Service Manual

ISM, ISMe, and QSM11

Volume 1

00201731

Copyright® 2011 Bulletin 3666322

Cummins Inc. Printed 22-JUNE-2011
Ail rights reserved
 Foreword
This manual contains instructions for troubleshooting and repairing this engine in the chassis, complete rebuild
procedures and specifications. Disassembly, cleaning, inspection, and assembly instructions are included. A listing
of accessory and component suppliers is located in Section M - Component Manufacturers. Suppliers can be
contacted directly for any information not covered in 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.

The repair procedures in this manual are based on the engine or component removed from chassis. Some rebuild
procedures require the use of special service tools. Make sure the correct tools are used as described in the
procedures. ,

When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used
in place of the recommended item.

A series of specific service manuals (for example: Troubleshooting and Repair, 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).

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 is 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 Cumminsi engines. When
replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts.
 Table of Contents
Section

Introduction ■ ■ :• '

Engine and System Identification E

Familiarization F

Troubleshooting Symptoms TS

Troubleshooting Symptoms (New Format) TT

Engine Disassembly Group 00 DS

Engine Assembly - Grpup 00 AS

Complete Engine - Group 00 ■ ■ °

Cylinder Block ■ Group 01 1

Cylinder Head - Group 02 '. 2

Rocker Levers - Group 03 ■ 3

Cam Followers/Tappets - Group 04 • 4

Fuel System - Group 05 5

Back ■ back
ISM, ISMe, and QSM11
Section i - Introduction Pa9e l"a

Section i - Introduction

Section Contents
Page

About the Manual ■ : !'}

General Information • :A'
Acronyms and Abbreviations "^
General Information ■•• !"^
General Cleaning Instructions '. ■ • !"™
Abrasive Pads and Abrasive Paper "™
Definition of Clean..! '. • h™
Fuel System ••■ — •• !"JJ
Gasket Surfaces • [~]\
Plastic Bead Cleaning ••■* !'^
Solvent and Acid Cleaning - Yy
Steam Cleaning .*:
General Repair Instructions !"°
General Information !"°
Welding pn a Vehicle with an Electronic Controlled Fuel System ";»
General Safety Instructions !"°
Important Safety Notice ; !"°
How to Use the Manual ■ |"r
General Information ■ !'^
Illustrations ; ;■•■■ !"°
General Information !""
Symbols • ■■■■• ■
General Information • ■ ''4
_ ISM, ISMe, andQSM11
Hage I"D Section i -1 ntroduction

This Page Left Intentionally Blank

,SM,ISMe,andQSM11
Section i - Introduction

About the Manual

General Information
This Service Manual is intended to aid in determining the cause of engine related problems and to provide
recommended repair procedures. Additionally the manual is intended to aid mechanics in disassembly, inspecting
parts for reuse, rebuilding and assembly of components.
The manual is divided into sections. Each section is equivalent to a group used in Cummins' fiimcard 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 and describe specific rebuild procedures.
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.
 How to Use the Manual ISM, ISMe, and QSM11
Page i-2 Section i - Introduction

How to Use the Manual

General Information

The troubleshooting and repair section of this manual is organized to provide an easy system installation and flow
from problem identification to problem correction.

System Installation

The installation guidelines section has been designed to provide instructions for installing the system. A technician
should read the instruction, learn the intent of the step, and install the component in a fashion that will comply to the
vehicle's configuration. Each deviation from the specific instructions provided in this procedure should be noted.
Refer to the OEM service manual for OEM specifications.
A list of troubleshooting symptoms containing the most common engine 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.

(Step 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
(Step 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.
(Step 3) Locate the probable cause in the left column then turn to
the procedure referenced in the right column
(Step 4) The Troubleshooting Symptom Charts are based on the
following assumptions:
The engine has been installed according to the
manufacturer's specifications.
The easiest repairs are done first.
"Generic" solutions to cover problems with the most
common applications and Original Equipment
Manufacturer (OEM).
The disassemble/assemblesections of this manual is divided into the same group system used for previous manuals
and the Cummins' filmcard, system.

Section 00 is organized into a logical sequence of engine disassemble/assemble, all other sections are in numerical
sequence. Refer to the Table of Contents at the front of the book to determine the section that details the desired
information.

Each section contains the following in sequence:

• Table of Contents

• Required Service Tool Listings

General Information containing the basic service, maintenance, design and revision information necessary to assist
in the rebuild of an engine or a component

Procedure instructions for the disassembly, inspection, maintenance, and assembly that can be required to rebuild
an engine; additional procedures that are not necessary during every rebuild, but can be necessary, are included.
These procedures depend on the length of time an engine has been in service and the conditions of the parts.
All the procedures are identified with a name and a number. Each digit in the procedure number has a specific
meaning.

The first three digits of the number refer to the specific section that the procedure can be found within the manual In
this example, "001" represents Section 01 — Cylinder Block. This number will range from 000 to 022.
»M,lSM..andQ8M11 How to Use the^anua.
Section i - Introduction

The second three digits of the number are unique and refer to a specific subject. In this example, "028" represents
Cylinder Liner. This number will range from 001 to 999.
Refer to Section V for specifications recommended by Cummins Engine Company, Inc. for your engine. Specifications
and torque values for each engine system are given in that section.
NOTE- Discharge of oil or oily water into or upon the water is a direct violation of today's laws. Violators are subject
to a penalty of various monetary charges. Dispose of these substances in accordance with standard set by the trA.
Symbols
ISM, ISMe, and QSM11
Page i-4
Section i - Introduction

Symbols
General Information

The following 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
meaning defined below:

WARNING - Serious personal injury or PERFORM a mechanical or time

extensive property damage can result if MEASUREMENT.
the warning instructions are not
followed.
LUBRICATE the part or assembly.
CAUTION - Minor personal injury can
a.WRENCH or TOOL SIZE
os inc.
structions are not followed.
TIGHTEN to a specific torque.
Indicates a REMOVAL or DISASSEI
step. T55 %,A PERFORM an electrical
MEASUREMENT.
Indicates an INSTALLATION or ASSEM
BLY step. Refer to another location in this manual
© Cummins lt>c, dltfonal
INSPECTION is required.

CLEAN the part or assembly. The component weighs 23 kg [50 Ib] or

more. To avoid personal injury, use a
hoist or get assistance to lift the compo
nent.
1780000S
 Illustrations
ISM, ISMe, and QSM11
Page i-5
Section i - Introduction

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.
 ISM, ISM., and QSM11
Section i - Introduction

General Safety Instructions

Important Safety Notice

AwarningA
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
ras&ssssytrbe f0"0W8d to provlde personal safeiy-specpai a*^-*; «■ b
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.

fSonnf! th6 ba"ff\.(ne9ative H 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. H y

nranShafThP!,p enQine barriu9 !echniques 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.

all0W the en^ine t0 CO0' before ^ '—ing the filler

b6f0re Performi^ -y service work. Do not work on

n "] thJ? air> Oi''Sel> and C00lin9 systems before any lines- fittin9s> or related items are removed
Dn no,IhS f i P°,sslb e Pressu/e 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.
jy
?6 ^fbmy of suffocation and frostbite, wear protective clothing and ONLY disconnect liquid
nrnS v Pi !?? "I??.,"1,,* "?" Vent"ated area" T° prOtect tne e™r°nment, liquid refrigerant systems murt be
Stmn/nh Pp 2 andfllled usm9 ^'P^ent that prevents the release of refrigerant gas (fluorocarbons) into the
atmosphere. Federal law requires capturing and recycling refrigerant.
g '
In S?S5enrhm P0SS^y oi ^T,^' ^H^] use a hois* ™ 9* assistance when lifting components that weigh 23
9[ i?r i ^V"™ ^ deViCeS SUCh aS °hainS| hooks' or slin9s are 'n 9ood condition and L of
tiOned COrreCtly A' d b

sa.s^nLY°s,3: xizz*^^t^^x^ forfor a miLum

nt Etthy' Kf°ne (-^EK) ar^ flammable material« ^d must be used with caution. Follow the
CHILDREN instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF

