guided Step 3G – Check orientation of connector.

Conditions

  • Turn keyswitch OFF.

Action

Check for the appropriate orientation of the rail fuel pressure sensor connector.

NOTE: Connector can be incorrectly installed, rotated 180 degrees.

Is the rail fuel pressure sensor connector installed correctly?
YES NO
No Repair

Reorient connector.

Repair complete

Guided Step 3H – Verify rail fuel pressure sensor accuracy.

Conditions

  • Turn keyswitch ON
  • Connect INSITE™ electronic service tool
  • INSITE™ Monitor
  • Engine
    not running.

Action

Monitor the fuel rail pressure.

Use INSITE™ electronic service tool to measure the fuel rail pressure.

Is the Fuel Rail Pressure (measured) less than 30 bar (435 psi)?
YES NO
No Repair

Replace the rail fuel pressure sensor. Use the following procedure in the ISB (4 cylinder) and ISBe (4 and 6 cylinder) Electronic Control System Troubleshooting and Repair manual, Bulletin 3666477.
Refer to Procedure 019-115 in Section 19.
Use the following procedure in the ISB, ISBe2, ISBe3, ISBe4, QSB4.5, QSB5.9, QSB6.7, ISC, QSC8.3, ISL, ISLe3, ISLe4, and QSL9 CM850 Electronic Control System Troubleshooting and Repair Manual, Bulletin 4021416.
Refer to Procedure 019-115 in Section 19.

Repair Complete

Guided Step 3I – Monitor fuel rail pressure while cranking the engine.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool
  • INSITE™ Monitor.

Action

Monitor Fuel Rail Pressure (measured) and Fuel Rail Pressure (commanded).

Use INSITE™ electronic service tool.

NOTE: Fuel Rail Pressure (commanded) can also be referred to as HPCR fuel setpoint.

Attempt to start the engine, engage the engine starter for at least 30 continuous seconds.

NOTE: Do
not overheat the starter.

NOTE: A minimum of 100 bar [1450 psi] of fuel rail pressure is required before the injectors will open and provide fuel.

NOTE: Attempting to start the engine for 30 continuos seconds allows the fault code logic time to run. If Fault Code 2215 or 559 becomes active, adequate fuel rail pressure is
not being developed. Discontinue using this troubleshooting tree and troubleshoot Fault Code 2215 or 559.

Did the Fuel Rail Pressure (measured) equal the Fuel Rail Pressure (commanded)?
YES NO
No Repair No Repair

Guided Step 4 – Fuel system troubleshooting procedures.

Guided Step 4A – Check for air in the fuel supply line.

Conditions

  • Turn keyswitch OFF.
  • Engine OFF.
  • Connect required service tools at the gear pump inlet.

Action

Check for air in the fuel

Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 006-003 in Section 6. Operate the engine at idle and check for air bubbles. If the engine will
not start, check while cranking the engine.

Note: Do
not overheat the starter.
SMALL | MEDIUM | LARGE

Is air present in the fuel supply?
YES NO

Locate and correct the cause of air ingestion in the fuel supply system. Sources of air ingestion include loose fuel filters, loose fuel line fittings, loose or cracked fuel tank stand-pipes, or severe restrictions in the fuel supply lines and filters that cause cavitation at high fuel flow rates.

 No Repair
Repair complete

Guided Step 4B – Measure fuel pressure at the inlet of the on engine fuel filter.

Conditions

  • Turn keyswitch OFF.
  • Engine OFF.
  • Connect required service tools at the inlet to the fuel filter, or if equipped, the fuel filter head diagnostic port (inlet).

Action

Check for air in the fuel

Use the following procedure in Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin 4021271.
Refer to Procedure 006-015 in Section 6.

Measure the fuel pressure at low idle:

  • Fuel pressure range: 5 to 13 bar [73 to 189 psi].

If the engine will
not start, measure the fuel pressure during engine cranking

  • Fuel pressure range: 3 to 11 bar [44 to 160 psi].

Record the fuel filter inlet pressure measured.
SMALL | MEDIUM | LARGE

Is the pressure measured within specification? Note: Record the measured fuel inlet pressure for use in the next step.
YES NO
No Repair No Repair
4C
4B-1

Guided Step 4B-1 – Measure the fuel inlet restriction.

Conditions

  • Turn keyswitch OFF.
  • Engine OFF.
  • Connect required service tools at the gear pump inlet.

