Service Manual ISBe, ISB, and QSB (Common Rail Fuel System) Volume 2
Service Manual ISBe, ISB, and QSB (Common Rail Fuel System) Volume 2 Copyright© 2014 Cummins Inc. All rights reserved Bulletin 4021271 Printed 29-OCTOBER-2014 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
Foreword This manual provides instructions for troubleshooting and repairing this engine in the chassis. Component and assembly rebuild procedures are provided in the engine shop manual. Refer to Section i - Introduction for instructions on how to use this manual. Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i Introduction.
Table of Contents Section Introduction ........................................................................................................................................................ i Fuel System - Group 05 ..................................................................................................................................... 5 Injectors and Fuel Lines - Group 06 .................................................................................................................
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ISB, ISBe and QSB (Common Rail [...] Section i - Introduction Page i-a Section i - Introduction Section Contents Page About the Manual .........................................................................................................................................................i-1 General Information.....................................................................................................................................................i-1 Acronyms and Abbreviations ...................
Page i-b ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section i - Introduction About the Manual Page i-1 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' filmcard system.
How to Use the Manual Page i-2 ISB, ISBe and QSB (Common Rail [...] Section i - Introduction How to Use the Manual General Information 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.
ISB, ISBe and QSB (Common Rail [...] Section i - Introduction Symbols Page i-3 Symbols General Information The symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below. NOTE: It is possible to have four symbols for each text and graphic combination. WARNING Serious personal injury or extensive property damage can result if the warning instructions are not followed.
Symbols Page i-4 ISB, ISBe and QSB (Common Rail [...] Section i - Introduction Indicates an INSTALLATION or ASSEMBLY step. INSPECTION is required. CLEAN the part or assembly. PERFORM a mechanical or time MEASUREMENT. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
ISB, ISBe and QSB (Common Rail [...] Section i - Introduction Symbols Page i-5 LUBRICATE the part or assembly. Indicates that a WRENCH or TOOL SIZE will be given. TIGHTEN to a specific torque. PERFORM an electrical MEASUREMENT. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
Symbols Page i-6 ISB, ISBe and QSB (Common Rail [...] Section i - Introduction Refer to another location in this manual or another publication for additional information. The component weighs 23kg [50 lbs] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift the component. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
ISB, ISBe and QSB (Common Rail [...] Section i - Introduction Illustrations Page i-7 Illustrations General Information Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition. The illustrations are intended to show repair or replacement procedures.
General Safety Instructions Page i-8 ISB, ISBe and QSB (Common Rail [...] Section i - Introduction General Safety Instructions Important Safety Notice WARNING Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation or other personal injury or death. Read and understand all of the safety precautions and warnings before performing any repair. This list contains the general safety precautions that must be followed to provide personal safety.
ISB, ISBe and QSB (Common Rail [...] Section i - Introduction General Safety Instructions Page i-9 • Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. • Do not connect the jumper starting or battery charging cables to any ignition or governor control wiring.
General Repair Instructions Page i-10 ISB, ISBe and QSB (Common Rail [...] Section i - Introduction General Repair Instructions General Information This system incorporates the latest technology at the time it was manufactured; yet, it is designed to be repaired using normal repair practices performed to quality standards. WARNING Cummins Inc. does not recommend or authorize any modifications or repairs to components except for those detailed in Cummins Service Information.
ISB, ISBe and QSB (Common Rail [...] Section i - Introduction General Repair Instructions Page i-11 • Use genuine Cummins new or ReCon® service parts and assemblies - The assembly instructions have been written to use again as many components and assemblies as possible. When it is necessary to replace a component or assembly, the procedure is based on the use of new Cummins or Cummins ReCon® components.
General Cleaning Instructions Page i-12 ISB, ISBe and QSB (Common Rail [...] Section i - Introduction General Cleaning Instructions Definition of Clean Parts must be free of debris that can contaminate any engine system. This does not necessarily mean they have to appear as new. Sanding gasket surfaces until the factory machining marks are disturbed adds no value and is often harmful to forming a seal. It is important to maintain surface finish and flatness tolerances to form a quality sealing surface.
ISB, ISBe and QSB (Common Rail [...] Section i - Introduction General Cleaning Instructions Page i-13 abrade the other part until contact is no longer being made between the two parts. If the damage sufficiently degrades the oil film, the two parts will come into contact resulting in early wear-out or failure from lack of effective lubrication. Abrasive particles can fly about during cleaning it is very important to block these particles from entering the engine as much as possible.
General Cleaning Instructions Page i-14 ISB, ISBe and QSB (Common Rail [...] Section i - Introduction pressure water or steam clean the parts before putting them in the cleaning tank. Removing the heaviest dirt before placing in the tank will allow the cleaner to work more effectively and the cleaning agent will last longer. Rinse all the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all the capscrew holes and the oil drillings.
ISB, ISBe and QSB (Common Rail [...] Section i - Introduction General Cleaning Instructions Page i-15 2 Operating Pressure — 270 kPa (40 psi) for piston cleaning. Pressure should not cause beads to break. 3 Steam clean or wash the parts with solvent to remove all of the foreign material and plastic beads after cleaning. Rinse with hot water. Dry with compressed air. CAUTION The bead blasting operation must not disturb the metal surface.
General Cleaning Instructions Page i-16 ISB, ISBe and QSB (Common Rail [...] Section i - Introduction is 76 microns [0.003 in] in diameter. One micron measures 0.001 mm [0.00004 in.]. The contaminants being filtered out are smaller than can be seen with the human eye, a magnifying glass, or a low powered microscope. The tools used for fuel system troubleshooting and repair are to be cleaned regularly to avoid contamination.
ISB, ISBe and QSB (Common Rail [...] Section i - Introduction Acronyms and Abbreviations Page i-17 Acronyms and Abbreviations General Information The following list contains some of the acronyms and abbreviations used in this manual. ANSI API ASTM ATDC BTU BTDC °C CAN CO CCA CARB C.I.B. C.I.D.
Acronyms and Abbreviations Page i-18 NOx NG O2 OBD OEM OSHA PID ppm psi PTO REPTO RGT rpm SAE SCA SCR STC SID TDC VDC VGT VS VSS ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Page 5-a Section 5 - Fuel System - Group 05 Section Contents Page EFC Actuator Valve ....................................................................................................................................................5-4 Finishing Steps...........................................................................................................................................................5-6 Initial Check..............
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ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Service Tools Page 5-1 Service Tools Fuel System The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from a local Cummins® Authorized Repair Location. Tool No. Tool Description Tool Illustration Fuel Pressure Gauge Adapter 3164044 Used to measure fuel pressure and detect air in the fuel system.
Service Tools Page 5-2 Tool No. ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Tool Description Tool Illustration Fuel Return Flow Hose (injector and fuel pump) 3164618 The tool uses a special fitting to connect to the fuel return circuits to measure return flow from the injectors and fuel pump (EGR engines only). Lift Pump Performance Test Orifice 3164621 This tool connects to the diagnostic fitting on the inlet to the fuel filter.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Tool No. Service Tools Page 5-3 Tool Description Tool Illustration Bearing Separator Tool Use to remove the fuel pump gear. 3375326 Fuel Return Flow Tester Kit Used to check injector and HPCR pump drain flow. 4918354 Fuel Drain Hose 4918433 Used with 5/16 quick disconnect fittings male connector (hose included in kit Part Number 4918354).
EFC Actuator Valve Page 5-4 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 EFC Actuator Valve (005-007) Preparatory Steps WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. WARNING When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury. Steam clean the fuel pump and the area around the fuel pump. Dry with compressed air.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 EFC Actuator Valve Page 5-5 With the keyswitch ON and the engine cranking, check the high pressure injection pump. Check the high pressure injection pump fuel flow as follows: • Disconnect the high pressure fuel line to the fuel rail from the high pressure injection pump. • Connect a clear hose to the outlet of the high pressure injection pump. • Place the high pressure fuel clear hose into an empty bucket.
Engine Fuel Heater, Electric Page 5-6 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Finishing Steps Operate the engine and check for leaks or fault codes. Engine Fuel Heater, Electric (005-008) Initial Check NOTE: The fuel heater is not controlled by the electronic control module (ECM). A bimetallic strip acts as a thermostat. The fuel heater will turn on below approximately 4°C [39°F] and turn off above approximately 27°C [81°F]. Remove the 2-pin connector from the fuel heater.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Engine Fuel Heater, Electric Page 5-7 NOTE: To test the voltage to the fuel heater, use the Fuel Heater Override test in INSITE™. Refer to INSITE™ documentation or Section 14 for more information. Check for proper voltage to the fuel heater during the Fuel Heater Override test.
Fuel Consumption Page 5-8 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 NOTE: Do not apply an excessive amount of Loctite due to its being passed into the fuel pump after installation. Apply Loctite 648, or equivalent, to the filter spud. Install the fuel filter spud. Torque Value: 30 N•m [ 22 ft-lb ] Install an o-ring between the fuel heater and the filter canister. Install the fuel filter. Torque Value: 34 N•m [ 25 ft-lb ] Connect the connector to the fuel heater.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Fuel Consumption Page 5-9 Install the remote tank (1). Install the return fuel line to the test tank, or the results will not be accurate. Measure the distance traveled with an accurate odometer. The odometer's accuracy can be checked by using measured kilometers [miles]. After traveling the route, remove the tanks, and weigh the remaining fuel. Compute the fuel used in liters [gallons] as required.
Fuel Consumption Page 5-10 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 In addition to the measurement of the fuel used, the following factors provide points for running a test similar to the recognized Type II Society of Automotive Engineers Fuel Test. These procedures are helpful in determining differences in fuel consumption between two vehicles under the same environmental, road, and test conditions. Perform the test with the test vehicle and a control vehicle.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Fuel Consumption Page 5-11 All the test results are based on comparing the fuel used by the test truck to the fuel used by the control truck. Drive the truck on a warm-up test run. Drive enough tests to achieve the following: • The difference in elapsed time between each test run can only be ±0.5 percent. This will be ±15 seconds over 80 km [50 mi] at 97 km/h [60 mph].
Fuel Pump Page 5-12 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 During the test, record the following: • Ambient temperature • Humidity • Barometric pressure • Wind velocity • Wind direction. NOTE: Avoid testing under any extreme conditions. Fuel Pump (005-016) General Information WARNING The fuel pump, high-pressure fuel lines, and fuel rail contain very high-pressure fuel. Do not loosen any fittings while the engine is running.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Fuel Pump Page 5-13 Test CAUTION Clean all fittings before disassembly. contaminants can damage the fuel system. Dirt or If the engine will not start, disconnect the high-pressure fuel outlet line from the high-pressure injection pump. Refer to Procedure 006-060 in Section 6. Disconnect the fuel pump actuator connector.
Fuel Pump Page 5-14 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 WARNING The fuel pump high-pressure fuel lines and fuel rail contain very high-pressure fuel. Never loosen any fittings while the engine is running. Personal injury and property damage can result. If the engine can be started, a measurement of the fuel return flow can diagnose a high-pressure fuel pump problem. The following steps describe how to test the high-pressure fuel pump return flow.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Fuel Pump Page 5-15 For marine engines, the return manifold is located on the side of the engine block, next to the ECM. WARNING Fuel can be returned at highly elevated temperatures. Wear safety glasses and protective gloves and clothing when performing this test. Avoid contact with returned fuel. Place the end of the fuel pressure gauge adapter tool or fuel drain hose into a 500 ml graduated beaker, Part Number 3823705.
Fuel Pump Page 5-16 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Fuel is flammable.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Fuel Pump Page 5-17 Marine Applications WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Fuel is flammable.
Fuel Pump Page 5-18 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Remove NOTE: A counter-torque must be applied to the fitting on the high-pressure pump. This is to prevent the fitting from being loosened and to prevent the possibility of a leak. Disconnect the high-pressure supply line from THE highpressure fuel pump to the fuel rail and loosen the holding brackets. Disconnect connector.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Fuel Pump Page 5-19 CAUTION Protect the fuel pump drive shaft threads from damage during gear removal. Install the fuel pump drive gear puller onto the drive shaft and gear. Hold the gear puller while removing the fuel pump drive gear. Remove the fuel pump assembly. Marine Applications Remove the three fuel pump flanged mounting nuts. Remove the fuel pump drive access cover with a 3/8-inch drive ratchet.
Fuel Pump Page 5-20 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 CAUTION Place a clean cloth in the air gap between the fuel pump drive gear and the gear cover, or use a screw driver to prevent the mounting nut and lock washer from being dropped into the front gear train. CAUTION The fuel pump drive gear is captive between the gear housing and the gear cover. Do not rotate the crankshaft while the gear is not supported by the fuel pump drive shaft.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Fuel Pump Page 5-21 Remove the spacer, Part Number 4918317, from the fuel pump drive shaft. Remove the fuel pump assembly. Disassemble Rear Gear Train Use a fuel pump retention tool, Part Number 3164707, and a ½-inch breaker bar to retain the fuel pump drive gear. Loosen the clamp load of the fuel pump drive gear retaining nut by rotating it counterclockwise. Do not remove it from the shaft.
Fuel Pump Page 5-22 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Install a Snap-On™ puller, Part Number CG150-02, or equivalent onto the bearing separator, Part Number 3375326, and the fuel pump driveshaft. Rotate the puller screw until the drive gear is separated from the driveshaft. Remove the drive gear retaining nut, lock washer, and drive gear from the fuel pump driveshaft.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Fuel Pump Page 5-23 Inspect the gear housing, high-pressure pump mounting bore, and mounting studs for cracks. Replace if damage is found. Marine Applications Inspect the driveshaft for damage. Replace the fuel pump if damage is found. Inspect the o-ring seal area for damage. Clean and repair any burred surfaces. Assemble The pump driveshaft nose and drive gear shaft mating surface must be clean and dry prior to assembly.