S^^hSfluSSSEL? tT8' b6walert f°r hOt partS °n pr0dUCtS that nave Just be^n turned off. exhaust gas
now, 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 oerformina
any service work. Use ONLY genuine Cummins® or Cummins ReCon® replacement parts Performin9
iWft (or equivalent) when replacing fasteners-Do
Souldo^p7aMpeH
should only be carried n"!
out hVal
be a fd re5'fCtment
trained technician.°f Before
any 9Uards COVerit19
removing rotatin9thecomponents,
any guards drives,
engine must and/oroffbelts
be turned 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.
 General Safety Instructions
ISM, ISMe,andQSM11 uenera. aa y _ (_?
Section i - Introduction

. 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 ~^-'^J?^
eves with larae amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin In case
contact' lm3S5 wSh 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 bjrt^ 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 fVes with large amounts of
water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of contact, immediately wash skin
and water.
with soap a
The Catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been^errtin^ih® ^ °!
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.
 General Repair Instructions |SM |SMe and m

Section i ■ Introduction

General Repair Instructions

General Information

This engine incorporates the latest technology at the time it was manufactured; yet, it is desiqned to be repaired usina
normal repair practices performed to quality standards. uwHBneu 10 De repaired using

AcautionA*
Cummins Inc. does not recommend or authorize any modifications or repairs to enqines or comDonents
comoPon«nt,hcf ^^ '" ^T™5 Service lnfo'mation- '" P^cilar, unauthorized "epatrtrsafeTy^ated
rotated? 6 PerS°n mJUry °r Be'OW iS 3 Partial liSting Of comPonents classified as safety
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

• Follow all safety instructions noted in the procedures

" Th?0^6 m*nufacturf r's recommendations for cleaning solvents and other substances used during the repair of
the engine Some solvents and used engine oil have been identified by government agencies as toxfc o
pScricn 23? ZZ^Tmg'in9estion and contact with such substanc-Al^• - ga0sod°sLUr
• Provide a clean environment and follow the cleaning instructions specified in the procedures
" wNrcTutnep?em^ure0we'ar"^ "^ * ^ *"" ^ ^ "^ Contami-tion of the engine or components
• Perform the inspections specified in the procedures
Replace all components or assemblies which are damaged or worn beyond the specifications
• Use genuine Cummins new or ReCon® service parts and assemblies

X ^SSSJTrSteS hrnnmnen W?en *° "" ^V* ^ comP°™^ and assemblies as possible. When
Cummins ReCon® rnmnnnl? X?th °r assemb|y> the Procedure is based on the use of new Cummins or
BS^?!S SmXn^i *6 rePa'r SemC6S d6SCribed " tWS manUal ^ aVailable fWm N Cummins
Follow the specified disassembly and assembly procedures to reduce the possibility of damage to the components
 . _„. • General Repair Instructions
ISM, ISMe, andQSMH uems K Page i-9
Section i - Introduction

Welding on a Vehicle with an Electronic Controlled Fuel System

AcautionA
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 no
connect the ground clampof the welder to any of the sensors, wiring harness, the ECM ^ZTt^sors
welding of any electronic engine component or engine mounted component must not be ^«^ *e"?"J
wiring harness, and ECM should be removed if nearby welding will expose these components to temperatures
beyond normal operation. Additionally, all ECM connectors must be disconnected..
 General Cleaning Instructions ISM> ISMe; and QSM11
Pagei"10 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 thev have to
appear as new.

Sanding gasket surfaces until the factory machining marks are disturbed adds no value and is often harmful to forminq
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 matinq Darts
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 cleaninq
later in this document. a

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 pbwer 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.

AwarningA
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.

?™ I™' ?°,?S "?[ecoTend the use of emery cloth or sand PaPer on anV Part of a" assembled engine or
component including but not limited to removing the carbon ridge from cylinder liners or to clean block decks or
couniGrDorss.

Great care must be taken when using abrasive products to clean'engine parts, particularly on partially assembled
SBn " hH3SIVe d6Tn9 Pr°dUCtS C°me in many fOrms and sizes" AN of them contain aluminum oxide particles
oSl q \? ur s°me °tner similar hard material. These particles are harder than most of the parts in the
hp?nmo!mheH^ ^tL^' 'f they are P,reSSed against softer material theV wi" either dam^ the material or
become embedded in It. These materials fall off the holding media as the product is used. If the products are used
rrTeqU'e P8 * ^ thr°Wn ab°Ut ^ en9in6" 'f ^ particles fa" between tw° moving parts, damage
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 eaoh 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
£Kfmn thepfsw'
epfsw' ?out dama9e 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.
parts Once embedded in one part it will
 General Cleaning Instructions
ISM, ISMe, and QSM11 Page i-11
Section i - Introduction

downSrea^. She lubricating oil filters. Plug the holes instead of trying to blow the abrasive-particles and debns 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 "^"f^WjjS^astel

AwarningA

can cause early cylinder wear-out or piston ring failures.

q all openings to any component interior before using abrasive pads or wire brushes. If really necessary

5SS^SaS25SSSS
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 nnwprPri nasket scraDers can save time but care must be taken to not damage the surface. The angled part of
fhe s^1?mu^SWn?fla3S 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

parts before putting them in the cleaning tank.

AwarningA'
When using solvents, acids, or alkaline materials for cleaning, follow the manufacturers recommendat.ons
tor use"wear goggles and protective clothing to reduce the possibility of personal Injury.
Exoerience 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 begma 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.
?heyoftln do not doa gSdjob 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.
General Cleaning Instructions
Pagei-12 ISM, ISMe, and QSM11
Section i - Introduction

Scleanin9'Dry completelv with compressed air-Blow th

^^^
Steam Cleaning

235 ■* it is a me.hod

AwarningA

Do not steam clean the following components:

• Electrical Components
• Wiring Harnesses
• Injectors
• Fuel Pump
• Belts and Hoses
• Bearings (ball or taper roller)
• Electronic Control Module (ECM)
• ECM Connectors
• Dosing Control Unit
• NOx Sensor.
Plastic Bead Cleaning

The praCesS ,s

AcautionA

AcautionA

used to
 General Cleaning Instructions
ISM, ISMe, and QSM11 , Page i-13
Section i - Introduction

AcautionA

other parts.

shell bead blast material is sometimes used to clean ferrous metals (iron and steel). Walnut shell blasting
SS^3SSSS^S?s»=Rasss
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 mediaals go

fs 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).