Action

Measure the fuel inlet restriction.

Refer to Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin 4021271. Operate the engine at high idle:

Maximum inlet restriction
– 50.8 kPa [15 in-Hg] (vacuum)

If the engine will
not
start, measure fuel restriction while the engine is cranking.

Note: Do
not overheat the starter.

Note: If the issue is intermittent (no start or engine shuts off unexpectedly)
and no issues can be found while the engine is being serviced, there can be debris in the fuel system causing an intermittent restriction. Install a fuel filter minder, Fleetguard® Part Number 3892576, at the connection between the OEM fuel supply lines and the engine. A fuel filter minder will capture the peak restriction in millimeters and inches of mercury. If the issue occurs again, the fuel filter minder can be checked to see if there is something on the OEM side causing an intermittent high restriction.

SMALL | MEDIUM | LARGE

Is the fuel inlet restriction greater than the specification?
YES NO

Find and correct cause of high inlet restriction. Look for plugged OEM fuel filters or screens, or a restricted ECM cooler, pinched OEM fuel lines, or restricted stand pipe in the OEM fuel tank.

Replace the high pressure fuel pump. Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 005-016 in Section 5.

Repair Complete
Repair Complete

Guided Step 4C – Measure fuel pressure at the outlet of the on engine fuel filter.

Conditions

  • Turn keyswitch OFF.
  • Engine OFF.
  • Connect required service tools at the outlet of the fuel filter, or if equipped, the fuel filter head diagnostic port (outlet).

Action

Measure fuel pressure at the outlet of the fuel filter.

Use the following procedure in Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin 4021271.
Refer to Procedure 006-015 in Section 6.

Calculate the pressure drop across the fuel filter by subtracting the pressure measured here from the pressure from Step 4B.

Measure the fuel pressure at high idle:

  • Maximum pressure drop across the fuel filter – 2 bar [29 psi].

If the engine will
not start, measure the fuel pressure during engine cranking

Is the pressure drop across the filter greater than the specification?
YES NO

Replace the fuel filter. Use the following procedure in Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin 4021271.
Refer to Procedure 006-015 in Section 6.

No Repair
Repair Complete

Guided Step 4D – Perform INSITE™ electronic service tool single cylinder cutout test.

Conditions

  • Turn keyswitch ON.
  • Engine running at low idle.
  • Connect INSITE™ electronic service tool.

Action

If the engine will not start or is difficult to start, move to the next step.

  • In the ECM Diagnostic Tests menu of INSITE™ electronic service tool, click on the Cylinder Cutout Test, and follow the instructions on the screen.
  • Operate the engine under the conditions in which the complaint occurs.
  • Use INSITE™ electronic service tool to perform the Cylinder Cutout Test to disable individual injectors.

Note: If this test is performed and there is
not a significant change while cutting out one injector, there can be a problem with more than one injector. It may be necessary to cut out multiple cylinders at a time.

Can the miss or excessive smoke be attributed to a single cylinder?
YES NO

Look for a cause of the complaint, including valve lash and excessive crankcase pressure that may indicate power cylinder damage or camshaft lobe wear. If no other damage is found, replace the fuel injector in the cylinder that was identified using the single cylinder cutout test. Use the following procedure in Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System)
Series Engines, Bulletin 4021271.
Refer to Procedure 006-026 in Section 6

No Repair
Repair Complete

Guided Step 4E – Perform a manual single cylinder cut-out test.

Conditions

  • Turn keyswitch OFF.
  • Install the injector leakage isolation tool.
  • Turn keyswitch ON.

Action

Perform a manual cut-out test.

  • With the engine
    not running, disconnect the fuel line running from the fuel rail to cylinder number 1. Use the following procedure in Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin 4021271.
    Refer to Procedure 006-051 in Section 6.
  • Install the injector leakage isolation tool

For 3.9L and 5.9L engines, install the injector leakage isolation tool, Part Number 3164325, on the rail where the number 1 cylinder fuel line connects.

Torque Value: 30 N•m [22 ft-lb]

For 4.5L and 6.7L engines, install the leakage isolation tool, Part Number 4918298, on the rail where the number 1 cylinder fuel line connects.

Torque Value: 35 N•m [26 ft-lb]

Attempt to start the engine or operate the engine at idle.