Fuel Pump Page 5-24 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Use the fuel pump gear retention tool, Part Number 3164707, and a 1/2 inch breaker bar to hold the drive gear in place while tightening the drive gear retaining nut. Torque Value: 105 N•m [ 77 ft-lb ] Install Automotive and Industrial Install the fuel pump on the gear housing. NOTE: Timing of the high-pressure pump with the crankshaft is not required. Install the fuel pump mounting nuts and tighten.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Fuel Pump Page 5-25 Front Gear Train CAUTION Place a clean cloth in the air-gap between the fuel pump drive gear and the gear cover, or use a screw driver to prevent the mounting nut and lock washer from being dropped into the front gear train. CAUTION The fuel pump drive gear is captive between the gear housing and the gear cover. Do not rotate the engine while the gear is not supported by the fuel pump drive shaft.
Fuel Pump Page 5-26 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Install a new seal ring on the front of the fuel pump assembly. Be sure the seal ring is not twisted. Lubricate the seal ring and the mounting bore of the gear housing with P-80 rubber lubricant emulsion, Part Number 3824878. Install the fuel pump onto the gear housing. Install the three fuel pump to gear housing mounting nuts and tighten.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Fuel Pump Page 5-27 Install a new square cut o-ring onto the fuel pump drive access cover. Install the fuel pump drive access cover with a 3/8-inch drive ratchet. The plate is threaded into the gear cover. Finishing Steps With Electric Lift Pump • For engines with a low mount fuel filter, install the fuel filter head. Refer to Procedure 006-017 in Section 6. • Install the low-pressure fuel supply lines.
Fuel Pump Page 5-28 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Marine Applications WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Fuel is flammable.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Fuel Pump Page 5-29 Prime Automotive and Industrial WARNING The fuel pump high-pressure fuel lines and fuel rail contain very high-pressure fuel. Never loosen any fittings while the engine is running. Personal injury and property damage can result. CAUTION Be sure that the fuel inlet and return valves are returned to the open position before cranking the engine.
Fuel Lift Pump Page 5-30 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Marine Applications WARNING Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Fuel Lift Pump Page 5-31 Measure WARNING Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system. WARNING Do not vent the fuel system on a hot engine; this can cause fuel to spill onto a hot exhaust manifold, which can cause a fire.
Fuel Lift Pump Page 5-32 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Voltage will only be present when the lift pump is commanded ON and when the lift pump is connected to the harness. To measure lift pump voltage, use the INSITE™ electronic service tool lift pump override test and a breakout connector between the lift pump and the engine harness Check the voltage and resistance at the lift pump. If the voltage does not meet the specifications, check the power supply.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Fuel Lift Pump Page 5-33 Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Disconnect the batteries. Shut off the fuel supply and return lines. Refer to the OEM service manual.
Fuel Lift Pump Page 5-34 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 For 24-volt systems with voltage regulators, remove the voltage regulator from the bottom edge of the ECM by removing the lower two ECM mounting capscrews. The relay is fastened to the wiring harness near the ECM connectors. Disconnect the voltage regulator wiring harness connectors and remove the voltage regulator assembly.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Stall Speed Test Page 5-35 Finishing Steps For marine applications, install the ECM cooling plate. Refer to Procedure Procedure 006-006 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.
Stall Speed Test Page 5-36 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 CAUTION Do not exceed 120°C [248°F] converter oil temperature. Overheating can result and converter damage can occur. If the oil temperature exceeds 120±C [248°F], put the transmission in neutral, and operate the engine until the oil temperature is below 120°C[248°F]. Check the converter oil level.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Stall Speed Test Page 5-37 Operate the engine until the converter temperature is 80°C [176°F] or above. Bring the engine speed back to low idle. CAUTION Do not exceed 120°C temperature. Overheating converter can occur. [248°F] converter oil and damage to the Quickly move the throttle to the full-open position with the vehicle brakes applied.
Stall Speed Test Page 5-38 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Check the speed (rpm) against the specifications for the equipment, converter, or automatic transmission. NOTE: The stall speed for the engine and converter/ transmission can vary ±8 percent from the manufacturer's specifications. If the stall speed is not within the specifications, refer to the Stall Speed Checklist at the end of this section.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 Stall Speed Test Page 5-39 Check the equipment manufacturer's specifications for the time to stall or the acceleration time. If the time is excessive, refer to the Stall Speed Checklist at the end of this procedure. Stall Speed Checklist Yes 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. No The tachometer is in error. Engine temperature is up to or above 70°C [160°F]. The converter oil is up to temperature 80°C [180°F].
Stall Speed Test Page 5-40 ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 11. The converter blading is interfering or in a stage of failure. Check the sump or filter for particles. The converter stators are free-wheeling instead of locking up. The engine is set for power other than that specified on the power curve. The converter is wrong due to improper build or rebuild of unit. The converter is performing to the published absorption curve.
ISB, ISBe and QSB (Common Rail [...] Section 5 - Fuel System - Group 05 6. 7. 8. 9. 10. Stall Speed Test Page 5-41 The converter turbine element is beginning to fail and lose blades, or the converter was originally built with the wrong size element. The engine and converter match is correct due to a revision in the engine rating or the converter performance.
Stall Speed Test Page 5-42 ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Page 6-a Section 6 - Injectors and Fuel Lines - Group 06 Section Contents Page Air in Fuel ....................................................................................................................................................................6-5 General Information...................................................................................................................................................
Page 6-b ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 High Mount Fuel Filter........................................................................................................................................... 6-44 Marine Applications............................................................................................................................................... 6-45 Preparatory Steps................................................................
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Page 6-c Clean and Inspect for Reuse....................................................................................................................................6-77 Finishing Steps.........................................................................................................................................................6-81 General Information............................................................
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ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Service Tools Page 6-1 Service Tools Injectors and Fuel Lines The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from a local Cummins® Authorized Repair Location. Tool No.
Service Tools Page 6-2 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Tool No. Tool Description Tool Illustration Injector Bore Brush Used to clean the injector bore. 3822510 Injector Puller Used to pull the injector. 3823024 Fuel Connector Remover Used to pull the fuel connector. 3164025 Fuel Pressure Gauge Adapter 3164044 Used to measure fuel pressure and detect air in the fuel system. Use with tool, Part Number 3164491.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Tool No. Service Tools Page 6-3 Tool Description Tool Illustration Compuchek® Quick-Connect Coupling 3376859 This tool connects to the diagnostic fitting on the inlet to the fuel filter. It is used when measuring inlet restriction when running the lift pump and does not contain an orifice (EGR engines only).
Service Tools Page 6-4 Tool No. ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Tool Description Tool Illustration Fuel Pressure Gauge Adapter Kit Used to check fuel pressure/restriction. 4918462 Fuel Tube Plug Used to plug low pressure fuel lines. 4918464 Compucheck® Fitting Used to check fuel pressure/restriction. 10 mm O-ring connection. 3824842 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Air in Fuel Page 6-5 Air in Fuel (006-003) General Information A replacement of fuel supply lines, fuel filters, fuel injection pump, high-pressure fuel lines, and injectors will let air enter the fuel system. Air in the system can make the engine hard to start, run rough, misfire, produce low power, or can cause excessive smoke and a fuel knock. A few bubbles exiting the line during the test is expected.
Air in Fuel Page 6-6 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 If air continues to bubble through the clear hose for several minutes, then an air leak is present. This test checks for air leaks in the fuel supply lines. If all components are functioning properly, the fuel lines after the lift pump will always have a positive pressure. Any poor connections in lines will result in an external leak and not air in the fuel.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Air in Fuel Page 6-7 NOTE: This test is performed with the engine not running. Start the lift pump by turning on the key switch. (The lift pump will operate for 30-60 seconds and then stop. Turning the key off and back on could be necessary to verify if air is still present.) This can also be done by using the INSITE™ electronic service tool lift pump override test. See the INSITE™ user's manual.
ECM Cooling Plate, Fuel Cooled Page 6-8 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Observe the fuel flow exiting the diagnostic fuel line while the engine runs at idle. If air continues to bubble through the clear hose for several minutes, then an air leak is present.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 ECM Cooling Plate, Fuel Cooled Page 6-9 Remove the ECM and cooling plate from the engine as an assembly. Refer to Procedure Procedure 019-031 in ISB (4 cylinder) and ISBe (4 and 6 Cylinder) Controls Troubleshooting and Repair Manual Bulletin 3666477. Disconnect the fuel lines from the inlet and outlet of the ECM cooling plate. Remove the ECM from the cooling plate.
ECM Cooling Plate, Fuel Cooled Page 6-10 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Fuel is flammable.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 ECM Cooling Plate, Fuel Cooled Page 6-11 Remove Remove the ECM and cooling plate mounting capscrews. Do not lose any of the heat-resistant grommets. Remove the ECM and cooling plate from the engine. Drain any remaining fuel into the fuel can. NOTE: The ECM cooling plate, ECM, and ECM mounting bracket are removed and installed as an assembly.
ECM Cooling Plate, Fuel Cooled Page 6-12 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Remove the four capscrews holding the ECM and fuel cooled ECM cooling plate to the mounting bracket. Remove the fuel lift pump. Refer to Procedure Procedure 005-045 Clean and Inspect for Reuse CAUTION To reduce the possibility of engine damage, do not paint the cooling plate. Make sure there is no grease or dirt between the ECM and the cooling plate.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 ECM Cooling Plate, Fuel Cooled Page 6-13 Install the fuel lift pump to the ECM plate. Refer to Procedure Procedure 005-045 Install the ECM and ECM cooling plate to the mounting bracket with four capscrews. Torque Value: 24 N•m [ 212 in-lb ] Install NOTE: For engines without an electric lift pump, the ECM and ECM cooling plate are installed as an assembly. Install the ECM cooling plate on the engine.
ECM Cooling Plate, Fuel Cooled Page 6-14 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Finishing Steps Install the ECM and cooling plate to the engine as an assembly. Refer to Procedure 019-031 in the ISB (4 cylinder) and ISBe (4 and 6 cylinder) Controls Troubleshooting and Repair Manual Bulletin 3666477. Connect the fuel lines to the inlet and outlet of the ECM cooling plate. WARNING Batteries can emit explosive gases.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 ECM Cooling Plate, Fuel Cooled Page 6-15 WARNING Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system. WARNING Batteries can emit explosive gases.
ECM Cooling Plate, Fuel Cooled Page 6-16 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Prime WARNING The fuel pump high-pressure lines and fuel rail contain very high-pressure fuel. Never loosen any fittings while the engine is running. Personal injury and property damage can result. CAUTION Use caution when disconnecting or removing fuel lines, replacing filters and priming the fuel system that fuel is not spilled or drained into the bilge area.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 ECM Cooling Plate, Fuel Cooled Page 6-17 WARNING The fuel pump high-pressure lines and fuel rail contain very high-pressure fuel. Never loosen any fittings while the engine is running. Personal injury and property damage can result. CAUTION Use caution when disconnecting or removing fuel lines, replacing filters and priming the fuel system that fuel is not spilled or drained into the bilge area.
Fuel Drain Line Restriction Page 6-18 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Drain Line Restriction (006-012) General Information The fuel drain line restriction is measured at a fuel return manifold located near the point at which the OEM connects the vehicle fuel drain line.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Drain Line Restriction Page 6-19 Marine Applications Without Fuel Cooler For Marine applications, the fuel return manifold is located on the engine block beside the ECM. This manifold contains both the inlet and outlet fuel. NOTE: If the engine has a fuel cooler, it will be located between the fuel return manifold and the OEM fuel drain line connection.
Fuel Drain Line Restriction Page 6-20 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Gear Housing Fuel Return Manifold Disconnect the quick-disconnect fitting on the fuel drain line closest to the connection to the OEM fuel drain line. Insert a pressure gauge adapter, Part Number 4918462, between the disconnected fuel drain line and the OEM fuel drain line connection. Attach a pressure gauge to the fitting on the fuel pressure gauge adapter.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Drain Line Restriction Page 6-21 Marine Applications CAUTION Use caution when disconnecting or removing fuel lines, replacing filters and priming the fuel system that fuel is not spilled or drained into the bilge area. Do not drop or throw filter elements into the bilge area. The fuel and fuel filters must be discarded in accordance with local environmental regulations.
Fuel Drain Lines Page 6-22 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 If the fuel drain line restriction is too high, check the original equipment manufacturer's fuel lines to the tank for proper size, leaks, bends, or clogs. Check the fuel drain valves for restrictions for plugging. Check for possible plugged fuel tank vents.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Drain Lines Page 6-23 Directions for service of a white tang quick-disconnect fitting: Push in white tang to release fuel line. Pull to lock fuel line. Directions for service of a two-button quick-disconnect fitting: Remove the quick disconnect style fuel lines by pressing in the locking tangs on both sides of the quick disconnect fitting.
Fuel Drain Lines Page 6-24 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Disconnect the batteries.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Drain Lines Page 6-25 Remove the fuel drain line from the fuel injector pump. Remove the fuel drain line from the fuel return manifold. NOTE: For marine applications, each of the drain lines individually connect to the fuel return manifold. WARNING Fuel is flammable.
Fuel Drain Lines Page 6-26 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Inspect for Reuse Inspect the fuel drain lines for clogging and pinched areas. Check the connector and o-ring for damage. Replace fuel line if damaged. Inspect the fuel drain lines for clogging, and pinched areas. Check the connector and o-ring for damage. Replace fuel line if damaged Inspect the face of the banjo connectors for sealing surface damage. Replace fuel line if damaged.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Drain Lines Page 6-27 NOTE: The fitting for the injector return flow on the back of the cylinder head contains a check valve to maintain proper back-pressure. Fuel exiting the check valve returns to the tank. Install the injector return flow fitting into the back of the cylinder head. NOTE: For engines with quick-disconnect fittings; attach the fuel drain line to the injector return flow drain fitting.
Fuel Drain Lines Page 6-28 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 NOTE: The fitting for the injector return flow on the back of the cylinder head contains a check valve to maintain proper back pressure. Fuel exiting the check valve returns to the combined fuel manifold then to the fuel cooler and fuel tank. Install the fitting using new sealing washers.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Filter (Spin-On Type) Page 6-29 Operate the engines and check for leaks. Fuel Filter (Spin-On Type) (006-015) General Information WARNING Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system.