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.beadI to get under the

c°arbon9«Hhe mlchiNn^*m*rK' onThe 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.
M6UPP hpari h,ast valve stems Tape or use a sleeve to protect the stems during bead blasting. Direct the nozzle across
thesea"^r^a^ ^mthStrSn 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 contamin'^ts- Pjior to dis .assembly
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 Section systems can operate at very high pressures. High pressure fuel can convert simple partces ofhrt 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 cleanerrather
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.

ran and olua fuel lines fittinqs and ports whenever the fuel system is opened. Rust, dirt, and paint can enter the
Ssvstm whenever a fuellPne or other component is loosened or removed from the engine. In many instances, a
goodSce is ?o 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/
chhDs thaTcan be created when a wrench contacts painted line nuts or fittings, or when quick disconnect fittings are
removed.
filters are rated in microns The word micron is the abbreviation for a micrometer, or one millionth of a meter.

fibred out are Smaller than can be seen with the human eye, a magnifying glass, or a low powered m.croscope.
The tools used for fuel system troubleshooting and repair are to be cleaned regularly to a^hc°^"^-"k« ^
system parts, tools that are coated with oil or fuel attract airborne contaminants. Remember the following points
regarding your fuel system tools:
 ISM, ISMe, and QSM1 1
Section i-Introduction
• 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.
 Acronyms and Abbreviations
ISM, ISMe, andQSM11 Page i-15
Section i - Introduction

Acronyms and Abbreviations

General Information
Acronyms and Abbreviations
ISM, ISMe, andQSM11
Page i-16
Section i - Introduction

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 Addith ie
SCR
Selective Catalytic Reduction
STC
Step Timing Control
SID
Subsystem Identification Descriptic
VDC
Volts of Direct Current
VS
Variable Speed
VSS
Vehicle Speed Sensor
ISM, ISMe, and QSM11 p E
Section E - Engine and System Identification M

* Section E - Engine and System identification

Section Contents

Page
E-6
Engine Diagrams ■ E6
Engine Views E1
Engine Identification • • " EA
Cummins® Engine Nomenclature ■ ■ "
ECM Dataplate jjp
Engine Dataplate E5
Fuel Injection Pump Dataplate
_ _. ISM.ISMe, andQSM11
Page E-b Section E - Engine and System Identification

This Page Left Intentionally Blank

 Engine Identification
ISM, ISMe, and QSM11 Page E-1
Section E - Engine and System Identification

Engine Identification
Engine Dataplate
Automotive Applications
The engine dataplate shows important facts about your
engine. The engine serial number and CPL provide data
for ordering parts and service. The engine dataplate must
not be changed unless approved by Cummins Inc.
The dataplate is located on the fuel pump side of the
engine, on the rocker housing. Have the following engine
data available when communicating with a Cummins®
Authorized Repair Location. The following information on
the dataplate is mandatory when sourcing service parts:
Engine Identification
ISM, IS Me, and QSM11
Page E-2
Section E - Engine and System Identification

00200104

1 Engine serial number

2 Model

3 Horsepower and rpm rating

4 CPL

5 Emission statement (if applicable).

Marine and Industrial Applications

The engine dataplate shows important facts about your
engine. The engine serial number and CPL provide data
for ordering parts and service. The engine dataplate must
not be changed unless approved by Cummins Inc.
The dataplate is located on the fuel pump side of the
engine, on the rocker housing. Have the following engine
data available when communicating with a Cummins
Authorized Repair Location. The following information on
the dataplate is mandatory when sourcing service parts:
 Engine Identification
ISM, ISMe, andQSM11
Page E-3
Section E - Engine and System Identification

00200104

1 Engine serial number

2 Model
3 Horsepower and rpm rating

4 CPL

5 Emission statement (if applicable).

ECM Dataplate
With CM870 and CM570
The CM870 is the primary electronic control module
(ECM) for the engine.
The ECM dataplate is located on the front of the ECM.
The abbreviations on the dataplate are explained as
follows:
© C? - . ■.-:;.

• P/N = part number

• S/N = serial number

19cO1295
• D/C = date code.

The CM570 is the fuel control module for the engine.

The fuel control module dataplate is located on the front
of the fuel control module.
The abbreviations on the dataplate are explained as
follows:

• P/N = part number

• S/N - serial number

• D/C = date code.

Automotive with CM876

The ECM dataplate is located on the front of the ECM.
The abbreviations on the dataplate are explained as
follows:

• P/N = part number

• S/N = serial number

• D/C = date code.

Engine Identification
ISM, ISMe, and'QSMH
Page E-4
Section E - Engine and System Identification

Automotive with CM570

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

The abbreviations on the datapiate are explained as
follows:

• P/N = part number

• S/N = serial number

• D/C = date code.

Marine and Industrial Applications

There are two dataplates on top of the ECM.
Electronic
Control
ESN-XXXXXXXX The datapiate on the left contains the part number (P/N)
Module ECM CODE ' "
serial number (S/N), and date code (D/C) of the ECM.
P/NXXXXXXXX xxxxxx.xx
S/N X X X X X X
D/C X X X X ■■■ , ;
DATE-XX/XX/XX The datapiate on the right contains the engine serial
number (ESN), ECM code, and date.

19200096

Cummins® Engine Nomenclature

Automotive Applications
IS M 400
The Cummins® engine nomenclature provides the data as
illustrated in the graphic.

Advertised
Brake Horsepower

-rtr- = Engine Model Designation

= Interact System

Industrial and Power Generation

QSM 11 - C 335
The Cummins® engine nomenclature provides the data as
illustrated in the graphic.

I
= Brake Horsepower
L=,Market Application (See Note)
- = Displacement (Liters)
■—•=Engine Model Designation
NOTE: The following letters, designate some of the
different market applications for a Cummins® engine.
• A = agriculture
• C = construction
• M = marine

• G = generator drive.
00200103
 Engine Identification
ISM, ISWIe, andQSWI11 Page E-5
Section E - Engine and System Identification

Marine Applications
The Cummins® engine nomenclature provides the data as
QSM 11 - C 335
illustrated in the graphic.
h tc. © Cummins Inc.
NOTE: The following letters designate some of the
different market applications for a Cummins® engine.
• A = agriculture -= Market Application (See Note)
• C = construction — = Displacement (Liters)

• M = marine

• G = generator drive.
00200103

Fuel Injection Pump Dataplate FUEL PUMP DATAPLATE

The fuel pump dataplate is located on'top of the fuel pump. Fuel Revision ,
It provides the data needed to calibrate the fuel pump. © Ci&Ptiinscgsie \ ' SMriiWoF"3 lm-

Vi
Part No. Part No.
fpsplga
Engine Diagrams ISM, ISMe, and QSM11
Page E-6 Section E - Engine and System Identification

Engine Diagrams
Engine Views

The following illustrations contain information about engine components, filter locations, drain points, and access
locations for instrumentation and engine controls. The information and configuration of components shown in these
illustrations are of a general nature. Some component locations will vary, depending on applications and installations
 Engine Diagrams
ISM, ISMe, andQSMH
Page E-7
Section E - Engine and System Identification

Automotive with CM570

2 3 4 5 6

19

1615 14 13 12 11 01200110

Left View - CM570

1 ECM cooling plate

2 ECM
3 Compressor air inlet

4 Blowby measurement

5 Ambient air pressure sensor

6 Fuel return to tank

7 Engine dataplate

8 Engine serial number

9 Starter

10. Flywheel ring gear sensor

11 Side oil drain

12 Centinel™ (optional)
13 Fuel inlet to pump

14 Fuel filter

15 Rail pressure

16 Power steering pump mounting location

17 Oil pressure and temperature sensor

18 Engine position sensor

19 Refrigerant compressor mounting location.

 Engine Diagrams
ISM, ISMe, andQSMH
Page E-8 Section E - Engine and System Identification

Automotive with CM570

25 4

15

18 17 01200109

Right View - CM570

1 Ether hookup

2 Before charge air cooler

3 Boost temperature sensor
4 Intake manifold pressure sensor
5 After charge air cooler (intake manifold)
6 Shutter stat

7 Engine coolant vent

8 Shutter stat port

9 Fan sensor

10 Coolant temperature sensor

11 Heater return
12 Coolant inlet pressure
13 Makeup line from radiator
14 Water pump pressure
15 Coolant inlet

16 Oil drain

17 Oil pan sump heater

18 Filter outlet pressure
19 Engine brake-oil supply
20 Filter inlet pressure port
21 Block coolant pressure port
22 Coolant heater port
23 Heater supply port