Repeat the above test, as necessary, with each cylinder blocked off.
SMALL | MEDIUM | LARGE

Did the engine start after blocking off a cylinder(s) or can the miss or excessive smoke be attributed to a cylinder(s)?
YES NO

Look for a cause of the complaint, including valve lash and excessive crankcase pressure that can indicate power cylinder damage or camshaft lobe wear. If no other damage is found, replace the fuel injector in the cylinder that was identified using the manual single cylinder cut-out test. Use the following procedure in Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin 4021271.
Refer to Procedure 006-026 in Section 6

No Repair
Repair Complete

Guided Step 4F – Measure the injector return fuel drain flow from the cylinder head.

Conditions

  • Turn keyswitch OFF.
  • Connect appropriate service tools to measure injector fuel drain flow from the cylinder head.

Action

Measure the injector return fuel drain flow from the cylinder head.

Use the following procedure in the ISBe, ISB, and QSB Service Manual, Bulletin 4021271.
Refer to Procedure 006-026 in Section 6.

Flow Specification:

Idle Conditions

4 cylinder engines – 120 ml/minute
[4 fl-oz per minute] maximum

6 cylinder engines – 180 ml/minute
[4 fl-oz per minute] maximum

Cranking Conditions

NOTE: Make sure
not to overheat the starter.

4 and 6 cylinder engines – 90 ml/minute [3 fl-oz per minute] maximum.

Is injector fuel drain flow from the cylinder head greater than specification?
YES NO
No Repair No Repair

Guided Step 4G – Determine which cylinder(s) is causing excessive injector fuel drain flow from the cylinder head.

Conditions

  • Turn keyswitch OFF.
  • Connect appropriate service tools to measure injector fuel drain flow from the cylinder head.
  • Install the injector leakage isolation tool.

Action

Measure the injector return fuel drain flow from the cylinder head and isolate a cylinder one at a time using the injector leakage isolation tool.

Use the following procedure in the ISBe, ISB, and QSB Service Manual, Bulletin 4021271.
Refer to Procedure 006-026 in Section 6.

The flow rate will decrease below the maximum specified flow when the cylinder with the leak is blocked.

Note: If this test is performed and there is
not a significant change in fuel return flow while cutting out one injector, there can be a problem with more than one injector. Compare the fuel flow difference across all injectors. Is there more than one injector that caused a noticeable decrease in fuel flow? If so, these could be the injectors with the problems.

Another cause of this problem could be that the customer is operating on fuels lighter than specified. Fuels with low viscosity will result in higher injector leakage and greater drain flow rates.

Did blocking off a cylinder(s) decrease the flow rate below the maximum specified flow rate?
YES NO

Remove the fuel connector and inspect for damage. Replace if necessary. Remove the injector and inspect the fuel connector contact surface for damage. Replace if necessary. Use the following procedures in the ISBe, ISB, and QSB Service Manual, Bulletin 4021271.
Refer to Procedure 006-052 in Section 6.
Refer to Procedure 006-026 in Section 6.

No Repair
Repair Complete

Guided Step 4H – Monitor Commanded Fuel Rail Pressure and Measured Fuel Rail Pressure.

Conditions

  • Turn keyswitch ON.
  • Electronic service tool connected.
  • Engine idling.

Action

Use an electronic service tool to monitor Commanded Fuel Rail Pressure and Measured Fuel Rail Pressure while the engine is idling.

Note: When monitoring, note whether any engine driven accessory (air conditioning compressor, air compressor, fan clutch, etc.) turns on. Also, note whether any accessories that put demand/load on the alternator (intake air heater, vehicle accessories, etc.). These items can affect the outcome of this check. The load on the engine should be constant.

Does the Measured Fuel Rail Pressure vary more than ± 35 bar
[± 500 psi] from the Commanded Fuel Rail Pressure?
YES NO

Replace the fuel pump actuator. Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 005-007 in Section 5.

No Repair
Repair complete

Guided Step 4I – Check the fuel pressure relief valve for excessive leakage.

Conditions

Action

Measure the fuel pressure relief valve drain flow.

Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 006-061 in Section 6.

Is the fuel pressure relief valve within specification?
YES NO
No Repair

Replace the fuel pressure relief valve. Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 006-061 in Section 6.

Repair complete

Guided Step 4J – Measure the high-pressure fuel supply pump fuel drain flow.

Conditions

Action

Measure the high-pressure fuel supply pump return flow.

Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 005-016 in Section 5.

Is the high-pressure fuel supply pump fuel drain flow greater than specification?
YES NO

Replace the high-pressure fuel supply pump. Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 005-016 in Section 5.

No Repair
Repair complete

Guided Step 4K – Measure fuel drain line restriction.

Conditions

  • Turn keyswitch OFF.
  • Connect appropriate service tools to measure fuel drain line restriction.

Action

Measure the fuel inlet restriction.

Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 006-012 in Section 6.

Operate the engine at high idle:

Maximum fuel drain line restriction: 0.19 bar [2.7 psi].

Is the drain line restriction less than specification?
YES NO
No Repair

Check OEM fuel drain lines to tank for proper size, leaks, bends, clogs and fuel tank vents for plugging.
Perform next troubleshooting procedure as outlined in Step 2.
Repair Complete

Guided Step 5 – Air handling troubleshooting procedures.

Guided Step 5A – Check intake manifold pressure sensor accuracy.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.
  • Engine OFF.

Action

Monitor the reading for intake manifold pressure with the engine OFF.

Start INSITE™ electronic service tool data monitor/logger and monitor the tool reading for intake manifold pressure with the engine OFF.

Intake manifold pressure reading is less than 102 mm-Hg [4 in-Hg]?
YES NO

Replace the intake manifold pressure sensor. If equipped with a combination Intake Manifold Pressure/Temperature Sensor, use the following procedure in the ISB (4 cylinder) and ISBe (4 and 6 cylinder) Electronic Control System Troubleshooting and Repair manual, Bulletin 3666477.
Refer to Procedure 019-159 in Section 19. Use the following procedure in the ISB, ISBe2, ISBe3, ISBe4, QSB4.5, QSB5.9, QSB6.7, ISC, QSC8.3, ISL, ISLe3, ISLe4, and QSL9 CM850 Electronic Control System Troubleshooting and Repair Manual, Bulletin 4021416.
Refer to Procedure 019-159 in Section 19.

Repair complete

Guided Step 5B – Check the Air intake System for Leaks.

Action

Check the air intake system for leaks

Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 010-024 in Section 10. Note: On engines equipped with a turbocharged air compressor, one often overlooked item as a source for air leaks is the air compressor intake line. The intake line supplies intake air from the intake of the engine to the air compressor.

Were any air intake system leaks found?
YES NO

Repair or replace the damaged component.

 No Repair
Repair complete

Guided Step 5C – Check air intake restriction.

Conditions

  • Turn keyswitch ON.
  • Engine running at rated speed and full load.

Action

Check the air intake restriction by installing a vacuum gauge (Cummins® Part Number ST-1111-3) into the air intake system.

Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 010-031 in Section 10.

Maximum Air Intake Restriction:

Dirty Filter

635 mm-H
2O; [25 in-H
2O]

Clean Filter

254 mm-H
2O; [10 in-H
2O]

SMALL | MEDIUM | LARGE

Is the air intake restriction greater than the specification?
YES NO

Correct the cause of high intake air restriction. Check for a plugged air filter or restricted air intake piping.

 No Repair
Repair Complete

Guided Step 5D – Inspect the turbocharger compressor blades for damage.

Conditions

  • Turn engine OFF.
  • Remove the intake piping from the turbocharger.
SMALL | MEDIUM | LARGE

Damage found on turbocharger blades?
YES NO

Replace the turbocharger assembly. Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 010-033 in Section 10.

No Repair
Repair Complete

Guided Step 5E – Determine if the turbocharger is a wastegated turbocharger.

Action

Determine if the turbocharger is a wastegated turbocharger.

Is the turbocharger a wastegated turbocharger?
YES NO
No Repair No Repair

Guided Step 5F – Inspect the wastegate actuator hose.

Conditions

  • Turn keyswitch OFF.
  • Remove the turbocharger if the wastegate actuator is inaccessible.

Action

Inspect the integral wastegate actuator hose for cracks or holes.

Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 010-050 in Section 10.

SMALL | MEDIUM | LARGE

Holes or cracks found in the wastegate actuator hose?

YES NO

Replace the wastegate actuator hose. Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 010-050 in Section 10.

No Repair
Repair complete

Guided Step 5G – Inspect the turbocharger wastegate capsule for air leaks.