Fuel Filter (Spin-On Type) Page 6-30 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Without Fuel Filter Diagnostic Ports Use the following steps to check the fuel filter restriction to measure the pressure drop across the fuel filter. Disconnect the gear pump supply line from the fuel filter inlet. Insert the fuel pressure gauge adapter, Part Number 3164044, between the gear pump supply line and the fuel filter head inlet.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Filter (Spin-On Type) Page 6-31 Install a M10 male Compuchek™ fitting, Part Number 3824842, on the diagnostic port on the outlet side of the fuel filter. Connect a fuel pressure gauge to the Compuchek™ fitting. Measure the pressure at low idle: Fuel Pressure Range At Fuel Filter Outlet with Electric Lift Pump (Engine Running) kPa psi 0 MIN 0 79.9 MAX 11.
Fuel Filter (Spin-On Type) Page 6-32 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 If the fuel pressure is below the minimum at the inlet side of the filter: 1 Check for a high fuel inlet restriction. Refer to Procedure 006-020 in Section 6. 2 For engines with an electric lift pump, check for a malfunctioning electric lift pump. Refer to Procedure 005-045 in Section 5. 3 Check for air in fuel. Refer to Procedure 006-003 in Section 6.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Filter (Spin-On Type) Page 6-33 Measure the fuel outlet pressure at low idle. Fuel Pressure Range At Fuel Filter Outlet without Electric Lift Pump (Engine Running) kPa psi 503 MIN 73 1303 MAX 189 Record the fuel filter outlet pressure and subtract it from the fuel filter inlet pressure.
Fuel Filter (Spin-On Type) Page 6-34 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Marine Applications NOTE: For marine application engines, the lift pump outlet pressure to the filter is measured at the diagnostic port on the inlet side of the fuel filter head. Refer to Procedure 005-045 in Section 5. To check the fuel filter restriction, measure the pressure drop across the fuel filter using the following steps.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Filter (Spin-On Type) Page 6-35 Install an M10 Compuchek™ fitting, Part Number 3824842, on the diagnostic port on the outlet side of the fuel filter. Connect a fuel pressure gauge to the quick-disconnect fitting. Measure the pressure at low idle: Fuel Pressure Range At Fuel Filter Inlet (Engine Running) kPa psi 0 MIN 0 79.9 MAX 11.
Fuel Filter (Spin-On Type) Page 6-36 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Install Lubricate the o-ring seal with clean lubricating oil. CAUTION Mechanical overtightening can distort the threads as well as damage the filter element seal or filter can. CAUTION Do not pre-fill the pressure side fuel filter with fuel unless a clean side block off plug is used. The system must be primed after the fuel filter is installed.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Filter (Spin-On Type) Page 6-37 Prime With Electric Lift Pump(s) WARNING The fuel pump high-pressure fuel lines and fuel rail contain very high-pressure fuel. Never loosen any fittings while the engine is running. Personal injury and property damage can result. WARNING Be sure that the fuel inlet and return valves are returned to the open position before cranking the engine.
Fuel Filter (Spin-On Type) Page 6-38 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Without Electric Lift Pump WARNING The fuel pump high-pressure fuel lines and fuel rail contain very high-pressure fuel. Never loosen any fittings while the engine is running. Personal injury and property damage can result. WARNING Be sure that the fuel inlet and return valves are returned to the open position before cranking engine.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Filter (Spin-On Type) Page 6-39 NOTE: It is not necessary to vent air from the highpressure fuel system before starting the engine. Cranking the engine will prime the fuel system. Operate the engine and check for leaks. Marine Applications WARNING The fuel pump high-pressure fuel lines and fuel rail contain very high-pressure fuel. Never loosen any fittings while the engine is running.
Fuel Filter Head Page 6-40 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Filter Head (006-017) General Information Due to the number of different fuel filter head designs and mounting locations, the steps in this procedure have been written to be generic. Some of the illustrations may not represent the parts being removed or installed. NOTE: Fuel filter may be remotely mounted off of the engine.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Filter Head Page 6-41 Remove Low Mount Fuel Filter NOTE: The fuel filter head and fuel filter head bracket may be one piece. Remove the fuel filter head bracket capscrews. Remove the fuel filter head. Remove the capscrews holding the fuel filter head bracket in place. High Mount Fuel Filter NOTE: The fuel filter head and fuel filter head bracket may be one piece. Remove the fuel filter head bracket capscrews.
Fuel Filter Head Page 6-42 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Marine Applications NOTE: The filter head is marked with an IN and OUT for the line connections. Be sure to note the direction of the markings as the filter head is removed to be sure the filter head is not installed backwards and the lines are not connected in reverse during installation. Remove the four mounting capscrews and the fuel filter head.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Filter Head Page 6-43 Assemble Automotive and Industrial Apply Loctite™ 648 sealant, or equivalent, to the filter adapter threads that are engaging the fuel filter head only. Assemble the filter head. Install the fuel filter adapter and fuel heater. Torque Value: 30 N•m [ 22 ft-lb ] NOTE: Make sure there is an o-ring between the fuel filter head and heater.
Fuel Filter Head Page 6-44 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Install the fuel filter. Refer to Procedure 006-015. Install fuel supply and drain lines. Refer to Procedure 006-024. High Mount Fuel Filter Install the fuel filter head bracket. Install the fuel filter head bracket capscrews. Torque Value: 24 N•m [ 212 in-lb ] Install the fuel filter head. Install the fuel filter head capscrews. Torque Value: 24 N•m [ 212 in-lb ] Install the fuel filter.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Filter Head Page 6-45 Marine Applications NOTE: The filter head is marked with an IN and OUT for the line connections. Be sure the filter head is installed in the same direction as it was removed. Install the fuel filter head. Tighten the retaining capscrews. Torque Value: 30 N•m [ 25 ft-lb ] Prime With Electric Lift Pump WARNING The fuel pump high-pressure fuel lines and fuel rail contain very high-pressure fuel.
Fuel Filter Head Page 6-46 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Without Electric Lift Pump WARNING The fuel pump high-pressure fuel lines and fuel rail contain very high-pressure fuel. Never loosen any fittings while the engine is running. Personal injury and property damage can result. WARNING Be sure that the fuel inlet and return valves are returned to the open position before cranking engine.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Filter Head Bracket Page 6-47 Marine Applications WARNING The fuel pump high-pressure fuel lines and fuel rail contain very high-pressure fuel. Never loosen any fittings while the engine is running. Personal injury and property damage can result. CAUTION Failure to properly prime the fuel system on marine engines can result in damage to the fuel cooler. Be sure the drain valve(s) are open.
Fuel Filter Head Bracket Page 6-48 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Disassemble Remove the fuel heater, if equipped. Refer to Procedure 005-008 Inspect for Reuse Inspect the filter head for cracks, passage blockage, and material or debris on the sealing surfaces. Assemble Apply Loctite 648, or equivalent, to the filter adapter threads that are engaging the filter head only Assemble the filter head. Install the filter adapter and fuel heater.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Manifold (Combined) Page 6-49 Install the fuel filter. Refer to Procedure 006-015 Install fuel return and supply lines. Refer to Procedure 006-024 Run the engine and check for leaks. Fuel Manifold (Combined) (006-019) Preparatory Steps WARNING Fuel is flammable.
Fuel Manifold (Combined) Page 6-50 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Remove Remove the two mounting capscrews and the combined fuel manifold. Disassemble Remove the fittings from the combined fuel manifold. Inspect for Reuse Inspect the manifold for cracks, passage blockage, and material or debris on the sealing surfaces. Inspect the o-rings on the fittings for cuts or damage.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Inlet Restriction Page 6-51 Install Use two capscrews and install the combined fuel manifold to the engine. Tighten the capscrews. Torque Value: 77 N•m [ 57 ft-lb ] Finishing Steps CAUTION Failure to properly prime the fuel system on marine engines can result in damage to the fuel cooler. Be sure the drain valve(s) are open.
Fuel Inlet Restriction Page 6-52 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Setup NOTE: If quick-disconnect fittings have a white tang, push the white tang in to release the line. Disconnect the fuel line from the electronic control module (ECM) cooler exit port. Install a fuel pressure gauge adapter, Part Number 3164044, between the cooling plate and the inlet to the gear pump. Install a vacuum gauge that has a range of at least 0 to 508.0 mm-Hg [0 to 20 in-Hg].
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Inlet Restriction Page 6-53 Remove the banjo bolt from the inlet to the gear pump. Measurement of the fuel inlet restriction requires the use of a pressure gauge adapter kit, Part Number 4918324. Install the M12 male x M12 female adapter, contained in the pressure gauge adapter kit, through the banjo fitting on the inlet to the gear pump.
Fuel Inlet Restriction Page 6-54 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Remove a plug in the portion of the combined fuel manifold and install a Compucheck® vacuum gauge fitting, Part Number 3824842, with a range of at least 0 to 508 mm-Hg [0 to 20 in-Hg]. Initial Check NOTE: For marine applications, open the fuel supply and return valves. Operate the engine to high idle and measure the fuel inlet restriction.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Inlet Restriction Page 6-55 Prime WARNING Depending on the circumstances, 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. WARNING The fuel pump high-pressure fuel lines and fuel rail contain very high-pressure fuel.
Fuel Inlet Restriction Page 6-56 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 WARNING Depending on the circumstances, 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. CAUTION The fuel pump high-pressure fuel lines and fuel rail contain very high-pressure fuel.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Supply Lines Page 6-57 Fuel Supply Lines (006-024) General Information Due to the number of different fuel supply line routings and connector styles, the steps in this procedure have been written to be generic. Some of the illustrations may not represent the parts being removed or installed. WARNING Be sure that the fuel inlet and return valves are returned to the open position before cranking engine.
Fuel Supply Lines Page 6-58 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Directions for service of a two-button quick-disconnect fitting: Remove the quick disconnect style fuel lines by pressing in the locking tangs on both sides of the quick disconnect fitting. To aid removal, a screwdriver may be inserted between the fuel line end and quick disconnect male union.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Supply Lines Page 6-59 Preparatory Steps CAUTION Use caution when disconnecting or removing fuel lines, replacing filters and priming the fuel system that fuel is not spilled or drained into the bilge area. Do not drop or throw filter elements into the bilge area. The fuel and fuel filters must be discarded in accordance with local environmental regulations. NOTE: Clean all fittings before disassembly.
Fuel Supply Lines Page 6-60 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 NOTE: For engines equipped with a fuel cooled ECM cooling plate, there is a fuel supply line connecting the ECM cooling plate to the electric fuel lift pump. Remove the fuel supply line connecting the ECM cooling plate to the electric fuel lift pump, if applicable. Remove the fuel supply line connecting the electric fuel lift pump, to the fuel filter inlet, if applicable.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Supply Lines Page 6-61 Disconnect the fuel line from the high pressure fuel pump to the fuel rail. Disconnect the fuel line from the fuel filter to the high pressure fuel pump. NOTE: Identify the location(s) where the p-clip(s) are located on the fuel line for correct installation of the fuel line. Disconnect the fuel line from the ECM cooling plate to the fuel filter.
Fuel Supply Lines Page 6-62 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Inspect for burrs or debris on metal connectors that may cause leaks. On quick-disconnect fittings, be certain that the o-rings are not frayed or cut, and that the lock tangs are not damaged. Inspect the face of the banjo connector for sealing surface damage. Use new sealing washers during installation. Replace the fuel lines if damaged.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Supply Lines Page 6-63 Inspect the straight thread fittings and fuel lines for cracks, bends or any damage. Replace the fuel lines as necessary. Install NOTE: Engines with a fuel cooled ECM cooling plate will have a fuel supply line connecting the ECM cooling plate to the inlet to the gear pump. Install the fuel supply line connecting the ECM cooling plate to the inlet to the gear pump, if applicable.
Fuel Supply Lines Page 6-64 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 NOTE: For engines equipped with a fuel cooled ECM cooling plate, there is a fuel supply line connecting the ECM cooling plate to the electric fuel lift pump. Install the fuel supply line connecting the ECM cooling plate to the electric fuel lift pump, if applicable. Install the fuel supply line connecting the electric fuel lift pump to the inlet of the fuel filter head.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Supply Lines Page 6-65 Connect the fuel line from the ECM cooling plate to the fuel filter. Install the p-clip(s) in their original location(s) Torque Value: Fuel Line Straight Thread Connections Step 1 37 N•m [ 27 ft-lb ] Torque Value: P-Clips Step 1 24 N•m [ 221 in-lb ] Connect the fuel line from the fuel lift pump to the ECM cooling plate.
Fuel Supply Lines Page 6-66 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Finishing Steps WARNING Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Supply Lines Page 6-67 WARNING The fuel pump high-pressure fuel lines and fuel rail contain very high-pressure fuel. Never loosen any fittings while the engine is running. Personal injury and property damage can result. After Filter Change: Primary Method: Unlock the manual priming pump handle by turning counterclockwise. Pump the primer handle until resistance is felt (approximately 140-150 strokes).
Injector Page 6-68 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Injector (006-026) General Information WARNING The fuel pump, high-pressure fuel lines, and fuel rail contain very high-pressure fuel. Do not loosen any fittings while the engine is running. Wait at least 10 minutes after shutting down the engine before loosening any fittings in the high-pressure fuel system to allow pressure to decrease to a lower level.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Injector Page 6-69 Setup Low Mount Fuel Drain Manifold 3.9L and 5.9L Engines Without EGR These engines have a quick-disconnect fitting, with a white tang in the fuel return port at the back of the cylinder head. Check for excessive flow in the injector return circuit due to leakage. Remove the quick-disconnect fuel line from the back of the cylinder head and attach the fuel pressure gauge adapter, Part Number 3164044.