24 Coolant temperature pickup port

25 Wastegate controller.
ISM, ISMe, and QSM11 Engine Diagrams
Section E - Engine and System Identification Page E-9

With CM870

8
00200113

Front View - CM870

1 Engine coolant outlet

2 Refrigerant compressor or alternator mounting location

3 Accessory drive belt

4 Accessory drive belt tensioner

5 Accessory drive pulley

6 Alternator drive belt

7 Fan hub

8 Vibration damper

9 Fan belt tensioner

10 Alternator.
Engine Diagrams ISM, ISMe, andQSM11
PageE-10 Section E - Engine and System Identification

With CM870

00200114

Left View - CM870

1 ECM dataplate
2 ECM

3 Blowby tube

4 Engine dataplate
5 Fuel control module dataplate
6 Engine serial number
7 Fuel control module cooling plate

8 Engine oil temperature sensor (behind fuel control module cooling plate)
9 Starter

10 Fuel control module

11 Centinel™ valve (optional)

12 Fuel filter

13 Fuel shutoff valve

14 Fuel pump

15 Air compressor

16 Air supply to air compressor

17 Engine oil pressure sensor

18 Air compressor coolant supply

19 Engine position sensor (not visible)
20 Air compressor coolant return.
 Engine Diagrams
ISM, ISWIe, andQSMH
Section E - Engine and System Identification PageE-11

With CM870

00200115

Rear View - CM870

1 Flywheel housing 3 Lubricating oil pan.

2 Lubricating oil drain

Engine Diagrams ISM, ISMe, and QSM11
Page E-12 Section E - Engine and System Identification

With GM870

3 4

21
11

20 19 18 1716 15 14 13 12 00200116

Right - ISM CM870 Automotive

1 Variable geometry turbocharger coolant return line 16 Turbocharger oil supply line
2 Water manifold 17 Lubricating oil filter out pressure
3 Cylinder head vent line (not visible) 18 Lubricating oil filter
4 Water manifold return tube 19 Lubricating oil fill/dipstick
5 Thermostat housing 20 Engine brake oil supply line
6 Coolant temperature sensor (not visible) 21 Coolant filter
7 Water pump 22 Block coolant pressure
8 Water pump pressure 23 Coolant heater
9 Coolant inlet pressure 24 Lubricating oil filter in pressure (lubricating pump out
10 Makeup line from radiator pressure)

11 Coolant inlet 25 Heater supply

12 Lubricating oil pump (not visible) 26 Coolant temperature pick-up

13 Heater return 27 Lubricating oil cooler

14 Variable geometry turbocharger coolant supply line 28 Exhaust manifold

15 Turbocharger oil drain tube 29 Air compressor air inlet tube.

 Engine Diagrams
ISM, ISMe,andQSM11
Section E - Engine and System Identification Page E-13

With CM870

2 3 4 5

rip

00200117

Top - ISM CM870 Automotive

1 Intake manifold pressure sensor 4 Intake manifold air temperature sensor

2 EGR differential pressure sensor 5 EGR temperature sensor. ,

3 Exhaust gas pressure sensor

Engine Diagrams ISM, ISMe, andQSMH
Page E-14 Section E - Engine and System Identification

With CM870

11200034

ISM CM870 Automotive - EGR System

1 Air intake connection
2 EGR differential pressure sensor tubes
3 EGR mixer
4 Exhaust gas pressure sensor tube
5 EGR valve coolant return tube
6 EGR valve
7 EGR valve coolant supply tube
8 EGR cooler coolant supply tube
9 EGR cooler coolant vent tubes
10 EGR cooler coolant return tube
11 EGR cooler
12 EGR cooler connection tube.
 Engine Diagrams
ISM, ISMe, andQSM11
Page E-15
Section E - Engine and System Identification

With CM870

. '..* L--"U_ S>~.-C1- lX* ■>

I Cummins trie*

10
10200086

ISM CM870 Automotive - Variable Geometry Turbocharger Control System

1 Compressed air from OEM air tank 6 Compressed air from turbocharger control valve
2 Turbocharger control shutoff valve filter head 7 Turbocharger compressor inlet air temperature sensor
3 Turbocharger control shutoff valve . 8 Turbocharger actuator
4 Compressed air from turbocharger control shutoff 9 Turbocharger speed sensor
valve filter head 10 Turbocharger control shutoff valve air filter.
5 Turbocharger control valve
Engine Diagrams
Page E-16
Automotive with CM876
10
1 Refrigerant compressor
2 Accessory drive belt tensioner
3 Accessory drive pulley
4 Alternator / fan drive belt
5 Fan hub
ISM, ISMe, and QSM11
Section E - Engine and System Identification
00201727
Front - ISM CM876 Automotive
6 Vibration damper
7 Fan belt tensioner
, 8 Alternator
9 Variable geometry turbocharger actuator
10 Engine coolant outlet.
 Engine Diagrams
ISM, ISMe, and QSM11 Page E-17
Section E - Engine and System Identification

Automotive with CM876

8 0O201729

Left - ISM CM876 Automotive

1 Open crankcase ventilation filter 6 Fuel shutoff valve

2 Blowby tube 7 Fuel pump •

8 Air compressor
3 ECM
4 Flywheel housing 9 Oil pressure sensor

5 Fuel filter 10 Engine position sensors.

Engine Diagrams ISM, ISMe, andQSMH
Page E-18 Section E - Engine and System Identification

Automotive with CM876

00201730

Rear - ISM CM876

1 EGR valve 5 Aftertreatment injector manifold
Variable geometry turbocharger electronic actuator 6 Aftertreatment fuel pressure sensor
3 Variable geometry turbocharger 7 Aftertreatment fuel shutoff valve
4 Aftertreatment injector assembly 8 Open crankcase ventilation filter.
 Engine Diagrams
ISM, ISMe, and QSM11 Page E-19
Section E - Engine and System Identification

Automotive with CM876

4 5

15

00201 728

Right - ISM CM876

9 EGR cooler coolant supply tube
1 EGR valve
2 Aftertreatment fuel injector adapter 10 Lubricating oil filter

11 Lubricating oil cooler

3 Differential pressure sensor tube
12 Lubricating oil dipstick
4 EGR cooler
13 Coolant filter
5 Air intake / EGR mixer
14 Variable geometry turbocharger
6 Turbocharger coolant return tube
7 Water manifold coolant return tube 15 Exhaust manifold.

8 Water pump
 Engine Diagrams
ISW, ISNIe, andQSMH
Page E-20
Section E - Engine and System Identification

Industrial and Generator Drive

20

19

":,.(■' ..