Conditions

  • Engine OFF.
  • Remove the wastegate actuator hose from the wastegate actuator.

Action

Perform a leak test on the wastegate actuator capsule.

Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 010-050 in Section 10.

Use Cummins® tool, Part Number 3823799, to apply a regulated air supply of 59 in-Hg (29 psi) to the wastegate actuator capsule. No air should be heard (i.e., leaking noise) through a functional wastegate capsule.
SMALL | MEDIUM | LARGE

Did the wastegate actuator capsule leak air?
YES NO

Replace the wastegate actuator. Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 010-050 in Section 10.

No Repair
Repair complete

Guided Step 5G-1 – Inspect the turbocharger wastegate for proper operation.

Conditions

  • Engine OFF.
  • Remove the wastegate actuator hose from the wastegate actuator.

Action

Check for wastegate actuator rod for movement.

Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 010-050 in Section 10.

Use Cummins® tool, Part Number 382379, to apply a regulated air supply of 59 in-Hg (29 psi) to the wastegate actuator capsule. Check for wastegate actuator rod for movement.
SMALL | MEDIUM | LARGE

Did the wastegate actuator rod move?
YES NO
No Repair No Repair

Guided Step 5G-2 – Inspect the turbocharger wastegate for proper operation.

Conditions

  • Engine OFF.
  • Remove the e-clip from the wastegate pin and disconnect the actuator rod from the wastegate lever.

Action

Check for wastegate actuator rod for movement with it disconnected from the turbocharger wastegate.

Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 010-050 in Section 10.

Use Cummins® Tool, Part Number 3823799, to apply a regulated air supply of 59 in-Hg (29 psi) to the wastegate actuator capsule. Check for wastegate actuator rod for movement.
SMALL | MEDIUM | LARGE

Does the wastegate actuator rod move?
YES NO

Move the wastegate lever back and forth and check for smooth operation. If the wastegate lever does
not move freely or binds, spray a penetrating oil on the wastegate lever joint and try to free the wastegate lever by working the lever back and forth. If the lever does
not
become free, then replace the turbocharger. Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 010-033 in Section 10.

Replace the wastegate actuator. Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 010-050 in Section 10.

Repair Complete
Repair Complete

Guided Step 5H – Measure turbocharger axial and radial clearance.

Conditions

  • Engine OFF.
  • Disconnect the exhaust and intake connections from the turbocharger.

Action

Follow the procedure for measuring the axial and radial clearances of the turbocharger.

Use the following procedure in the Service Manual, ISB, ISBe, and QSB
(Common Rail Fuel System) Series Engines, Bulletin 4021271.
Refer to Procedure 010-033 in Section 10.

See Clearance Specifications:

Are the axial and radial clearances within specification
YES NO
No Repair

Replace the turbocharger assembly. Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 010-033 in Section 10.

Repair complete

Guided Step 5I – Inspect charge-air cooler

Conditions

  • Turn keyswitch OFF.

Action

Inspect the charge air cooler for cleanliness, cracks, holes, or other damage.

Note: The pressure test and the temperature differential test in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin 4021271, can be used to verify charge-air cooler problems.
Procedure 010-027 in Section 10.

SMALL | MEDIUM | LARGE

Does the charge-air cooler pass the visual inspection as well as the pressure test and temperature differential test?
YES NO
No Repair

Repair or replace the charge-air cooler assembly. Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 010-027 in Section 10.

Perform the next troubleshooting procedure as outlined in Step 2.
Repair complete

Guided Step 6 – Verify electronic features are operating correctly

Guided Step 6A – Verify accelerator (throttle) pedal travel.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.

Action

Monitor accelerator (throttle) position while fully depressing and releasing the throttle pedal

Use INSITE™ electronic service tool.

Does the accelerator (throttle) position read 0 percent when the accelerator
(throttle) is fully released and 100 percent when the accelerator (throttle)
is fully depressed?
YES NO
No Repair

Refer to the OEM service manual for accelerator (throttle) pedal troubleshooting.

Repair Complete

Guided Step 6B – Monitor the vehicle speed

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.

Action

Monitor the vehicle speed while the vehicle is not moving

  • Use INSITE™ electronic service tool.

Does the vehicle speed read zero while the vehicle is not moving?
YES NO
No Repair

Verify the VSS parameters are adjusted correctly in the ECM. Check the VSS and OEM harness.

Repair complete

Guided Step 6C – Verify electronic feature settings are correct.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.