Injector Page 6-70 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 High Mount Fuel Drain Manifold with Two Banjo Fittings 5.9L Engines with EGR These engines have a banjo fitting in the fuel return port at the back of the cylinder head. If the pressure relief valve fuel return flow measures zero, proceed with this procedure. If the pressure relief valve fuel return flow is not zero, use the following procedure for reseating or replacement instructions.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Injector Page 6-71 Isolation of the fuel rail pressure relief valve flow from the injector return flow requires the use of the fuel rail pressure relief valve flow tester kit, Part Number 4918295. Remove the banjo bolt from the fuel rail pressure relief valve. Install the fuel rail pressure relief valve fuel drain hose onto the pressure relief valve using the banjo bolt supplied in the tester kit.
Injector Page 6-72 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Remove the banjo bolt from the injector drain line at the fuel return manifold. Insert a fuel drain hose, Part Number 3164618, in place of the banjo bolt. Insert the end of the fuel drain hose into a graduated cylinder, Part Number 3823705, to measure injector return flow. Gear Housing Fuel Drain 4.5L Industrial and Automotive Applications It also applies to 6.7L automotive applications and some 6.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Injector Page 6-73 For engines with a quick-disconnect fitting on the fuel rail pressure relief valve, use a female quick-disconnect drain hose and a block-off fitting to isolate the fuel pressure relief valve flow. Remove the quick-disconnect fitting from the pressure relief valve. Install a pressure gauge adapter, Part Number 4918462, on the fuel rail pressure relief valve and drain into a bucket.
Injector Page 6-74 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Initial Check WARNING Fuel can be returned at highly elevated temperatures. Wear safety glasses and protective gloves and clothing when performing this test. To reduce the possibility of personal injury, avoid contact with returned fuel. WARNING The pressure within the fuel rail is sufficient to penetrate the skin and cause serious personal injury. Wear gloves and protective clothing.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Injector Page 6-75 Test Before attempting to isolate the leak, make sure that all the high pressure fuel connectors are tightened to the correct torque. Refer to Procedure 006-052 in Section 6.. If a connector is not tightened to the proper torque, tighten the connector and perform the previous test again.
Injector Page 6-76 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Repeat the leakage flow test with cylinder one blocked off and record the flow rate. Install the fuel injector supply line. Refer to Procedure 006-051 in Section 6. Repeat the leakage test with each cylinder blocked off. Record the flow rate for each test. The flow rate will decrease below the maximum specified flow when the cylinder with the leak is blocked.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Injector Page 6-77 Remove Disconnect the solenoid wires. Remove the two injector hold-down capscrews and remove the injector hold-down clamp. NOTE: The injector hold-down clamp is not removable on all engines. Use the injector remover, Part Number 3823024, to remove the injector from the cylinder head. NOTE: A small heel pry bar can also be used to pry up the injector.
Injector Page 6-78 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 CAUTION The incorrect sealing washer can cause highpressure fuel leaks and/or performance problems because of incorrect injector protrusion. Verify the injector sealing washer is the correct thickness. Sealing washers 1.5 mm [0.06 in] come in a flat and saucer shape. Install Make sure the injector bore is clean and that only one (1) sealing washer is installed on the injector nozzle.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Injector Page 6-79 Install the injector hold-down and injector hold-down capscrews, but do not tighten. Inspect the fuel connector. Look for burrs or deformation around the inlet and outlet sides of the connector. Check the edge filters for signs of plugging or material contamination. Do not reuse a high-pressure fuel connector if debris is present. Check for o-ring tearing or deterioration.
Injector Page 6-80 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Tighten the injector hold-down capscrews. Make sure to tighten the hold-down capscrews evenly. Check to make sure the gap between the hold-down clamp and the injector is equally spaced around the injector body. Tighten finger-tight and alternate between capscrews, turning 90 degrees per turn until reaching the following torque value. Torque Value: (3.9L and 5.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Return Overflow Valve Page 6-81 Finishing Steps • Install the exhaust rocker and adjust the exhaust valve lash. Refer to Procedure 003-008 in Section 3. • Install the rocker lever cover. Refer to Procedure 003-011 in Section 3. • Install the high-pressure fuel line from the fuel rail to the high-pressure connector. Refer to Procedure 006-051 in Section 6.
Fuel Return Overflow Valve Page 6-82 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Inspect for Reuse Make sure all holes and internal passages are clear and free of debris. Depress the center of the valve at the end of the overflow valve with a soft plastic or wooden object. The valve should depress easily and return fully. Clean Clean the mounting hole with quick-dry contact cleaner.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Injector Supply Lines (High Pressure) Page 6-83 Operate the engine and check for leaks. Injector Supply Lines (High Pressure) (006-051) General Information WARNING The fuel pump, high-pressure fuel lines, and fuel rail contain very high-pressure fuel. Do not loosen any fittings while the engine is running.
Injector Supply Lines (High Pressure) Page 6-84 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Initial Check WARNING While testing the injectors, keep hands and body parts away from the injector nozzle. Fuel coming from the injector is under extreme pressure and can cause serious injury by penetrating the skin. WARNING Fuel is flammable.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Injector Supply Lines (High Pressure) Page 6-85 Install Loosen the capscrews for the fuel rail. Do not remove the fuel rail. The capscrews are loosened to allow proper alignment of the fuel rail after installing the new fuel line. Install and hand-tighten all of the fuel lines. Tighten the Injector High Pressure Supply Lines: 3.9L and 5.9L without electric lift pump. Torque Value: 22 N•m [ 195 in-lb ] 5.
Fuel Connector (Head Mounted) Page 6-86 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Connector (006-052) (Head Mounted) General Information WARNING The fuel pump, high-pressure fuel lines, and fuel rail contain very high-pressure fuel. Do not loosen any fittings while the engine is running. Wait at least 10 minutes after shutting down the engine before loosening any fittings in the high-pressure fuel system to allow pressure to decrease to a lower level.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Connector (Head Mounted) Page 6-87 Remove Remove the fuel connector retaining nut. Install the fuel connector remover, Part Number 3164025. NOTE: When removing the fuel connector from the cylinder head, care must be taken to make sure the connector o-ring is not damaged. Remove the fuel connector from the cylinder head. Clean and Inspect for Reuse Inspect the fuel connector.
Fuel Rail Page 6-88 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Install Lubricate the fuel connector o-ring and the threads on the fuel connector retaining nut. Carefully insert the fuel connector, aligning the guide ball with the slot in the cylinder head at the 12-o'clock position. NOTE: Use even axial force when installing to prevent the possibility of damage. Make sure not to tear the o-ring as the connector is being installed.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Rail Page 6-89 Directions for service of a white tang quick-disconnect fitting: Push in the white tang to release the fuel line. Pull to lock the fuel line. Directions for service of a two-button, quick-disconnect fitting: Remove the quick disconnect style fuel lines by pressing in the locking tangs on both sides of the quick disconnect fitting.
Fuel Rail Page 6-90 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Preparatory Steps Automotive and Industrial WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Rail Page 6-91 WARNING Depending on the circumstance, diesel fuel is flammable. When inspecting or performing service or repairs on the fuel system, to reduce the possibility of fire and resulting severe personal injury, death or property damage, never smoke or allow sparks or flames (such as pilot lights, electrical switches, or welding equipment) in the work area.
Fuel Rail Page 6-92 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Clean and Inspect for Reuse CAUTION Internal passages of the fuel rail can only be cleaned with contact cleaner, Part Number 3824510 or equivalent. Do not use a parts washer to clean the fuel rail. Dirt or Contaminants can damage the fuel system. Inspect the fuel line connections at the fuel rail for cracks or scratches. Inspect the inlets of the high-pressure lines for damaged sealing surfaces.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Rail Page 6-93 CAUTION Injector supply lines and the high-pressure supply line must be torqued prior to tightening the fuel rail cap screws. Install the injector supply line(s) that connect the fuel rail to the fuel injectors. Refer to Procedure 006-051 in Section 6. NOTE: If the fuel filter head bracket capscrews were loosened during removal of the fuel rail, tighten the fuel filter head bracket capscrews.
Fuel Rail Page 6-94 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Finishing Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Connect the batteries. Refer to Procedure 013-009 in Section 13.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Pressure Relief Valve Page 6-95 Fuel Pressure Relief Valve (006-061) General Information WARNING The fuel pump, high-pressure fuel lines, and fuel rail contain very high-pressure fuel. Do not loosen any fittings while the engine is running. Wait at least 10 minutes after shutting down the engine before loosening any fittings in the high-pressure fuel system to allow pressure to decrease to a lower level.
Fuel Pressure Relief Valve Page 6-96 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Directions for service of a two-button quick-disconnect fitting: Remove the quick disconnect style fuel lines by pressing in the locking tangs on both sides of the quick disconnect fitting. To aid removal, a screwdriver may be inserted between the fuel line end and quick disconnect male union.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Pressure Relief Valve Page 6-97 Install a quick-disconnect block-off fitting, Part Number 3164583 onto the drain line removed from the fuel pressure relief valve. 3.9L and 5.9L with Banjo Fitting on Pressure Relief Valve The purpose of this test is to check for a fuel rail pressure relief valve that leaks excessive fuel to the fuel drain line. Disconnect the fuel drain line from the fuel pressure relief valve.
Fuel Pressure Relief Valve Page 6-98 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Two Button Fitting on Pressure Relief Valve The purpose of this test is to check for a fuel rail pressure relief valve that leaks excessive fuel to the fuel drain line. Disconnect the fuel drain line from the fuel pressure relief valve. Attach a fuel drain hose with a female quick-disconnect, Part Number 4918434, to the fuel pressure relief valve.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Pressure Relief Valve Page 6-99 3.9L and 5.9L Engines Disconnect the fuel pressure relief valve line. 4.5L and 6.7L Engines If applicable, remove the cap screw holding the combination temperature and pressure sensor in place. Refer to Procedure Procedure 100-002 (Engine Views) for sensor location. If applicable, remove the air temperature and pressure sensor.
Fuel Pressure Relief Valve Page 6-100 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Install Inspect and clean the sealing surface between the rail and the fuel pressure relief valve. Install the fuel pressure relief valve and tighten. NOTE: Overtightening the fuel pressure relief valve can result in a leak. Torque Value: 100 N•m [ 74 ft-lb ] Finishing Steps 3.9L and 5.9L Engines Connect the fuel pressure relief valve line.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Pressure Relief Valve Page 6-101 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Connect the batteries.
Fuel Cooler Page 6-102 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Cooler (006-062) Preparatory Steps WARNING Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system.
ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Fuel Cooler Page 6-103 Clean and Inspect for Reuse Clean the hose sealing surfaces of the fuel cooler. Inspect the core area of the fuel cooler for debris. Clean if required. Inspect the core for damage to the inter core surfaces. Pressure test the fuel side of the fuel cooler. Install a plug in one end of the cooler. Install fittings and apply shop air pressure.
Fuel Cooler Page 6-104 ISB, ISBe and QSB (Common Rail [...] Section 6 - Injectors and Fuel Lines - Group 06 Finishing Steps WARNING Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system. CAUTION Failure to properly prime the fuel system on marine engines can result in damage to the fuel cooler.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Page 7-a Section 7 - Lubricating Oil System - Group 07 Section Contents Page Engine Oil Heater ........................................................................................................................................................7-3 Clean and Inspect for Reuse......................................................................................................................................
Page 7-b ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Clean........................................................................................................................................................................ 7-28 Finishing Steps.........................................................................................................................................................7-29 Inspect for Reuse.................................................
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Service Tools Page 7-1 Service Tools Lubricating Oil System The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from a local Cummins® Authorized Repair Location. Tool No. Tool Description Tool Illustration Pressure/Vacuum Module 3164491 Used to measure fuel pressure and restriction.
Service Tools Page 7-2 Tool No. ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Tool Description Tool Illustration Tube (Filter) Cutter Used to cut open the filter to permit inspection of the filter element. 3376579 Compucheck® Fitting Used to measure fuel inlet restriction. 3824842 Black Light Lamp (12VDC) 3163338 Black light with rechargeable battery and charger used with fluorescent tracer to locate oil and/or coolant leaks.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Engine Oil Heater Page 7-3 Engine Oil Heater (007-001) Preparatory Steps WARNING Some state and federal agencies 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. If not reused, dispose of in accordance with local environmental regulations.
Engine Oil Heater Page 7-4 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Check for cracks in the heating element. Test Perform a resistance test on the engine lubricating oil heater element. The readings must be a minimum of 91 ohms to a maximum 101 ohms. Install Replace the heater element. Torque Value: 80 N•m [ 59 ft-lb ] Connect oil heater electrical cord. Finishing Steps Refill the engine with clean oil to the correct level.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Cooler Page 7-5 Operate the engine and check for leaks. Lubricating Oil Cooler (007-003) General Information The lubricating oil cooler is mounted between the lubricating oil cooler cover and the cylinder block.
Lubricating Oil Cooler Page 7-6 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 WARNING Coolant is toxic. Keep away from pets and children. If not reused, dispose of in accordance with local environmental regulations. WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Cooler Page 7-7 WARNING Coolant is toxic. Keep away from pets and children. If not reused, dispose of in accordance with local environmental regulations. WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
Lubricating Oil Cooler Page 7-8 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. CAUTION Use a solvent that will not harm copper to clean the oil cooler elements. Use solvent to clean the oil cooler housing and cover.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Cooler Page 7-9 Leak Test Use the lubricating oil cooler pressure test kit, Part Number 3823876, to pressure-test the element to check for leaks. If leaks are detected, replace the element. Air Pressure Test kPa 449 MIN 518 MAX psi 65 75 Install NOTE: Be sure to remove the shipping plugs from the oil cooler element. NOTE: When installing a new lubricating oil cooler be sure to use the correct part number.
Lubricating Oil Cooler Page 7-10 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Finishing Steps Automotive and Industrial CAUTION If the engine does not produce oil pressure in 15 seconds after starting the engine, shut off the engine to avoid component damage. Connect the turbocharger lubricating oil supply line. Refer to Procedure 010-046. Install the lubricating oil filter. Refer to Procedure 007-013. Fill the engine with clean lubricating oil.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Dipstick Page 7-11 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Connect the batteries. Operate the engine and check for leaks.