01200141

QSM11 Industrial and Generator Drive

1 ECM cooling plate 11 Side oil drain
2 ECM
12 Centinel™ (optional)
3 Compressor air inlet 13 Fuel inlet to pump
4 Blowby measurement 14 Fuel filter
5 Ambient air pressure sensor 15 Rail pressure
6 Fuel return to tank
16 Power steering pump mounting location
7 Engine dataplate
17 Oil pressure and temperature sensor
8 Engine serial number 18 Engine position sensor
9 Starter
19 Freon compressor mounting location.
10 Flywheel ring gear speed sensor
20 Compressor air discharge (not visible).
 Engine Diagrams
ISM, ISMe, and QSM11 Page E-21
Section E - Engine and System Identification

Industrial and Generator Drive

25

■■■■■■ ■■■■■:>■■" ■■■■■

15

01200109
19 18
Right-QSM11 Industrial and Generator Drive
14 Water pump pressure
1 Ether hookup

2 Before charge air cooler 15 Coolant inlet

3 Boost temperature sensor 16 Oil drain

4 Intake manifold pressure sensor 17 Oil pan pump heater

5 After charge air cooler (intake manifold) 1 8 Filter outlet pressure

6 Shutter stat 19 Engine brake oil supply

7 Engine vent coolant 20 Filter inlet pressure

21 Block coolant pressure

8 Shutter stat

9 Fan sensor 22 Coolant heater

10 Coolant temperature sensor 23 Heater supply

11 Heater return
24 Coolant temperature pickup

12 Coolant inlet pressure 25 Wastegate controller.

13 Makeup line from radiator

Engine Diagrams ISM, ISMe, and QSM11
Page E-22
Section E - Engine and System Identification

Marine Applications

17200015

Front -QSM11 Marine

1 Zinc plugs 6 Alternator
2 Air crossover 7 Vibration damper
3 Coolant filter 8 Front engine mounts
4 Fuel Filter
9 Aftercooler-to-heat-exhanger pipe
5 Crankcase breather 10 Heat exchanger.
 Engine Diagrams
ISM, ISMe, andQSMH Page E-23
Section E - Engine and System Identification

Marine Applications

11
17200013

Left (Port) - QSM11 Marine - Components

1 Crankcase breather 8 Zinc anode (fuel cooler)

9 Fuel cooler drain plug
2 ECM
10 Fuel cooler
3 Exhaust elbow
11 Sea water pump
4 Zinc anode
12 Fuel pump
5 Gear cooler drain plug
13 Sea-water-pump-to-aftercooler pipe
6 Starter

7 Oil pan
14 Oil fill.
 Engine Diagrams
ISM, ISMe, and QSM11
Page E-24
Section E - Engine and System Identification
Marine Applications

15600831

Left (Port) - QSM 11 Marine - Sensors

1 Ambient air pressure sensor 3 Engine position sensor (behind fuel pump).
2 Oil pressure/temperature sensor (behind fuel pump)
 Engine Diagrams
ISM, ISMe, andQSM11 Page E-25
Section E - Engine and System Identification

Marine Applications

17200017

Back-QSM11 Marine
4 Flywheel housing
1 Turbocharger
5 Alternator.
2 Air cleaner

3 Flywheel
 Engine Diagrams
Page E-26 ISM, ISMe, and QSM11
Section E - Engine and System Identification
Marine Applications

17
16 15 14 13 12 11
17200014

Right (Starboard) - QSM11 Marine - Components

1 Gear oil cooler
10 Vibration damper
2 Zinc anode (gear cooler) 11 Oil pan drain plug
3 Heat exchanger 12 Coolant drain
4 Expansion tank 13 Water pump
5 Aftercooler 14 Oil dipstick .
6 Thermostat housing 15 Oil fill
7 Zinc anode
16 Engine oil cooler
8 Engine lifting bracket 17 Zinc a!node
9 Zinc anode
18 Gear oil cooler drain plug.
 Engine Diagrams
ISM, ISMe, and QSM11
Page E-27
Section E - Engine and System Identification

Marine Applications

fii t; ,

15d00841

Right (Starboard) - QSM11 Marine - Sensors

1 Intake manifold temperature sensor

2 Intake manifold pressure sensor

3 Coolant temperature sensor

4 Coolant level sensor.

 Engine Diagrams
ISM, ISMe, andQSMH
Page E-28
Section E - Engine and System Identification
Marine Applications

08200244

Right (Starboard) - QSM11 Marine - Heat Exchanger

1 Turbocharger with water cooled turbine housing
'2 Coolant flow from heat exchanger
3 Aftercooler sea water outlet
4 Heat exchanger

5 Coolant flow to heat exchanger

6 Expansion tank
7 Water pump

8 Aftercooler
9 Aftercooler sea water inlet
10 Water cooled exhaust manifold.
 Engine Diagrams
ISM, ISMe, and QSM11 Page E-29
Section E - Engine and System Identification

Marine Applications

08200245

Right (Starboard) - QSM11 Marine - Keel Cooled

1 Turbocharger with water cooled turbine housing

2 Coolant inlet (aftercooler)

3 Coolant in from Keel Cooler

4 LTA thermostat housing

5 Coolant out to Keel Cooler

6 Water pump

7 Coolant to water pump

8 Aftercooler

9 Coolant outlet (aftercooler) to water pump

10 Gear oil cooler (optional)

11 Water cooled exhaust manifold
12 Coolant out from turbocharger.
 Engine Diagrams
ISM, ISWIe, andQSMH
Page E-30
Section E - Engine and System Identification
Marine Applications

y -""'I *rf \y ^*-j

17200016

Top-QSM11 Marine
1 Alternator 5 Coolant fill
2 Oil fill (alternate) 6 Air cleaner
3 Intake manifold temperature sensor 7 Turbocharger
4 Intake manifold pressure sensor 8 Exhaust elbow.
ISM, ISMe, and QSM11 Page F-a
Section F - Familiarization

Section F - Familiarization

Section Contents
Page
F-40
Air Intake System - Overview F 40
General Information • " F1
Complete Engine - Overview ""^
General Information : F_60
Compressed Air System - Overview F-60
General Information ,., ; p_25
Cooling System - Overview F 25
General Information -. ' F-1
Cylinder Block - Overview 'F ^
Theory of Operation "F 65
Electrical Equipment - Overview ■ F|65
General Information '. F_gg
Engine Testing - Overview • " g
Fuel Flow Measurement on Engine or Chassis Dynamometer j.^
General Information ■ : "F47
Exhaust System - Overview ■ F 47
General Information "F43
Flow Diagram, Air Intake System ; F43
Flow Diagram F_g3
Flow Diagram, Compressed Air System •- ■ F'63
Compressed Air System F 26
Flow Diagram, Cooling System ■ f;26
Flow Diagrams v
Flow Diagram, Exhaust System F"52
Flow Diagram....,' "F11
Flow Diagram, Fuel System • "F ^
Fuel System • ' F 2n
Flow Diagram, Lubricating Oil System F 20
Engine Views F2
Fuel System - Overview ■ -"-
Installation Recommendations ■
Injectors and Fuel Lines - Overview •■•• ; ■ F'g
Theory of Operation , F 15
Lubricating Oil System - Overview F]15
General Information F"71
Vehicle Braking - Overview ; F]71
General Information..., ■ F"_71
Engine Brake Solenoid
 ISM, ISMe, andQSM11
Pa9e F"b Section F - Familiarization

This Page Left Intentionally Blank

 Cylinder Block - Overview
ISM, ISMe, and QSM11
Page F-1
Section F - Familiarization

Complete Engine - Overview (000-^999)

General Information
The procedures required to replace an engine will vary bmins inc.
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
Inc.
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. ew200hd

Cylinder Block - Overview (001-999)