Action

Verify the following adjustable parameters are correctly set:

Use INSITE™ electronic service tool to verify:

  • Maximum vehicle speed
  • Powertrain protection
  • Rear axle ratio
  • Transmission tailshaft teeth
  • Tire revolutions per mile
  • Gear-down protection
  • Cruise control droop settings
  • Cruise control maximum vehicle speed
  • Accelerator type
  • Road speed governor
  • Vehicle acceleration management
  • Transmission type.

Are electronic features set correctly?
YES NO
No Repair

Correct programmable features.

Repair Complete

Guided Step 6D – Check temperature sensor accuracy.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.
  • The engine
    must be turned off long enough for engine coolant temperature to be equal to ambient air temperature.

Action

Monitor the following temperatures:

Use INSITE™ electronic service tool to verify:

  • Engine coolant temperature sensor
  • Intake manifold air temperature sensor
  • If equipped, the turbocharger compressor inlet air temperature sensor

Are all temperature readings within 5.6°C or 10°F of each other?
YES NO
No Repair

Check for a short from the signal pin of the temperature sensor in question to all other pins in the harness. Use the following procedure if no short is found, replace the temperature sensor that is reading higher or lower than the other sensors. Use the following procedure in Electronic Control System Troubleshooting and Repair manual.
Refer to Procedure 019-360 in Section 19.
See Section 19 for specifications on each temperature sensor.

Repair Complete

Guided Step 6E – Check ambient air pressure sensor accuracy.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.

Action

Start the INSITE™ electronic service tool data monitor/logger.

Start INSITE™ electronic service tool data monitor/logger and compare INSITE™ electronic service tool reading for barometric air pressure to the local barometric pressure.
Refer to Procedure 018-028 in Section 18.

INSITE™ electronic service tool reading is within 50.8 mm-Hg [2 in-Hg] of local barometric pressure?
YES NO
No Repair

Replace the barometric pressure sensor.
Perform the next troubleshooting procedure as outlined in Step 2.
Repair complete

Guided Step 7 – Perform base engine mechanical checks.

Guided Step 7A – Verify overhead adjustments are correct.

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.

Action

Measure the overhead settings.

Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 003-004 in Section 3.

SMALL | MEDIUM | LARGE

Are the overhead settings within the lash check limits?
YES NO
No Repair

Adjust the overhead settings again. Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 003-004 in Section 3.

Repair complete

Guided Step 7B – Check exhaust restriction.

Conditions

  • Turn keyswitch ON.
  • Engine running at rated speed and full load.

Action

Measure the exhaust system back pressure

Measure the exhaust system back pressure by installing a pressure gauge, Part Number ST-1273, into the exhaust system immediately downstream of the turbocharger exhaust outlet.

Maximum back pressure measured at the turbocharger outlet (exhaust manifold outlet for naturally aspirated engines)
is:

  • 10 kPa (1.5 psi)
  • 15 kPa (2.2 psi).
SMALL | MEDIUM | LARGE

Is the exhaust back pressure greater than the specification?
YES NO

Correct the cause of high back pressure; look for collapsed or plugged exhaust pipes.

 No Repair
Repair Complete

Guided Step 7C – Verify engine crankcase pressure (blowby) is within specification

Conditions

  • Turn keyswitch OFF.
  • Connect appropriate service tools to measure blowby.

Action

Measure engine crankcase pressure (blowby).

Use the following procedure in the Troubleshooting and Repair Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin 4021271.
Refer to Procedure 014-010 in Section 14.

SMALL | MEDIUM | LARGE

Is the engine crankcase pressure (blowby) less than specification?

YES NO
No Repair

See the Crankcase (Blowby) Excessive Troubleshooting Symptom (TS) tree.

See the Crankcase Gases (Blowby) Excessive Troubleshooting Symptom (TS)
tree.

Guided Step 7D – Check for internal engine damage.

Conditions

  • Turn keyswitch OFF.

Action

Remove the oil filter.

Use the following procedures in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 007-013 in Section 7.

Refer to Procedure 007-083 in Section 7.

Cut the oil filter open and inspect for debris and area of probable damage.

Did cutting the oil filter open reveal evidence of internal engine damage?
YES NO

Determine the area of probable damage and repair as necessary. Remove the lubricating oil pan and rocker lever cover, if necessary, to inspect for damage. Use the following procedures in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System), Bulletin 4021271.
Refer to Procedure 007-025 in Section 7.
Refer to Procedure 003-011 in Section 3.