Lubricating Oil Dipstick Tube Page 7-12 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Wipe off the dipstick, and install it in the dipstick tube housing. Fill the oil pan to the specified high oil level. The high oil level can be found by looking up the oil pan option for the engine serial number on QuickServe OnLine. Remove the dipstick, and scribe an mark across the stick at the oil level. Label the mark with an H to indicate the high oil level.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Filter (Spin-On) Page 7-13 Install Apply a thin bead of thread sealant around the bottom of the knurled end of the tube. Place knurled end of tube into the dipstick tube bore in the cylinder block. Use the dipstick tube installer tool, Part Number 3823875, to install the dipstick tube into the cylinder block. Lightly drive the dipstick tube until it seats against the block casting.
Lubricating Oil Filter (Spin-On) Page 7-14 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Install CAUTION The lack of lubrication during the delay until the filter is pumped full of oil at start-up can damage the engine. Use clean 15W-40 oil to coat the gasket surface of the filter. Fill the filter with clean 15W-40 oil. NOTE: Be careful that no debris is poured into the filter.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Filter Head (Remote Mounted) Page 7-15 Lubricating Oil Filter Head (Remote Mounted) (007-017) Preparatory Steps WARNING To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin. WARNING Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity.
Lubricating Oil Filter Head (Remote Mounted) Page 7-16 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Remove the two mounting capscrews and the lubricating oil filter head. Disassemble CAUTION To prevent the possibility of high filter restriction after installation and causing filter damage, be sure to mark the lubricating lines, oil filter head inlet and outlet ports. Failure to do so can cause the center filter media to break up and be pumped through the engine.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Filter Head (Remote Mounted) Page 7-17 Install CAUTION To prevent the possibility of high filter restriction after installation and causing filter damage, be sure the lubricating lines, oil filter head inlet and outlet ports are orientated correctly to the bracket prior to installation. Failure to do so can cause the center filter media to break up and be pumped through the engine.
Lubricating Oil Filter Head Adapter Page 7-18 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Filter Head Adapter (007-018) Preparatory Steps WARNING To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin. WARNING Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Filter Head Adapter Page 7-19 Inspect the sealing surfaces for signs of leakage or burrs. Use a fine crocus cloth to remove burrs. Install NOTE: Use new o-rings and seal rings when installing the filter head adapter. Install a new o-ring in the groove on the underside of the filter head cover. Install a small o-ring in the groove on the other side of the filter head cover.
Lubricating Oil Leaks Page 7-20 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Finishing Steps Install the lubricating oil lines for the oil filter. Refer to Procedure 007-092 Operate the engine and check for leaks. Lubricating Oil Leaks (007-024) Initial Check WARNING Wear safety glasses or a face shield, as well as protective clothing, to prevent personal injury when using a steam cleaner or high-pressure water.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Pan Page 7-21 Inspect the engine crankcase breather tube and hose for restriction or leaks. Refer to Procedure 003-018 in Section 3. Check for a loose or missing oil dipstick tube, dipstick, or oil fill cap. Lubricating Oil Pan (007-025) Preparatory Steps WARNING Batteries can emit explosive gases.
Lubricating Oil Pan Page 7-22 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Remove Oil Pan, Suspended Remove the lubricating oil pan support mounting flange and gasket. Remove the suction tube, if necessary. Refer to Procedure 007-035 in Section 7. Oil Pan, Standard Remove the lubricating oil pan and gasket. Discard the gasket. Remove the suction tube, if necessary. Refer to Procedure 007-035 in Section 7.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Pan Page 7-23 Oil Pan, Formed-in-Place Gasket Remove the lubricating oil pan. NOTE: You can damage the lubricating oil pan flange by using a pry bar or screwdriver to break the formed-inplace gasket seal. Use a utility knife to cut the seal and loosen the pan. Remove the suction tube, if necessary. Refer to Procedure 007-035 in Section 7.
Lubricating Oil Pan Page 7-24 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Inspect the oil pan support flange, suction tube, and tube braces for cracks or other damage. NOTE: If cracks or other damage is found, replace the damaged part. Do not attempt to repair the oil pan by welding. If the suction tube must be replaced, Refer to Procedure 007-035 in Section 7.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Pan Page 7-25 Oil Pan, Formed-in-Place Gasket If installing a formed-in-place gasket pan, apply a 4-mm [1/8-inch] bead of sealant, Part Number 3164070, to the oil pan mounting surfaces at the cylinder block to front gear housing joints and the cylinder block to rear gear housing joints. Make sure there is a continuous sealing path.
Lubricating Oil Pan Page 7-26 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Oil Pan, Standard Assemble a new gasket onto the oil pan. Four-Cylinder Tighten all capscrews in the sequence shown in the illustration. Torque Value: 28 N•m [ 249 in-lb ] Six-Cylinder Tighten all capscrews in the sequence shown in the illustration. Torque Value: 28 N•m [ 249 in-lb ] Clean and check the oil drain plug threads and sealing surface. Install and tighten the oil pan drain plug.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Pressure Regulator (Main Rifle) Page 7-27 Finishing Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Fill the engine with clean lubricating oil.
Lubricating Oil Pressure Regulator (Main Rifle) Page 7-28 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Clean WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Pressure Regulator (Main Rifle) Page 7-29 Measure the pressure regulator spring at the following heights. Pressure Regulator Spring Pressure N @41.25 mm [1.624 in] 127 MIN @44.50 mm [1.752 in] 109 MIN lb 29 25 NOTE: When the load is 105 N [24 lb], the regulator valve opens. When the load is 142 N [32 lb], the regulator valve is seated.
Lubricating Oil Pump Page 7-30 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Pump (007-031) Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Disconnect the batteries. Remove the drive belt.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Pump Page 7-31 Remove the belt guards. Refer to Procedure Procedure 008-001 Remove the seawater pump drive belt. Refer to Procedure Procedure 008-126 Remove the water pump drive belt. Refer to Procedure Procedure 008-002 Remove the fan hub. Refer to Procedure Procedure 008-039 Remove the crankshaft position sensor.
Lubricating Oil Pump Page 7-32 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Some solvents are flammable and toxic. Read the manufacturer's instructions before using.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Pump Page 7-33 If debris has been expected to have gone through the lubricating oil pump, the rear cover plate can be removed to inspect for internal damage. NOTE: The lubricating oil pump is serviced/replaced as an assembly. No internal parts are available for rebuild/ replacement. Inspect the rear cover plate for scoring or grooves.
Lubricating Oil Pump Page 7-34 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Measure the clearance of the gerotor drive/gerotor planetary to port plate. Gerotor Drive/Planetary to Port Plate Limit mm in 0.127 MAX 0.005 Measure the gear backlash. Backlash Limits (used pump) mm 0.170 MIN 0.300 MAX in 0.007 0.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Pump Page 7-35 Using the sequence shown, torque the capscrews in the following sequence: Initial Torque Torque Value: 8 N•m [ 70 in-lb ] Final Torque Torque Value: 24 N•m [ 212 in-lb ] NOTE: The back plate on the pump seats against the bottom of the bore in the cylinder block. When the lubricating oil pump is correctly installed, the flange on the lubricating oil pump will not touch the cylinder block.
Lubricating Oil Pump Page 7-36 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Connect batteries. Operate the engine and check for leaks. Install the front gear cover.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Suction Tube (Block-Mounted) Page 7-37 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Connect the batteries.
Lubricating Oil Suction Tube (Block-Mounted) Page 7-38 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Remove Remove the suction tube mounting capscrews. Remove the suction tube. Clean and Inspect for Reuse Using a putty knife, clean the gasket surfaces. Clean the suction tube surface with hot, soapy water. Inspect the suction tube for cracks. Install CAUTION The suction tube gasket is not symmetrical.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Suction Tube (Block-Mounted) Page 7-39 Finishing Steps Install oil pan and gasket. Refer to Procedure Procedure 007-025 Fill the engine with lubricating oil. Refer to Procedure Procedure 007-037 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries.
Lubricating Oil System Page 7-40 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil System (007-037) Measure WARNING Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. If not reused, dispose of in accordance with local environmental regulations.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil System Page 7-41 Increase engine speed to rated speed and hold for 30 seconds. Record the lubricating oil pressure readings at rated engine speed. Oil Pressure at Rated Engine Speed kPa psi 207 MIN 30 Remove the oil pressure gauge/Compuchek® fitting and install the previously removed plug. For pipe plugs, Refer to Procedure Procedure 017-007.
Lubricating Oil System Page 7-42 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 WARNING Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. If not reused, dispose of in accordance with local environmental regulations. WARNING To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil System Page 7-43 NOTE: Use a high-quality 15W-40 multiviscosity oil, such as Cummins Premium Blue®, or its equivalent, in Cummins® engines. Choose the correct oil for your operating climate. Refer to Cummins Engine Oil Recommendations, Bulletin 3810340 Fill the lubricating oil pan with clean 15W-40 lubricating oil to the low level.
Lubricating Oil Contamination Page 7-44 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Shut off the engine. Wait approximately 5 minutes to let the oil drain from the upper parts of the engine. Check the level again. Add oil as necessary to bring the oil level to the H (high) mark on the dipstick. Lubricating (007-044) Oil Contamination General Information Lubricating Oil Dilution CAUTION Diluted oil can cause severe engine damage.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Contamination Page 7-45 During operation, the lubricating oil pressure will be higher than coolant pressure. A leak in the lubricating oil cooler will show as lubricating oil in the coolant. However, following an engine shutdown, the residual pressure in the coolant system can cause coolant to seep through the leak path into the lubricating oil.
Lubricating Oil Contamination Page 7-46 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Use the following logic to determine the source of the oil dilution with fuel: A worn or damaged fuel injection pump shaft seal will allow fuel to leak into the gear housing and then into the lubricating oil pan. The seal is designed to provide increased sealing as the pump case pressure increases. Pressure forces the lip (1) tighter around the shaft.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Contamination Page 7-47 To check for such a leak, or a damaged seal (Bosch® VE only) , remove the fuel drain manifold connection (1) at the pump, and install a plug (2). Remove the access cover, and rotate the engine so one of the holes in the fuel injection pump gear exposes the back gear housing. Activate the fuel shutdown valve by turning the switch to the ON position.
Lubricating Oil Contamination Page 7-48 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Incomplete combustion in the cylinders can result in unburned fuel draining into the oil pan. This condition can be caused by a leaking injector or reduced compression caused by inadequate piston ring sealing. An increase in white exhaust smoke during the first start of the day is a symptom that an injector is leaking.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil and Filter Analysis Page 7-49 Another remote possibility, is that a crack or porosity in the head casting will allow fuel to leak to the air intake and onto the cylinders. Lubricating Oil Pressure Sensor, OEM (007-052) Remove Disconnect the wire from the sending unit. Remove the pressure sensor. NOTE: The sending units illustrated can differ from those installed by the original equipment manufacturer (OEM).
Lubricating Oil and Filter Analysis Page 7-50 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 For additional oil analysis information, refer to Cummins® Engine Oil and Oil Analysis Recommendations, Bulletin 3810340. NOTE: Do not disassemble an engine for repair based solely on the results of an oil analysis. Inspect the oil filters. If an oil filter shows evidence of internal engine damage, find the source of the problem and repair the damage.
ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Lubricating Oil Lines Page 7-51 Lubricating Oil Lines (007-092) Remove WARNING To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin. WARNING Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil.
Lubricating Oil Lines Page 7-52 ISB, ISBe and QSB (Common Rail [...] Section 7 - Lubricating Oil System - Group 07 Install CAUTION When installing the lubricating oil lines, make sure the oil lines are not touching or rubbing each other or any other engine parts. Damage to the lines can result in a loss of engine lubricating oil pressure. Install the hoses to the lubricating oil filter connectors and tighten finger tight.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Page 8-a Section 8 - Cooling System - Group 08 Section Contents Page Belt Guard ....................................................................................................................................................................8-3 Inspect for Reuse........................................................................................................................................................8-4 Install.......
Page 8-b ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System .........................................................................................................................................................8-29 Coolant Replacer Method.........................................................................................................................................8-30 Drain...................................................................................
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Page 8-c Finishing Steps.........................................................................................................................................................8-71 Flush.........................................................................................................................................................................8-66 Inspect for Reuse.........................................................
Page 8-d ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Clean and Inspect for Reuse....................................................................................................................................8-97 Finishing Steps.........................................................................................................................................................8-98 General Information......................................................................
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Service Tools Page 8-1 Service Tools Cooling System The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from a local Cummins® Authorized Repair Location. Tool No. Tool Description Tool Illustration Combustion Gas Leak Tester Used to test for combustion gasses in the cooling system.
Service Tools Page 8-2 Tool No. ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Tool Description Tool Illustration Coolant Dam/Pressure Tester 3824319 Using shop air pressure the coolant dam creates a vacuum, holding the coolant in with little or no coolant loss. Black Light Lamp (12VDC) 3163338 Used with fluorescent tracer to locate coolant and/or oil leaks. Lamp operates off vehicle battery or portable rechargeable battery included in kit.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Belt Guard Page 8-3 Belt Guard (008-001) Remove Remove the two wing nuts (A) and three capscrews (B) on the sea water pump belt guard. Remove the upper belt guard. Remove the three wing nuts on the alternator/engine water pump belt guard. Remove the lower belt guard. Remove the five rubber isolators from the upper and lower belt guard mounting studs.
Belt Guard Page 8-4 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Inspect for Reuse Inspect the belt guards for cracks or other damage. If damaged, they must be replaced. Inspect the isolators for damage. If the isolators are hard and brittle, they must be replaced. If damaged or bent, replace the belt guard studs. Install NOTE: Two of the studs are attached with nuts from the rear side of the gear housing. Install and tighten the five studs and nuts as shown.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Drive Belt, Cooling Fan Page 8-5 Align and install the upper belt guard to the engine. Tighten the wing nuts (A) finger tight. Attach the top belt guard to the lower belt guard and engine; use the three mounting capscrews (B). Torque Value: 5 N•m [ 44 in-lb ] Drive Belt, Cooling Fan (008-002) Remove CAUTION The belt tensioner is spring-loaded and must be pivoted away from the drive belt.