Theory of Operation

AcautionA
Do not replace main bearing shells without performing this inspection. Engine damage is possible if the main
bearing shells are replaced without performing this inspection.
Fretting is micro-motion between the main bearing cap and block that results in material loss at the joint. This motion
causes a loss of crankshaft to main bearing running clearance that can lead to a spun main bearing, aspun connecting
rod bearing, and/or a broken crankshaft.
There is risk when overhauling or replacing the main bearings in a block that has incurred main cap fretting. Inserting
new standard main bearing shells into a joint that has sustained sufficient loss of material can lead to zero crankshaft/
bearing clearance. This can cause the crankshaft to lock in place.
Recent long-hour engineering tests have shown the addition of Loctite® 518, a block stiffener plate, and increased
main bearing clamp loads reduces torsional motions in the main cap/block joint. Loctite® 518 adds an additional shear
strength and seals the main bearing cap/block joint from oil and debris. The stiffener plate increases block stiffness
by 15 percent and the new torque-plus-angle method increases main bearing clamp load by 1588 kg [3500 Ib].
NOTE: The inspection must be performed with the original main cap and bearing shells. During the reduction of
bearing running clearance, the original main bearing develops a wear pattern, which is an indicator of main cap
fretting.
Plastigage™ provides a fast and accurate method to check bearing clearances. Plastigage™ is a special extruded
plastic thread of a definite diameter with accurately controlled crush properties. Plastigage™ is packaged in calibrated
envelopes 12 envelopes per box. These envelopes not only protect the plastic threads but also serve directly as
scales to measure the bearing clearance. Both sides of the envelope have a printed scale of graduations. One side
is calibrated in inches, the other in millimeters. The numbers on the scale are the bearing clearances in thousandths
of an inch or millimeter. When the width of a compressed section of Plastigage™ in a bearing or journal is compared
with the appropriate-numbered graduation, the bearing clearance can be read directly from the scale.
Plastigage™ is available from a local parts store in four styles to cover different clearance ranges. Both Plastigage™
thread and its matching envelope have a distinctive color for each clearance range.
Acceptance limits were developed to make sure of proper oil film thickness between the main bearings and crankshaft.
The minimum acceptable clearance is 0.05 mm [0.002 in] for the ISM series engines. The maximum acceptable
clearance is 0.13 mm [0.005 in] for the ISM series engines. Blocks not condemned can be up-fitted with the block
stiffener plate.
The block meets acceptance limits if the main bearing bore passes inspection and can be reassembled with new
standard bearing shells if all of the following conditions exist:
• Main cap and block mating surfaces exhibit little or no fretting
• Lower main bearing shells (2 through 6) do not show copper exposure or uneven wear

• Plastigage™ (if done) is equal to or greater than 0.05 mm [0.002 in] and equal to or less than 0.13 mm [0.005 in],
The block main bearing bore does not pass inspection when the two following conditions exist:
• Main cap and block mating surfaces exhibit fretting
• Plastigage™ clearance on any main bearing (2 through 6) is less than 0.05 mm [0.002 in] or greater than 0.13 mm
[0.005 In].
Fuel System - Overview ISM, ISMe, andQSMH
PageF-2 Section F - Familiarization

Repair options for blocks with one main journal that do not meet acceptance limits and have not spun a main bearing:

• Install an undersized main bearing kit to incrase bearing clearance.

Repair options for blocks with multiple main journals that do not meet acceptance limits or have spun a main bearing:
• Replace block with service block kit

• Replace block with ReCon® service block kit

• Replace block with ReCon® short block

• Replace engine with ReCon® engine.

NOTE: Cummins Inc. must approve all warrantable block repairs'.

Fuel System - Overview (005-999)

Installation Recommendations

Installation Publications

The following publications are available to provide fuel

system installation recommendations approved by
Cummins Inc.:

Automotive Installation Recommendations (Fuel System),

Bulletin 3382707.

\ Contact the nearest Cummins® Authorized Repair

Location for engine fuel system specifications and
requirements provided on the Engine Data Sheet for your
specific engine and application.

Overhead Fuel Tank Requirements

If the fuel filter is lower than the fuel pump, install a check
valve in the filter outlet fuel line. See the Installation
Recommendations Bulletin 3382015.
The check valve on the outlet side of the fuel filter prevents
gear pump fuel drainback during filter removal.

Install a shutoff valve between the filter and the fuel tank.

fpSvohn

AwarningA
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.

If the fuel line valve is not used, the overhead tank can
drain when the fuel filter is changed. Spilled fuel is afire
hazard.
 Fuel System - Overview
ISM, ISMe, and QSM11 Page F-3
Section F - Familiarization

Proper Use of Fuel System Gauges

To be sure the reading is correct, always remove the air
from the pressure gauge line before taking a reading.
© Cummins
Loosen the connection at the gauge to remove the air.
Do not loosen the vacuum gauge connections when the
engine is operating.

© Cum

Read the gauge in direct alignment with the gauge hand.

Read the flow meter in direct alignment with the float.

Read the level of the floats where indicated.

©Ci

©Cm toe,

© cummins ir»Cj_ © Cummins

Portable fuel pressure gauges must be checked regularly

against a reference gauge or against the gauge on the fuel
pump test stand. Adjust the valve on the gauge until the
gauge needle stops vibrating.
 ISM, ISMe, andQSMH
Fuel System - Overview Section F - Familiarization
Page F-4

When measuring the fuel inlet and drain line restriction,

the manometer or gauges must be on the same level as
the connection point.

Always use the same size and material of line or hoses as

was originally supplied with the gauge.

The distance from the gauge to the connection point

1 must be as short as possible.

AcautionA
Never exceed the maximum capacity of the gauge or
flow meter. If the maximum is exceeded, check the
gauge against a reference gauge.
 Injectors and Fuel Lines ■ Overview
ISM, ISMe, and QSM11
Page F-5
Section F - Familiarization

Injectors and Fuel Lines - Overview (006-999)

Theory of Operation
Hydromechanical Subsystem
The 2002 ISM engine utilizes a different injector than the previous ISM engine, with flow characteristic changes and
improved reliability. The injector is specially designed to maximize the benefit of cooled EGR and lower the emission
levels.

The fuel pump is located in the same location as a

CELECT™ Plus fuel pump.

The fuel pump is a gear type of pump. The assembly

includes a pressure regulator, pulsation damper, and
solenoid valve.
1 Pressure regulator

2 Pulsation damper

3 Solenoid valve.

tpBOOpi

The ECM mounts on a cooling plate. During engine

operation, fuel circulates through the cooling plate to
absorb heat generated by the ECM.
Injectors and Fuel Lines - Overview
ISM, ISMe, andQSMH
Page F-6
' Section F-Familiarization

On CM876 engines, fuel flows from the fuel rifle at the rear
of the engine to the aftertreatment shutoff valve. It then
flows to the aftertreatment fuel injector.
When fuel is not flowing to the injector, fuel remaining
between the aftertreatment shutoff valve number 1 and
aftertreatment fuel injector passes through ,the
aftertreatment shutoff valve number 2 and goes to drain.

The injector assembly includes a solenoid valve, which

controls the end of the fuel metering and the beginning of
injection. The solenoid valve is normally open. An
electronic signal from the ECM closes the valve as
required.

The fuel system uses the camshaft to create adequate

Injector Drive Train
pressure for injection.

ti2000k

A cutaway view of the electronically controlled injector

with the internal components identified is illustrated.
ISM, ISMe, and QSM11 Injectors and Fuel Lines - Overview
Section F - Familiarization Page F-7

Injection Cycle

At the start of metering, the metering plunger and the

timing plunger are at the lower limits of their travel. The
injector control valve is closed.

As the camshaft rotates, the timing plunger return spring

forces the timing plunger upward.

Fuel flows past the metering check ball and into the
metering chamber. This flow continues as long as the
timing plunger is moving upward, and the injector control
valve is closed.

Supply pressure, acting on the bottom of the metering

piston, forces it to maintain contact with the timing Solenoid

plunger. '■ !"V?!fV8!ins inc.

fi800gd

The ECM determines the end of metering by signaling the

injector control valve to open.

tins Inc.

Solenoid
..Valve. .

fi800ge

Fuel at supply pressure then flows into the timing

chamber, thereby stopping metering piston travel.