No Repair
Repair Complete
Perform the next troubleshooting procedure as outlined in Step 2.

Guided Step 8 – Excessive vibration checks

Guided Step 8A – Check engine idle speed

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.
  • INSITE™ Monitor.

Action

Monitor the engine speed while the engine is idling.

Use INSITE™ electronic service tool.

See the engine dataplate for idle speed specifications.

Is the engine idle speed within specification?
YES NO
No Repair

Adjust or increase the engine idle speed.

Repair Complete

Guided Step 8B – Check if the feature Fast Idle Warm Up is available and enabled

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.

Action

Check the features and parameters and check if the feature Fast Idle Warm Up is available and enabled.

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.
  • INSITE™ Monitor.

Is the feature Fast Idle Warm Up available and enabled?
YES NO
No Repair No Repair

Guided Step 8B-1 – Monitor the Fast Idle Warm Up Status

Conditions

  • Turn keyswitch ON.
  • Connect INSITE™ electronic service tool.
  • INSITE™ Monitor.

Action

Monitor Fast warm-up status

Connect INSITE™ electronic service tool.

Is the feature Fast Idle Warm Up becoming active?
YES NO

Adjust the fast idle warm up idle speed or check with the customer on disabling the feature.

Note: Disabling the Fast Idle Warm Up feature can affect warranty.

 No Repair
Repair Complete

Guided Step 8C – Check front engine driven accessory(s)

Conditions

  • Turn keyswitch OFF.
  • Isolate front engine driven accessory(s).

Action

Isolate front engine driven accessory(s) one at a time, including:

  • Alternator(s)
  • Refrigerant compressor(s)
  • Fan hub(s)
  • Hydraulic/Power steering pump(s)
  • Water pump
  • Cooling fan
  • Crankshaft driven PTO accessories.

Did isolating the front engine driven accessory(s) correct the vibration?
YES NO

Repair or replace the malfunctioning component.

 No Repair
Repair Complete

Guided Step 8D – Check the Vibration Damper/Crankshaft speed indicator ring.

Conditions

  • Turn keyswitch OFF.

Action

Isolate front engine driven accessory(s) one at a time, including:

Check the vibration damper/crankshaft speed indicator ring for damage.

Use the following procedure for engines equipped with a rubber vibration damper in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin 4021271.
Refer to Procedure 001-051 in Section 1.

Use the following procedure for engines equipped with a viscous damper in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin 4021271.
Refer to Procedure 001-052 in Section 1.

Use the following procedure for engines equipped with a crankshaft speed indicator ring only in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin 4021271.
Refer to Procedure 001-071 in Section 1.

Is the vibration damper/crankshaft speed indicator ring damaged?
YES NO

Replace the damaged vibration damper/crankshaft speed indicator ring.

 No Repair
Repair Complete

Guided Step 8E – Check the engine support brackets, mounts and/or isolators.

Conditions

  • Turn keyswitch OFF.

Action

Check the engine support brackets, mounts and/or isolators for damage

Use the following procedures for front and rear engine supports in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System), Bulletin 4021271.
Refer to Procedure 016-002 in Section 16.

Refer to Procedure 016-003 in Section 16.

Are the engine support brackets, mounts, and/or isolators or damaged?
YES NO

Replace the damaged engine support brackets, mounts and/or isolators.

No Repair
Repair Complete

Guided Step 8F – Check engine gear driven accessory(s).

Conditions

  • Turn keyswitch OFF.

Action

Check if the engine has an engine gear driven / air compressor driven hydraulic pump.

Does the engine have an engine gear driven/air compressor driven hydraulic pump?
YES NO
No Repair No Repair

Guided Step 8F-1 – Isolate engine gear driven accessory(s).

Conditions

  • Turn keyswitch OFF.
  • Isolate/remove the gear/air compressor driven hydraulic pump.

Action

Isolate/remove the gear driven air compressor driven hydraulic pump and operate the engine.

Use the following procedure for general hydraulic pump remove and install instructions in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System)
Series Engines, Bulletin 4021271.
Refer to Procedure 009-016 in Section 9.