Drive Belt, Cooling Fan Page 8-6 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Inspect the idler pulleys for wear or cracks. Plastic pulleys often have a build-up of road dirt and belt material that is not to be confused with wear. The dirt can be removed with a suitable tool to check for wear. Clean, check and reuse idlers with a build up of dirt, rather than replacing. Replace the belt tensioner idler.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Coolant Heater Page 8-7 Coolant Heater (008-011) Preparatory Steps WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
Coolant Heater Page 8-8 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Clean and Inspect for Reuse Clean the cup plug bore (or hole) thoroughly with a clean rag. Make sure there are no burrs, metal shavings, or sharp edges that can possibly cut the o-ring. WARNING To reduce the possibility of personal injury, do not touch the electrical supply wires or component while the testing procedure is in action. Check the coolant heater for cracks on the element.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Coolant Thermostat Page 8-9 Threaded Lubricate the new heater o-ring with clean engine oil. Install the heater. Tighten the retaining nut. Torque Value: 55 N•m [ 41 ft-lb ] Finishing Steps WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. • Attach the heater electrical cord. • Fill the engine cooling system. Refer to Procedure 008-018.
Coolant Thermostat Page 8-10 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 CAUTION Never operate the engine without a thermostat. Without a thermostat, the path of least resistance for the coolant is through the bypass to the water pump inlet. This can cause the engine to overheat. An incorrect or malfunctioning thermostat can cause the engine to run too hot or too cold. CAUTION A missing check ball can cause the engine to run cold, resulting in engine damage.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Coolant Thermostat Page 8-11 WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
Coolant Thermostat Page 8-12 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Install a hose of the same size on the water outlet connection long enough to reach a remote, dry container used to collect coolant. Install and tighten a hose clamp on the water outlet connection. Place the other end of the hose in a dry container. Operate the engine at rated rpm for 1 minute. Shut off the engine and measure the amount of coolant collected in the container.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Coolant Thermostat Page 8-13 Complete the following test in-chassis to test the thermostat opening temperature. Start the engine and monitor the water temperature with an electronic service tool or a gauge.
Coolant Thermostat Page 8-14 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Remove NOTE: This stepblock does not apply to QSB5.9 marine engines with keel cooling. Remove the water outlet connection capscrews. Remove the water outlet connection. Remove the thermostat. On QSB5.9 marine engines with keel cooling, remove the water inlet connection capscrews and the water inlet connection from the thermostat housing used with keel cooling.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Coolant Thermostat Page 8-15 NOTE: Do not allow the thermostat or thermometer to touch the container. Suspend the thermostat and a thermometer in a container of water. 100°C [212°F] To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
Coolant Thermostat Page 8-16 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Heat the water and check the thermostat as follows: The nominal operating temperature is stamped on the thermostat. The thermostat must meet the following criteria: • It must begin to open within 1°C [2°F] of nominal temperature. • It must be fully open within 12°C [22°F] of nominal temperature.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Coolant Thermostat Page 8-17 Install CAUTION Always use the correct thermostat and do not operate the engine without a thermostat installed. The engine can overheat if operated without a thermostat because the path of least resistance for the coolant is through the bypass to the pump inlet. An incorrect thermostat can cause the engine to overheat or run too cold. Install the thermostat into the thermostat housing.
Coolant Thermostat Page 8-18 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Finishing Steps CAUTION Always vent the engine during filling to remove air from the coolant system, or overheating can result. On marine applications with heat exchangers, install the heat exchanger coolant hose.Refer to Procedure 008-053. Fill the cooling system.Refer to Procedure 008-018. NOTE: On engines with EGR, the pipe plug in the EGR coolant line must be removed during filling.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Coolant Thermostat Housing Page 8-19 Operate the engine and check for leaks. Coolant Thermostat Housing (008-014) General Information This procedure applies to QSB5.9 keel cooled engines only To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
Coolant Thermostat Housing Page 8-20 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Coolant is toxic. Keep away from children and pets.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Coolant Thermostat Housing Page 8-21 Leak Test The engine thermostat and thermostat seal must operate properly in order for the engine to operate in the most efficient heat range. Overheating or overcooling will shorten engine life. Fabricate a test fixture to seal all of the water connections except the outlet port to the keel cooler and the inlet port of the thermostat housing.
Coolant Thermostat Housing Page 8-22 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Disassemble Remove the three capscrews and hose connections from the ends of the thermostat housing. Remove the o-rings from the ends of the housing. Remove the keel cooler hose connections. Remove the coolant vent fitting and pipe plugs from the housing. Clean and Inspect for Reuse WARNING Wear appropriate eye and face protection when using compressed air.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Coolant Thermostat Housing Page 8-23 Assemble Install the thermostat into the thermostat housing. Install a new o-ring on the thermostat housing. Install the water inlet connection and three mounting capscrews. Tighten the capscrews. Torque Value: 44 N•m [ 32 ft-lb ] Install a new o-ring on the other end of the thermostat housing and the water outlet connection. Install the three capscrews and tighten.
Coolant Thermostat Housing Support Page 8-24 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Finishing Steps • Install the coolant inlet and outlet hoses. • Install the coolant vent line. Refer to Procedure 008-017 • Install the keel cooler inlet and outlet hoses. Refer to the OEM troubleshooting and repair manual. • Fill the engine with coolant. Refer to Procedure 008-018 • Connect the batteries. Refer to Procedure 013-009 Operate the engine and check for leaks.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Coolant Thermostat Housing Support Page 8-25 Remove Remove the three thermostat housing support mounting capscrews and the thermostat housing support. Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Some solvents are flammable and toxic.
Coolant Vent Lines Page 8-26 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Install Install the thermostat housing bracket and mounting capscrews. Tighten the capscrews. Torque Value: 44 N•m [ 32 ft-lb ] Finishing Steps • Install the thermostat housing. Refer to Procedure 008-014 • Fill the engine with coolant. Refer to Procedure 008-018 Operate the engine and check for leaks. Coolant Vent Lines (008-017) General Information This procedure applies to the QSB5.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Coolant Vent Lines Page 8-27 Preparatory Steps WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
Coolant Vent Lines Page 8-28 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Disconnect the coolant vent line from the top of the expansion tank and the top of the thermostat housing. Install Connect the coolant vent line at the top of the expansion tank and the top of the exhaust manifold. Connect the coolant vent line for the turbocharger at the top of the expansion tank. Connect the coolant vent line to the top of the turbocharger.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System Page 8-29 Finishing Steps • Fill the cooling system. Refer to Procedure 008-018 Operate the engine and check for leaks. Cooling System (008-018) General Information WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
Cooling System Page 8-30 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Fill the cooling system with coolant to the bottom of the fill neck in the radiator fill or recovery/expansion tank. NOTE: Some radiators have two fill necks, both of which must be filled when the cooling system is drained. Coolant Replacer Method Evacuation The following steps are used to evacuate the cooling system using the coolant replacer tool, Part Number 2892459.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System Page 8-31 WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. CAUTION Do not use the coolant replacement tool to evacuate contaminated coolant or a system that is suspected of contamination. This could result in cross contamination of coolant.
Cooling System Page 8-32 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Attach the fill hose quick disconnect coupling (1) of the coolant replacement tool to the quick disconnect fitting. Location of the fitting may vary between OEMs, but the fitting is generally located in the lowest point of the vehicle/equipment cooling system package. NOTE: Most Volvos are equipped with a different style fitting located in the radiator.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System Page 8-33 Injection CAUTION The cooling system must be filled properly to prevent air locks or serious engine damage can result. The following steps are used to inject coolant into the cooling system using the coolant replacer tool, Part Number 2892459.
Cooling System Page 8-34 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Be sure there is no air pressure in the coolant replacement tool tank by opening the pressure relief valve (1) located on the control block of the coolant replacement tool. Connect the coolant replacement tool to a shop air supply regulated at 621 kPa [90 psi].
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System Page 8-35 CAUTION The cooling system must be filled properly to prevent air locks or serious engine damage can result. NOTE: If all coolant drained from the system was collected, the same volume or more must go back into the system.
Cooling System Page 8-36 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Attach the coolant dam handle (1) to the fill hose of the coolant replacement tool. Attach the appropriate size coolant dam rubber adapter (1) onto the coolant dam handle. The size of the fill neck will differ between OEMs choose the appropriate sized coolant dam rubber adapters. Connect the coolant replacement tool to shop air regulated at 621 kPa [90 psi].
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System Page 8-37 When air bubbles are no longer being drawn to the top of the cooling system move the control lever to the middle position. Remove the vacuum on the coolant replacement tool tank by opening the pressure relief valve located on the control block of the coolant replacement tool (1). Remove the coolant dam from the radiator fill neck or overflow tank.
Cooling System Page 8-38 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Check for damaged hoses and loose or damaged hose clamps. Replace as required. Check the radiator for leaks, damage, and buildup of dirt. Clean and replace as required. After the cooling system is completely drained, close the drain valves. Reference the OEM service manual for complete cooling system drain information. Marine Applications WARNING Do not remove the pressure cap from a hot engine.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System Page 8-39 Fill Automotive and Industrial CAUTION The system must be filled properly to prevent air locks or serious engine damage can result. During filling, air must be vented from the engine coolant passages. Wait 2 to 3 minutes to allow air to be vented; then add mixture to bring the level to the top.
Cooling System Page 8-40 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [122°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. WARNING Do not stand near the surge tank or radiator while operating the engine with the pressure cap off.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System Page 8-41 Figure 1: Sequence of Events for Coolant Fill and Deaeration. NOTE: If all coolant drained from the system was collected, the same volume or more must go back into the system. If any drained coolant remains after filling, this is an indication of an air pocket which must be purged before returning the vehicle to service.
Cooling System Page 8-42 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Marine Applications QSB5.9 with Heat Exchanger CAUTION To avoid engine damage, the system must be filled properly to reduce the possibility of air locks. During filling, air must be vented from the engine coolant passages. Wait 2 to 3 minutes to allow air to be vented; then add mixture to bring the level to the top. CAUTION Never use water alone for coolant.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System Page 8-43 Fill the engine with the correct coolant. Use a mixture of 50-percent water and 50-percent ethylene glycol or propylene glycol antifreeze to fill the cooling system. Reference the Cummins® Coolant Requirements and Maintenance, Bulletin 3666132. Fill the engine until coolant is visible from the keel-cooled thermostat housing. Close the aftercooler and remote mounted heater petcocks.
Cooling System Page 8-44 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 NOTE: An alternate to using sodium carbonate, as outlined in this procedure, is to use Restore™. Restore™ is a heavy-duty cooling system cleaner that removes corrosion products, silica gel, and other deposits. The performance of Restore™ is dependent on time, temperature, and concentration levels.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System Page 8-45 WARNING Coolant is toxic. Keep away from children and pets. Dispose of in accordance with local environmental regulations. WARNING Do not stand near the surge tank or radiator while operating the engine with the pressure cap off. If the vehicle is equipped with a fill door on side of the surge tank, keep it closed due to coolant expansion.
Cooling System Page 8-46 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 WARNING Do not stand near the surge tank or radiator while operating the engine with the pressure cap off. If the vehicle is equipped with a fill door on side of the surge tank, keep it closed due to coolant expansion. CAUTION Do not operate the engine with the pressure cap off at temperatures above 93°C [200°F].
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System Page 8-47 Marine Applications RESTORE™ is a heavy-duty cooling system cleaner that removes corrosion products, silica gel, and other deposits. The performance of RESTORE™ is dependent on time, temperature, and concentration levels. An extremely scaled or flow-restricted system, for example, can require higher concentrations of cleaners, higher temperatures, longer cleaning time,s or the use of RESTORE Plus™.
Cooling System Page 8-48 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Fill the cooling system with clean water. WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [122°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury. Operate the engine for 5 minutes with the coolant temperature above 85°C [185°F].
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System Diagnostics Page 8-49 Cooling System Diagnostics (008-020) General Information The following procedure covers common troubleshooting steps to help identify: • Engine overheat causes. See the Initial Check step of this procedure. NOTE: At the end of this procedure, a worksheet is provided to record any measured values taken during troubleshooting. The worksheet will help in gathering and analyzing the data.
Cooling System Diagnostics Page 8-50 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Check the coolant temperature when the shutters are opened. Compare this value to what is stamped on the shutter control. Cummins Inc. recommends that the shutters open at 85°C [185°F]. Check the coolant temperature when the fan is engaged. Compare this value to what is stamped on the fan control. Cummins Inc. recommends that the fan engage at 96°C [205°F].
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System Diagnostics Page 8-51 Pressure Test Check the coolant level and fill if necessary. Refer to Procedure 008-018 in Section 8. To aid in determining the location of the coolant leak, it may be necessary to add fluorescent tracer, Part Number 3377438, to the coolant. Add one unit of fluorescent tracer to each 38 liters [10 U.S. gallons] of coolant.
Cooling System Diagnostics Page 8-52 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 The Coolant Dam™/Pressure Tester service tool, Part Number 3824319, can also be used to pressurize the cooling system. The Coolant Dam™/Pressure Tester uses shop air rather than a hand air pump. For external coolant leaks, inspect the exterior of the engine for coolant leaks and repair if necessary. Pay close attention to areas around the: • Lubricating oil cooler.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System Diagnostics Page 8-53 For suspected fuel in the coolant/coolant in the fuel, disconnect the fuel drain connection at the rear of the cylinder head. Refer to Procedure 006-013 in Section 6. NOTE: For engines with quick-disconnect fittings, it may be necessary to remove the check valve installed in the fuel drain port in the cylinder head to gain access to the fuel drain port.
Cooling System Diagnostics Page 8-54 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Pour the test fluid into the combustion gas leak test instrument until it is up to the yellow fill line on the instrument. Insert the rubber tip of the combustion gas leak test instrument into the radiator fill neck. Hold the instrument down firmly and turn back and forth to make certain that an airtight seal is formed between the tester and the radiator fill neck.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System Diagnostics Page 8-55 If the color of the test fluid does not change from blue to yellow or green during the 30-minute test period, return the engine to low idle. Check the test instrument to make sure it is firmly sealed in the radiator fill neck. Insert the tip of the rubber ball into the hole in the top of the test instrument.