During this time, the bias spring makes sure the metering
plunger remains stationary; that it does not drift upward
as the timing plunger moves upward. This same force
against the metering plunger results in enough fuel
pressure below the piston to keep the metering check ball
seated.

A precisely metered quantity of fuel is now trapped in the

metering chamber. This determines the quantity of fuel
that will be injected.
Injectors and Fuel Lines - Overview ISM, ISMe, and QSM11
Page F-8 Section F - Familiarization

The timing plunger continues to move upward, and the

timing chamber fills with fuel.

Timing
R!

Solenoid
ins Inc .

fi8O0Ql

The timing plunger begins its downward travel. Initially,

the injector control valve remains open, allowing fuel to
flow from the timing chamber, through the injector control
Timing valve, and into the fuel supply passage.
iRIunger l>,

Metering Solenoid
Plunger Otototmbm In*.

fiaoogh

At the appropriate time, as determined by the ECM, the

injector control valve closes, trapping fuel in the timing
chamber. This trapped fuel creates a solid hydraulic link
Timing between the timing plunger and the metering plunger,
ift§ 3?K

Solenoid
Metering
plunge*

fiSOOgi

As a result, the metering plunger is forced to move

downward with the timing plunger.

Because the fuel is trapped, the downward force on the

timing plunger is transferred to the metering plunger,
thereby increasing pressure in the metering chamber.
 Injectors and Fuel Lines - Overview
ISM, ISWIe, andQSMH Page F-9
Section F - Familiarization

When this pressure reaches approximately 34,474 kPa

[5000 psi], the needle valve begins to be forced upward.
Continued downward movement of the timing plunger and Timing
metering plunger results in steadily increasing fuel Pluriger?
pressure. The result is that fuel is forced past the needle
valve, through the spray holes, and into the combustion
chamber.
Solenoid
Metering. Valve.
Plungerr

fiBOOgk

Injection continues until the spill passage of the metering

plunger passes the metering spill port.
Metering chamber pressure drops rapidly, allowing the Timing
Plunger
needle valve to close abruptly. This action results in a
positive end of injection. The positive end of injection
prevents dribble and results in cleaner burning.
It is also at this point that the pressure relief valve "pops
Metering
off", thereby reducing the effects of the high-pressure
Plunger-
"spike" that occurs at the time of the metering spill.

fi800gl

Immediately after the metering spill port is opened, the

upper edge of the metering plunger passes the timing spill
port.
Cutekiiif'S

Solenoid
QCuNMHftMinc,

fi8009m

This action allows the fuel in the timing chamber to be

spilled back to the fuel drain as the timing plunger
completes its downward movement.
Timing
This completes the injection cycle. s Plunger-

Metering. Solenoid
Plunger.:"

fiBOOgn
 Injectors and Fuel Lines - Overview ISM, ISMe, andQSMH
PageF-10 Section F - Familiarization

'£

filOOgr

Injector Drivetrain
1 Injector

2 Injector link

3 Rocker lever

4 Push rod
5 Cam follower

6 Camshaft.
 Flow Diagram, Fuel System
ISM, ISMe, andQSMH PageF-11
Section F - Familiarization

Flow Diagram, Fuel System (200-001)

Fuel System
Automotive with CWI875, CM870 and CM570

05800084

1 Fuel supply from tank

2 Fuel pump

3 Fuel filter

4 Injector

5 Fuel drain from injector

6 Fuel to injector

7 ECM cooling plate.

 Flow Diagram, Fuel System
ISM, ISMe, andQSMH
Page F-12
Section F - Familiarization

Automotive with CM876

13

05200170

1 Fuel supply from tank

2 Fuel filter
3 Fuel Pump

4 Fuel supply to ECM cooler

5 ECM cooling plate

6 Fuel supply to injectors

7 Injector

8 Fuel supply to aftertreatment injector system

9 Aftertreatment shutoff valve
10 Aftertreatment pressure sensor
11 Fuel supply to aftertreatment fuel injector
12 Aftertreatment fuel injector
13 Fuel drain to tank
 Flow Diagram, Fuel System
ISM, ISMe, andQSMH Page F-13
Section F - Familiarization

Marine Applications

O5200156

1 Fuel supply from tank

2 Fuel filter

3 Fuel pump

4 ECM cooling plate

5 Fuel to injector

6 Fuel drain to from injector

7 Injector

8 Fuel cooler

9 Fuel return to supply tank

Flow Diagram, Fuel System ISM, ISMe, and QSM1 1
Page F-14 Section F - Familiarization

Industrial and Generator Drive

05800084

1 Fuel supply from tank

2 Fuel pump

3 Fuel filter

4 Injector

5 Fuel drain from injector

6 Fuel to injector

7 ECM cooling plate

 Lubricating Oil System - Overview
ISM, ISMe, andQSM11
Page F-15
Section F - Familiarization

Lubricating Oil System - Overview (007-999)

General Information
With EGR
The use of quality engine lubricating oils, combined with appropriate oil drain and filter change intervals, is a critical
factor in maintaining engine performance and durability.
Cummins Inc. recommends engines using exhaust gas recirculation (EGR) must use a high quality' J5W-40
multiviscosity heavy-duty engine oil that meets the requirements of Cummins Engineering Specification U=b ZOUti
(such as Valvoline® Premium Blue® or Premium Blue® Extreme). American Petroleum Institute (API) specification CI-4
meets the CES 20078 requirement. The oil grades CC, CD, CE, CF or CG must not be used.
If oils meeting CES 20078 are not available, CES 20071, 20072, or 20077 can possibly be used for EGR equipped
engines at reduced oil drain intervals. Consult the operation and maintenance manual for the particular engine model
and duty cycle for more detailed recommendations.
Shortened drain intervals can possibly be required with monograde oils as determined by close monitoring of the oil
condition with scheduled oil sampling. Use of single-grade oils can affect engine oil consumption control.
For further details and an explanation of engine lubricating oils for Cummins® engines, refer to Cummins® Engine Oil
Recommendations, Bulletin 3810340.
Additional information regarding lubricating oil availability throughout the world is available in the Engine
Manufacturing Association (EMA) Lubricating Oils Data Book for Heavy Duty Automotive and Industrial Engines. The
data book can be ordered from:
Engine Manufacturer's Association
Two North LaSalle Street

Suite 2200

Chicago, IL 60602 U.S.A.

Phone: (312)644-6610

Fax:(312)827-8737

The API service symbols are shown in the accompanying <^^»

illustration.

1 The upper half of the symbols display the appropriate

oil categories.
2 The lower half contains words to describe oil energy-
conserving features.

3 The center section identifies the SAE oil viscosity

grade.

07100061

Oil viscosity must be chosen according to the typical

°C -40-30-20-10 0 10 20 30 40 50
climate conditions experienced by the user. Use of "F -40 -22 -4 14 32 SO 68 S6 104 122
15W-40 viscosity is recommended for the best engine 1 1 1 1 1 1 1 r-

durability at higher ambient temperature. For cold

temperature conditions, 10W-30 or 5W-30 viscosity can be
used for easier starting, improved oil flow, and improved
Winter Conditions rt
fuel economy.
Arctic Conditions
■"fflBlSW-3
1 1 I' I '< I r-
•C -40-30-20-10 0 10 20 3D 40 50

•F -40-22-4 14 32 SO 6B 86 104 122

oi900da
 Lubricating Oil System Overview ISM, ISMe, and QSM11
Page F-16
Section F - Familiarization

New Engine Break-in Oil

Special "break-in" engine lubricating oils are not

recommended for new or rebuilt Cummins® engines. In
general, use the same oil during break-in as that used in
normal operation. To make sure the piston rings seat
properly, use a high quality petroleum-based engine
lubricating oil during the first engine oil drain period.