Note: Some engines require an accessory drive to drive the hydraulic pump. It could be necessary to isolate this as well. Use the following procedure to isolate the accessory drive in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) in Series Engines, Bulletin 4021271.
Refer to Procedure 009-001 in Section 9

Did isolating/removing engine gear driven/air compressor driven hydraulic pump correct the vibration?
YES NO

Repair or replace the damaged component.

 No Repair
Repair Complete

Guided Step 8F-2 – Check if the engine is equipped with an air compressor.

Conditions

  • Turn keyswitch OFF.

Action

Check if the engine is equipped with an engine gear driven air compressor.

Is the engine equipped with an engine gear driven air compressor?
YES NO
No Repair No Repair

Guided Step 8F-3 – Unload the air compressor and operate.

Conditions

  • Turn keyswitch OFF.
  • Unload the air compressor.

Action

With the air compressor unloaded, operate the engine in the condition in which the vibration complaint occurs.

The air compressor can be unloaded by:

1. Disconnecting the air governor signal line and connecting regulated shop air, with a pressure gauge, to the air compressor governor air signal port.

Note:
Typically 621 kPa (90 psi) of air pressure is the set point for unloading the air compressor. See the OEM service manual.

2. Disconnecting the air compressor discharge line and air intake hose from the air compressor.

Note: On turbocharged air compressors, make sure to plug the air intake hose attached to the intake manifold.

Did unloading the air compressor significantly reduce or eliminate the vibration?
YES NO
No Repair No Repair

Guided Step 8F-4 – Check the air compressor timing.

Conditions

  • Turn keyswitch OFF.
  • Check the timing of the air compressor.

Action

Note: 3.9 L and 5.9 L engines do not require the air compressor to be timed to the engine.

Check that the air compressor is correctly timed to the engine.

Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 012-014 in Section 12.

Note: When troubleshooting a vibration issue in which it is suspected that the air compressor is the cause of the vibration, it may be necessary to isolate the air compressor from the engine.

Was the air compressor correctly timed to the engine?
YES NO

Replace the air compressor. Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 012-014 in Section 12.

Correctly time the air compressor to the engine. Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 012-014 in Section 12.

Repair Complete
Repair Complete

Guided Step 8G – Check/isolate the engine driven components.

Conditions

  • Turn keyswitch OFF.
  • Isolate/remove any engine driven components.

Action

Isolate/remove any engine driven components and operate the engine.

Engine driven components include:

Did isolating/removing any engine driven component correct the vibration?
YES NO

Replace the malfunctioning component. Refer to the OEM service manual.

 No Repair
Repair Complete

Guided Step 8H – Check the flywheel housing alignment.

Conditions

  • Turn keyswitch OFF.
  • Engine driven components removed.

Action

Measure the flywheel housing bore and face runout.

Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedure 016-006 in Section 16.

Is the flywheel housing bore and face runout within specification?
YES NO
No Repair

Use the following procedure for flywheel housing repair options in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin 4021271.
Refer to Procedure 016-006 in Section 16.

Repair Complete

Guided Step 8I – Check if engine is equipped with an internal engine balancer.

Conditions

  • Turn keyswitch OFF.

Action

Check if engine is equipped with an internal engine balancer.

Use the engine serial number to look up the engine build history to see if the engine was built with an internal engine balancer option.

Note:
Only 4 cylinder engines can be equipped with an internal engine balancer.

Is the engine equipped with an internal engine balancer?
YES NO
No Repair No Repair

Guided Step 8l-1 – Check the internal engine balancer.

Conditions

  • Turn keyswitch OFF
  • Lubricating oil pan removed

Action

Remove the lubricating oil pan and inspect the internal engine balancer.

Use the following procedure in the ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual, Bulletin 4021271.
Refer to Procedures 007-025 in Section 7

Check to make sure the internal engine balancer is correctly timed to the engine.

Check for any damage to the internal engine balancer.

Note:
Only 4 cylinder engines can be equipped with an internal engine balancer.

Is the internal engine balancer timing incorrect or is the balancer damaged?
YES NO

Repair or replace the internal engine balancer.

 No Repair
Repair Complete

Last Modified:  17-Aug-2010
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Published by Jack

Hello, I'm Jack, a diesel engine fan and a blogger. I write about how to fix and improve diesel engines, from cars to trucks to generators. I also review the newest models and innovations in the diesel market. If you are interested in learning more about diesel engines, check out my blog and leave your feedback.