Cooling System Diagnostics Page 8-56 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 A positive result from the combustion gas leak tester indicates the following: • Cylinder head gasket or cylinder head casting leakage. Refer to Procedure 002-004 in Section 2. • On marine engines, the wet exhaust manifold can be cracked. Refer to Procedure 011-008 in Section 11.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling System Diagnostics Page 8-57 Operate the engine at rated rpm until it reaches a temperature of 82°C [180°F]. Check for a continuous flow of air bubbles from the hose in the water container. NOTE: The engine coolant temperature must be stable to perform this test. An increasing coolant temperature will give a false indication of air due to expansion of the coolant in the system.
Fan Hub, Belt Driven Page 8-58 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 200 205 Cool engine down Fan Clutch, On-Off (008-027) General Information All fan clutches can be controlled by the engine electronic control module (ECM). The ECM monitors coolant temperature and intake manifold termperature to determine when to engage the cooling fan.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Fan Hub, Belt Driven Page 8-59 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Disconnect the batteries. Refer to Procedure 013-009 (Battery Cables and Connections) in Section 13.
Fan Hub, Belt Driven Page 8-60 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Clean and Inspect for Reuse WARNING When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury. WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. Steam clean the exterior of the fan hub. Dry with compressed air.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Fan Hub, Belt Driven Page 8-61 Install Install the fan hub. Torque Value: 33 N•m [ 24 ft-lb ] Install the hub with four mounting capscrews. Torque Value: 33 N•m [ 24 ft-lb ] Install the fan hub pulley with the six mounting capscrews. Torque Value: 12 N•m [ 106 in-lb ] Finishing Steps WARNING Batteries can emit explosive gases.
Fan Shroud Assembly Page 8-62 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Install the drive belt, cooling fan. Refer to Procedure 008-002 (Drive Belt, Cooling Fan) in Section 8.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Fan Spacer and Pulley Page 8-63 Install To install the fan shroud, refer to the original equipment manufacturer's manual. Fan Spacer and Pulley (008-039) Preparatory Steps Remove the cooling fan drive belt. Refer to Procedure 008-002 (Drive Belt, Cooling Fan) in Section 8. Remove Remove the four fan capscrews, fan, and spacer. Remove the cooling fan drive belt. Refer to Procedure 008-002 (Drive Belt, Cooling Fan) in Section 8.
Fan Spacer and Pulley Page 8-64 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Inspect the fan pulley for cracks near the bolt holes and for damage at the drive belt contact surface. If damage is found on the fan pulley, the fan hub must also be inspected. Refer to Procedure 008-036 (Fan Hub, Belt Driven) in Section 8. Install Install the fan pulley. Install the cooling fan and drive belt. Refer to Procedure 008-002 (Drive Belt, Cooling Fan) in Section 8.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Fan, Cooling Page 8-65 Fan, Cooling (008-040) Inspect for Reuse WARNING Do not rotate the engine by pulling or prying on the fan. The fan blade(s) can be damaged and cause the fan to fail and cause personal injury or property damage. Use the accessory drive shaft or the crankshaft barring tool to rotate the crankshaft. A visual inspection of the cooling fan is required daily.
Marine Gear Oil Cooler Page 8-66 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Marine Gear Oil Cooler (008-041) Flush Shut off the sea water inlet valve on the vessel hull, if so equipped. Remove the marine gear oil cooler drain plug and drain the sea water from the gear oil cooler. Disconnect the sea water inlet and outlet connections. Use clean water to back flush all the debris from the cooler.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Marine Gear Oil Cooler Page 8-67 Open the sea water valve on the vessel hull, if closed. Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.
Marine Gear Oil Cooler Page 8-68 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Remove CAUTION Removing the sea water supply line for the shaft log seal will allow sea water to leak into the vessel, if the line is not plugged. To reduce the possibility of damage, be sure to plug the supply line and prevent sea water from leaking into the vessel. Remove the aftercooler sea water discharge hose from the gear cooler.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Marine Gear Oil Cooler Page 8-69 WARNING Troubleshooting with high pressure air presents the risk of equipment damage, personal injury, or death. Troubleshooting must be performed by trained, experienced technicians. WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.
Marine Gear Oil Cooler Page 8-70 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Submerge the cooler into a tank of water for one minute. Inspect for air leaks at the braze joints of the end caps and any bubbles from the gear oil ports. If leaks are detected, replace the gear oil cooler. Remove the cooler from the tank. Shut off the air supply and disconnect the air supply. Remove the test equipment.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Marine Gear Oil Cooler Page 8-71 Install Install the marine gear oil cooler to the mounting bracket with two mounting capscrews. Tighten the capscrews. Torque Value: 18 N•m [ 159 in-lb ] Install the mounting bracket to the engine block with two mounting capscrews. Tighten the capscrews. Torque Value: 44 N•m [ 32 ft-lb ] Install the marine gear oil cooler sea water discharge hose and tighten the hose clamp.
Radiator Page 8-72 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Radiator (008-042) General Information Air forced through the fins of the radiator by a fan cools the coolant pumped through the radiator. Environmental debris (such as paper, straw, lint, and dust) can obstruct the fins and stop the flow of air, which will reduce the cooling effect of the radiator. Initial Check WARNING Wear appropriate eye and face protection when using compressed air.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Radiator Pressure Cap Page 8-73 WARNING If a liquid refrigerant system (air conditioning) is used, wear eye and face protection, and wrap a cloth around the fittings before removing. Liquid refrigerant can cause serious eye and skin injuries. WARNING To protect the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas into the atmosphere.
Expansion Tank Page 8-74 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Pressure-test the radiator cap. Refer to the OEM service manual for radiator cap test procedures. The pressure cap must seal within 14 kPa [2 psi] of the value stated on the cap, or it must be replaced. An incorrect or malfunctioning cap can result in the loss of coolant and the engine running hot.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Expansion Tank Page 8-75 Initial Check Check the expansion tank, connections for signs of leaks. hoses and vent line Check the expansion tank, hoses, and vent line connections for signs of leaks. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
Expansion Tank Page 8-76 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Coolant is toxic. Keep away from children and pets.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Expansion Tank Page 8-77 Remove the coolant vent lines at the front of the expansion tank. Remove the four mounting capscrews and lift the expansion tank from the engine. Disconnect the coolant make-up hose from the expansion tank and the coolant transfer tube. Remove the coolant vent lines from the rear of the expansion tank.
Expansion Tank Page 8-78 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Remove the mounting capscrews and the expansion tank. Refer to the OEM troubleshooting and repair manual. Inspect for Reuse Inspect the mounting areas for cracks. Inspect all connection points for cracks or signs of leakage. Inspect the fill neck and pressure cap for leakage or cracks. Inspect the mounting areas for cracks. Inspect all connection points for cracks or signs of leakage.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Expansion Tank Page 8-79 Install the vent line connections at the front of the expansion tank. Torque Value: 14 N•m [ 124 in-lb ] Install the fill neck (if removed) Install the turbocharger vent tube to the expansion tank. Torque Value: 14 N•m [ 124 in-lb ] Install the coolant make-up hose and clamps to the expansion tank and coolant transfer tube. Tighten the hose clamps.
Expansion Tank Page 8-80 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Install the coolant make-up hose and clamps to the expansion tank and coolant transfer tube. Tighten the hose clamps. Torque Value: 8 N•m [ 70 in-lb ] Finishing Steps WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. • Connect the engine coolant level sensor connector.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Heat Exchanger Page 8-81 Heat Exchanger (008-053) Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Coolant is toxic. Keep away from children and pets.
Heat Exchanger Page 8-82 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 NOTE: The rear mounting capscrew has a retaining clip. Remove the four mounting capscrews, retaining clamps and isolators, and the heat exchanger. Clean and Inspect for Reuse WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. NOTE: The heat exchanger core can be cleaned and leak tested by a radiator cleaning facility.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Sea Water Pump Page 8-83 Connect the engine coolant heat exchanger inlet hose (1). Connect the engine coolant heat exchanger outlet hose (2). Connect the sea water coolant heat exchanger inlet hose (3). Connect the sea water coolant heat exchanger outlet hose (4). Tighten all of the hose clamps. Torque Value: 8 N•m [ 71 in-lb ] Tighten the heat exchanger mounting capscrews.
Sea Water Pump Page 8-84 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 CAUTION Zinc plugs expand and can break off during removal. Inspect the zinc plug to make sure it is in one piece. Refer to Procedure 008-059. If not, it must be replaced with a new zinc plug, and the broken pieces must be retrieved from the aftercooler to prevent damage to components downstream in the sea water system. Shut off the sea water supply.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Sea Water Pump Page 8-85 CAUTION If the impeller has failed and pieces are missing, all pieces must be retrieved. The engine heat exchanger, gear oil cooler, and sea water aftercooler must be flushed. Refer to procedures 008-053, 008-041, and 010-005 for flushing these components. Failure to do so can result in overheating and damage to engine can occur. Impeller debris can also drop into the inlet piping.
Sea Water Pump Page 8-86 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Be sure to note the direction of impeller fins for proper reinstallation. Mark the outer surface. If the impeller does not have a threaded bore, grasp the hub of the impeller with pliers and remove the impeller from the impeller bore. Inspect for damage such as rips, tears, chunks of material missing, or wear on the edges of the blades. Replace as necessary. Clean the internal pump surfaces.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Sea Water Pump Page 8-87 An oil filter strap wrench or even plastic wire straps can be used as an installation aid to hold the vanes. Guide the impeller into the housing, twisting it counterclockwise as it is advanced so that the vanes will be deflected in the proper direction. Continue to turn the impeller while pushing it into the housing. It will slide all the way in when the keyway lines up with the key.
Sea Water Pump Page 8-88 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Install a new gasket, cover plate, and capscrews. Tighten the capscrews. Torque Value: 24 N•m [ 212 in-lb ] Preparatory Steps CAUTION Zinc plugs expand and can break off during removal. Inspect the zinc plug to make sure it is in one piece.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Sea Water Pump Page 8-89 Remove the four sea water pump mounting capscrews. Rotate the sea water pump top hose connection away from the engine (clockwise when facing the front of the engine) until the mounting flange of the sea water pump aligns with the cutouts on the sea water pump mounting bracket, and remove the sea water pump. Inspect for Reuse Inspect the pump for cracks, leakage points or other exterior damage.
Sea Water Pump Support Page 8-90 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Finishing Steps • • • • • • Install the sea water pump inlet and outlet hoses. Refer to Procedure 008-104. Install the zinc plug in the aftercooler. Refer to Procedure 010-005. Install the sea water pump drive pulley. Refer to Procedure 008-127. Install the sea water pump drive belt. Refer to Procedure 008-126. Open the sea water supply. Install the belt guard. Refer to Procedure 008-001.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Sea Water Pump Support Page 8-91 Remove the sea water pump mounting bracket support. Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Some solvents are flammable and toxic. Read the manufacturer's instructions before using.
Sea Water Pump Support Page 8-92 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Install Install the sea water pump mounting bracket support. Push the mounting bracket support against the front of the cylinder head and hold in place while the capscrews are being tightened to maintain belt alignment. Torque Value: 44 N•m [ 32 ft-lb ] Install the sea water pump mounting bracket and mounting capscrews. Tighten the capscrews.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Zinc Anode Page 8-93 Zinc Anode (008-059) Remove CAUTION Zinc plugs expand and can break off during removal. Inspect the zinc plug to make sure it is in one piece. If not, it must be replaced with a new zinc plug, and the broken pieces must be retrieved from the aftercooler to prevent damage to components downstream in the sea water system.
Water Pump Page 8-94 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Install CAUTION Do not use thread sealant or Teflon™ tape on the zinc anodes. Use of any type of Thread sealant will insulate the zinc anode and prevent a good ground. Install the zinc anode plugs in the aftercooler assembly. Torque Value: 45 N•m [ 35 ft-lb ] Install the zinc anode plug in the bottom of the heat exchanger. Torque Value: 45 N•m [ 35 ft-lb ] Open the sea water supply valve(s).
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Water Pump Page 8-95 Initial Check Inspect the water pump housing for cracks and/or damage. Check the water pump seal weep hole. The water pump seal design requires a coolant film for lubrication and cooling. Therefore, it is normal to observe a minor chemical buildup or streaking at the weep hole. Use the following guidelines to determine if water pump replacement is necessary: Make sure the weep hole is open.
Water Pump Page 8-96 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Marine Applications WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Do not remove the pressure cap from a hot engine.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Water Pump Page 8-97 Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Some solvents are flammable and toxic. Read the manufacturer's instructions before using. WARNING Wear appropriate eye and face protection when using compressed air.
Water Pump Page 8-98 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Install Install a new sealing ring into the water pump groove. Install the water pump and mounting capscrews. Tighten the capscrews. Torque Value: 9.8 Grade 24 N•m [ 212 in-lb ] Torque Value: 10.9 Grade 30 N•m [ 22 ft-lb ] Finishing Steps Automotive and Industrial WARNING Batteries can emit explosive gases.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Water Pump Page 8-99 Marine Applications WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries.
Sea Water Strainer Page 8-100 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Measure Measure the coolant pressure at a coolant tap on the exhaust side of the cylinder head. Marine applications, use the 3/4-inch NPT plug at the rear of the cylinder head. NOTE: Marine applications use the 3/4-inch NPT plug at the rear of the cylinder head.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Sea Water Strainer Page 8-101 NOTE: Sea water strainer arrangements may differ. Inspect the sea water strainer daily for any foreign objects that could restrict water flow. CAUTION A restricted or clogged sea water strainer can result in hotter than normal, or overheated, engine coolant and marine gear oil temperatures. For more detailed information, refer to Sea Water Strainer Cleaning in this section.