Maximum Oil Drain Intervals

Oil Additives in Used Oil
As the engine oil becomes contaminated, essential oil
additives are depleted. Lubricating oils protect the engine
as long as these additives are functioning properly.
Progressive contamination of the oil between oil and filter
Active Additive
change intervals is normal. The amount of contamination
will vary depending on the operation of the engine,
kilometers or miles on the oil, fuel consumed, and new oil
added.

Extending oil and filter change intervals beyond the

Kilometers [Mileage]/Hours- recommendations will decrease engine life due to factors
07100062 such as corrosion, deposits, and wear.

See the oil drain chart in this section to determine which

oil drain interval to use for your application.

Without EGR

The use of quality engine lubricating oils, combined with appropriate oil drain and filter change intervals is a critical
factor in maintaining engine performance and durability.
Cummins Inc. recommends the use of a high quality 15W-40 multiviscosity heavy-duty engine oil that meets the
eq7 ri SS^"9-"66 n"9 S,Pecification CES 20071 or CES 20076 (such as Valvoline™ Premium Blue®
m 5 f 20°°>-1Ameri°an Petroleum Institute (API) specification CH-4 can be used as an alternative to CES
fnflL?hS e mfet API specification CG-4 can be used, but at a reduced drain interval according to the Oil Drain
Intervals by Severity of Service mi [km] chart. The oil grades CC, CD, CE, or CF has been obsoleted by API and must
JlOl UC UbGQ.

wUhTrhSnlS^ii ?arVa'f Can> ?6 rTire? with ™n°9««te oils as determined by close monitoring of the oil condition
with scheduled oil sampling. Use of single-grade oils may affect engine oil control.
Synthetic engine oils, API category III, are recommended for use in Cummins® engines operatinq in ambient
temperature conditions consistently below -25°C [-13°F], Above this temperature it is recommended the prtSleum
based multigrade lubricants be used. Synthetic OW-30 oils that meet API category III can be used in operations where
the ambient temperature never exceeds 0°C [32°F]. OW-30 oils do not offer the same level of protection against fuel
di ution as do higher multigrade oils. Higher cylinder wear can be experienced when using OW-30 oils in high-load
situations.

*" explanation of engine lubricatin9 oils for Cummins® engines. Refer to Service Bulletin
Additional information regarding lubricating oil availability throughout the world is available in the Enoine
Manufacturing Association (EMA) Lubricating Oils Data Book for Heavy Duty Automotive and Industrial Engines The
aaia dook can be ordered from:

Engine Manufacturer's Association

Two North LaSalle Street
Suite 2200
Chicago, IL 60602 U.S.A.
 Lubricating Oil System - Overview
ISM, ISMe, and QSM11 Page F-17
Section F - Familiarization

Phone: (312)644-6610
Fax: (312)827-8737

The API service symbols are shown in the accompanying

illustration.
1 The upper half of the symbols display the appropriate
oil categories. ■so Cui

2 The lower half contains words to describe oil energy-

conserving features.

3 The center section identifies the SAE oil viscosity

grade.

0710006

Oil viscosity must be chosen according to the typical ■C -40-30-20-10 0 10 20 30 40 50

climate conditions experienced by the user. Use of •F -40 -22 -4 14 32 SO 8B 86 104 122
15W-40 viscosity is recommended for the best engine H 1 1 1 1 1 1 1 H

durability at higher ambient temperature. For cold

temperature conditions, 10W-30 or 5W-30 viscosity can be All Se

used for easier starting, improved oil flow, and improved

Winter Conditions
fuel economy.
Arclic Conditions

<—p.p"j'-j-'y;f;
°C -40 -30 -20-10 0 10 20 3D 40 50

°F -40-22 -4 14 32 50 6B 86 104 122

oiSOOda

New Engine Break-in Oil

Special "break-in" engine lubricating oils are not
recommended for new or rebuilt Cummins® engines. In
general, use the same oil during break-in as that used in
normal operation. Synthetic or partially synthetic engine
lubricating oils, however, can not be used during break-in
of a new or rebuilt engine. To make sure the piston rings
seat properly, use a high quality petroleum-based engine
lubricating oil during the first engine oil drain period.
Lubricating Oil System - Overview ISM, ISMe, andQSMH
Page F-18 Section F - Familiarization

Oil Drain Interval

Oil Additives in Used Oil
As the engine oil becomes contaminated, essential oil
additives are depleted. Lubricating oils protect the engine
as long as these additives are functioning properly.
Progressive contamination of the oil between oil and filter
change intervals is normal. The amount of contamination
will vary depending on the operation of the engine,
kilometers or miles on the oil, fuel consumed, and new oil
added.

Extending oil and filter change intervals beyond the

recommendations will decrease engine life due to factors
Kilometers [Mileage]/Hours
O7100062
such as corrosion, deposits, and wear.

See the oil drain chart in this section to determine which

oil drain interval to use.

Centinel™ System (ISM Engines)

The integrated Centinel™ system is continuous oil
replacement system of electromechanical design. The
Centinel™ system extends oil and filter change intervals
through continuous oil exchange. This is accomplished by
injecting engine oil at a controlled rate, proportional to fuel
consumed, into the fuel system for consumption. Makeup
oil (fresh) is introduced into the engine at a rate equal to
the oil consumed by Centinel™. The Centinel™ system also
monitors the oil level in the makeup tank.
1 Control module
07200051
2 Maintenance/fluids lamp
3 OEM interface connector on the engine control module
4 Makeup tank wiring harness
5 Return fuel line
6 Fresh oil to oil control valve
7 Remote oil level switch
8 Makeup oil tank
9 Main oil rifle

10 Hose from makeup oil tank to oil control valve

11 Fresh oil to oil pan
12 Fuel/lube oil blend to engine
13 Oil control valve
14 Vehicle fuel tank.

ISM, ISMe, andQSMH
Section TT - Troubleshooting Symptoms (New Format)
STEP 3F: Check for a pin-to-pin short circuit in the engine harness.
Condition:
Turn keyswitch OFF.
Disconnect the fuel control module actuator connector from the fuel control module.
Disconnect the engine harness from the ECM.
Remove the engine harness ring terminal from the fuel shutoff valve.
Action
Check for a pin-to-pin short circuit.
• Measure the resistance between the fuel
shutoff valve SIGNAL pin of the engine
harness fuel control module actuator
connector and all pins in the engine harness
engine control module connector.
Refer to the wiring diagram or circuit diagram for
connector pin identification.
Use the following procedure for general
resistance measurement techniques. Refer to
Procedure 019-360 in Section 19.
 Engine Performance Troubleshooting Tree
Page TT-23
Specification/Repair Next Step
Greater than 100k ohms? 3G
YES
Repair
Greater than 100k ohms?
complete
NO
Repair:
Repair or replace the engine harness.
See one of the following procedures:
• Use the following procedure in the
Troubleshooting and Repair Manual,
Electronic Control System, ISM and
QSM11 Engines, Bulletin 3666266. Refer
to Procedure Procedure 019-043 in
Section 19.
• Use the following procedure in the
Troubleshooting and Repair Manual,
CM870 Electronic Control System, ISM
Engines Bulletin 4021381. Refer to*
Procedure Procedure 019-043 in Section
19.
• Use the following procedure in the
Troubleshooting and Repair Manual,
CM875 Electronic Control System, ISM
Engines, Bulletin 4O21477.Refer to
Procedure Procedure 019-043 in Section
19.
win
19202563