Sea Water Strainer Page 8-102 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Remove the sea water strainer assembly. Be careful not to damage o-ring. Retain and inspect for damage. Remove the sea water strainer basket. Clean Marine Applications Empty all debris from the sea water strainer basket. Clean the sea water strainer. Prime Marine Applications Prime the sea water strainer with clean water.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Water Inlet Connection Page 8-103 Assemble Marine Applications Install the sea water strainer. Inspect o-ring seal for tears or damage. Replace if necessary. Be sure o-ring is seated properly. Install and tighten the wing nut(s). Open the sea water inlet valves. Water Inlet Connection (008-082) Initial Check Check the alignment of the fan belt and for evidence of leaks.
Water Inlet Connection Page 8-104 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Disconnect the batteries. WARNING Coolant is toxic. Keep away from children and pets.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Water Inlet Connection Page 8-105 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Coolant is toxic. Keep away from children and pets.
Water Inlet Connection Page 8-106 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Loosen and slide the two hose clamps on the coolant return junction connection hose back on the coolant return junction. Remove the three mounting capscrews from the water inlet connection. Slide the water inlet connection from the coolant return junction and remove the water pump inlet and sealing ring. Discard the sealing ring.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Water Inlet Connection Page 8-107 Inspect the sealing surface for cracks or other damage. Install Install the capscrews, water inlet connection, gasket, and rectangular sealing ring. Align the roll pins against the front face of the cylinder block and tighten the capscrews. Torque Value: M10 Step 1 43 N•m [ 32 ft-lb ] Torque Value: M12 Step 1 80 N•m [ 59 ft-lb ] Install the coolant hoses.
Water Inlet Connection Page 8-108 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Slide the two hose clamps into place on the coolant return junction connection and tighten. Torque Value: 8 N•m [ 71 in-lb ] Finishing Steps WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. Install the fan belt tensioner. Refer to Procedure 008-087 Install the cooling fan drive belt.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Keel Cooler Page 8-109 WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. Fill the engine with coolant. Refer to Procedure 008-018 Install the fan belt tensioner. Refer to Procedure 008-087 Install the alternator mounting bracket. Refer to Procedure 013-003 Install the alternator. Refer to Procedure 013-001 Connect the batteries.
Keel Cooler Page 8-110 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Temperature Differential Test Install temperature probes into the inlet and outlet test ports of the keel cooler thermostat housing. Run the engine under rated rpm and load until the engine temperature reaches its maximum. Record the inlet and outlet coolant temperatures. A temperature differential of 25°C [77°F] or greater is required for adequate system cooling.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Cooling Fan Belt Tensioner Page 8-111 Run the engine under rated rpm and load until the engine temperature reaches its maximum. Record the inlet and outlet coolant pressures. If the pressure difference is less than 34 kPa [5 psi], remove and test the keel cooler thermostat. Refer to Procedure 008-014 If the pressure difference is greater than 34 kPa [5 psi], inspect the vessel's keel coolers.
Sea Water System Diagnostics Page 8-112 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Install Install the belt tensioner. Install and tighten the belt tensioner capscrew. Torque Value: 43 N•m [ 32 ft-lb ] Finishing Steps • Install cooling fan drive belt. Refer to Procedure 008-002.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Sea Water System Diagnostics Page 8-113 Initial Check Locate and verify that the sea water inlet valve is in the full open position. If it is closed or partially closed, open the valve and recheck the engine temperature. Inspect the sea water strainer for foreign objects that could restrict the water flow. Some strainers have clear covers for easy inspection.
Sea Water System Diagnostics Page 8-114 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Test Attach a vacuum gauge to the inlet side of the sea water pump. Start the engine. Record the sea water inlet restriction from low idle to rated speed at 500 rpm increments. This test can be conducted while the vessel is at the dock and not in gear or underway. Refer to Procedure specifications.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Sea Water System Diagnostics Page 8-115 If the sea water inlet restriction readings fluctuate during the test, inspect the sea water supply for leaks or air intrusion. Troubleshooting and repair of excessive sea water restriction is a boat manufacturer or boat owner responsibility. Refer to the vessel's OEM service manual. Troubleshooting and repair for sea water aeration is not covered under Cummins warranty.
Sea Water System Diagnostics Page 8-116 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 If sea water pressure is not present, check the pump for damage. Refer to Procedure 008-057 If the sea water pump outlet pressure is above the maximum specification test the individual sea water system components for excessive pressure drop as described in the Pressure Differential Test step. Refer to Procedure specifications.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Sea Water System Diagnostics Page 8-117 If the pressure drop between the inlet side of the aftercooler and the outlet side of the aftercooler is within specification, attach the pressure gauge to the gear oil cooler drain plug located on the outlet and check for pressure drop across the gear oil cooler.
Sea Water System Diagnostics Page 8-118 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 If the pressure drop across the heat exchanger is within specification, determine the pressure drop across the exhaust elbow (diffuser). This is done by subtracting the heat exchanger outlet pressure form the sea water pump outlet pressure. If this pressure exceeds the maximum specification, check for blockage in the exhaust elbow (diffuser) and exhaust system of the vessel.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Coolant Return Junction Block Page 8-119 If the sea water temperature difference is less than 3°C [5°F], check the heat exchanger for possible plating to the heat exchanger core. Excessive plating or coating to the inside or outside of the cooling tubes will effect the efficiency of the heat exchanger.
Coolant Return Junction Block Page 8-120 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Remove the expansion tank coolant fill tube from the coolant return junction. Loosen the hose clamps on both ends of the coolant return junction and remove the tube. Clean and Inspect for Reuse Clean the inlet connection of the coolant return junction. Inspect the connection ends for cracks or other damage.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Coolant Return Junction Block Page 8-121 Install turbocharger water drain hose and tighten the hose clamps. Torque Value: 8 N•m [ 71 in-lb ] Install the expansion tank fill line tube to the coolant return junction and tighten the hose clamp. Torque Value: 8 N•m [ 71 in-lb ] Finishing Steps WARNING Batteries can emit explosive gases.
Drive Belt, Sea Water Pump Page 8-122 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Drive Belt, Sea Water Pump (008-126) Preparatory Steps • Remove the belt guard. Refer to Procedure 008-001 (Belt Guard) in Section 8. • Remove the belt guard. Refer to Procedure 008-001 (Belt Guard) in Section A. • Remove the belt guard. Refer to Procedure 008-002 (Drive Belt, Cooling Fan) in Section 8.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Drive Belt, Sea Water Pump Page 8-123 Inspect for Reuse Inspect the belts daily. Replace the belts if they are cracked, frayed, or have chunks of material missing. Small cracks are acceptable. Adjust belts that have a glazed or shiny surface, which indicates belt slippage. Correctly installed and tensioned belts will show even pulley and belt wear.
Drive Belt, Sea Water Pump Page 8-124 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 For cogged belts, make sure that the belt tension gauge is positioned so that the center tensioning leg is placed directly over the high point (hump) of a cog. Other positioning will result in incorrect measurement. Refer to Procedure 018-005 (Belt Tension) in Section V for the correct gauge and tension value for the belt width used.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 • Push the pump in, use a pry bar so that the belt can be rolled onto the pulley by hand. • Align the seawater pump. • Place the capscrews back in the pump. • Torque capscrews to specifications. Refer to Procedure 008-057 (Sea Water Pump) in Section 8. • Rotate the pulley clockwise to make sure that the belt is properly aligned. Sea Water Pump Pulley Page 8-125 Finishing Steps • Install the belt guard.
Sea Water Pump Pulley Page 8-126 ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Some solvents are flammable and toxic. Read the manufacturer's instructions before using.
ISB, ISBe and QSB (Common Rail [...] Section 8 - Cooling System - Group 08 Sea Water Pump Pulley Page 8-127 Finishing Steps • Install the sea water pump drive belt. Refer to Procedure 008-126 • Install the belt guard. Refer to Procedure 008-001 Operate the engine and check for leaks. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
Sea Water Pump Pulley Page 8-128 ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Page 9-a Section 9 - Drive Units - Group 09 Section Contents Page Accessory Drive ..........................................................................................................................................................9-1 Assemble....................................................................................................................................................................
Page 9-b ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Finishing Steps.........................................................................................................................................................9-22 Install........................................................................................................................................................................ 9-17 Preparatory Steps..........................................................
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Accessory Drive Page 9-1 Accessory Drive (009-001) Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Disconnect the batteries. Remove the driven accessory.
Accessory Drive Page 9-2 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 NOTE: Make sure the oil supply hole in the accessory drive housing is open and free of debris. Inspect the accessory drive housing for cracks. Inspect the accessory drive gear and shaft splines for cracks, broken teeth, and other damage. NOTE: If there is damage to the accessory drive gear teeth or there are signs of excessive heat, make sure to inspect the associated camshaft and fuel pump gears for damage.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Accessory Drive Page 9-3 WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. Clean the accessory drive components with solvent. Dry with compressed air.
Accessory Drive Page 9-4 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Measure the inside diameter of the bearing bore in the accessory drive adapter housing. Bearing Bore Inside Diameter (Accessory Drive Adapter) mm in 67.759 MIN 2.6755 67.983 MAX 2.6765 If out of specification, replace the housing.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Accessory Drive Page 9-5 Initial Check NOTE: If oil supply to the accessory drive is not required and the gasket does not have oil passages, this check is not required. If the accessory drive uses o-rings for seals, this check is not required. Prior to installing the accessory drive, identify which gasket is going to be installed so that, if necessary, the gasket can be properly oriented.
Hydraulic Pump Drive Page 9-6 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Connect the batteries. Operate the engine and check for leaks.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Hydraulic Pump Drive Page 9-7 NOTE: Refer to the OEM service manual for removal procedures. Remove the hydraulic pump and gear assembly. Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Some solvents are flammable and toxic.
Hydraulic Pump Drive Page 9-8 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Inspect the hydraulic pump drive for cracks, broken teeth, and other damage. Inspect the inside diameter of the drive gear bore for excessive wear or damage; replace if necessary. Install Support the pump in place on the bracket. Insert the bolts through the bracket and the pump. Install the nuts on the end of the bolts. Alternately tighten the bolts.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Hydraulic Pump Drive Page 9-9 Connect all hydraulic lines to the pump. Tighten mounting capscrews. Torque Value: 62 N•m [ 46 ft-lb ] Finishing Steps • Install the pulley onto the hydraulic pump shaft and retaining capscrews. Torque Value: 33 N•m [ 288 in-lb ] • Install the drive belt. Refer to Procedure 008-126 in Section 8. • Remove the hydraulic line connection covers.
REPTO Page 9-10 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 • Remove the hydraulic line connection covers. • Connect all hydraulic lines to the hydraulic pump. • Operate the engine and check for leaks.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 REPTO Page 9-11 9 Seal, o-ring, idler 1 10 Gear, idler 2 assembly (service assembly) 11 X2 housing oil seal o-rings 12 PTO shaft housing screws 13 PTO shaft housing 14 X2 PTO shaft support housing oil seal o-rings 15 PTO shaft housing bearing 16 PTO shaft plug 17 PTO shaft. Preparatory Steps WARNING Batteries can emit explosive gases.
REPTO Page 9-12 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Remove the PTO shaft (4) using an installer/puller tool similar to that shown in the illustration. The tool used must be 5 inches in length and be able to accept the 12mm bolts on the pump mounting face of the flywheel housing. Press the PTO shaft out of the bearing using a large washer or similar to blank the hole in the center of the shaft and by screwing the threaded portion of the tool.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 REPTO Page 9-13 Remove the six retaining bolts and idler 2 support housing. Remove and discard the two oil seal o-rings from the support housing. Remove the three bolts and retainer washer from idler assembly 1. Remove idler assembly 1 and the support shaft. The bearing has a split inner race and part of this remains fixed on the support shaft. The retaining edge part of the inner race is removed in this process.
REPTO Page 9-14 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Clean and Inspect for Reuse WARNING When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury. Use a steam cleaner to clean all areas of the REPTO assembly. Inspect the PTO shaft bearings for wear or damage. Replace the PTO shaft bearings if they are worn or damaged.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 REPTO Page 9-15 Inspect the teeth, side faces, and bore of idler gear 1. Inspect the teeth, side faces, and bore of idler gear 2. Replace the complete idler assembly if there are cracks or discoloration from heat damage, or any other damage. Inspect the bearing of idler 1. Inspect the bearing of idler 2. Replace the complete idler assembly if there is any damage or wear present in the bearing.
REPTO Page 9-16 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Position the flywheel housing with the transmission mating face downward. Leave a path for the bearing to exit. Support on a flat surface so the load is evenly distributed. Use a hammer and suitable bearing drift to push out the bearing. Do not damage the flywheel housing. Discard the bearing.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 REPTO Page 9-17 Use assembly lubricant, Part Number 3163087 or equivalent, to lubricate the new PTO shaft oil seal. Position the flywheel housing with the transmission mating face downward. Support on a flat surface so the load is evenly distributed. Press the new PTO shaft oil seal fully into the flywheel housing recess. Make sure the new seal is fully seated on the shoulder and is aligned correctly.
REPTO Page 9-18 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Inspect the rear gear cover mating surfaces and make sure they are clean and free from any form of contamination or damage. Apply a continuous bead of RTV sealant, Part Number 3164067 or equivalent, around the specific path on the REPTO gear cover shown. Refer to Procedure 001-034 in Section 1. NOTE: The sealant must be applied with care around the auxiliary oil port cavity.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 REPTO Page 9-19 Install two new o-rings on idler assembly 2 shaft support housing. Use clean vegetable oil to lubricate the o-rings. Install idler assembly 2 shaft support housing complete with the correctly positioned inner bearing race into the REPTO gear cover. Do not damage the two new o-rings during this process. Tighten the six retaining bolts in a crisscross diagonal pattern.
REPTO Page 9-20 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Install the capscrews and tighten in the sequence shown. Torque Value: M12: 85 N•m [ 63 ft-lb ] Torque Value: M10: 49 N•m [ 36 ft-lb ] NOTE: Capscrew number 21 is inserted from the engine side of the flywheel housing. Refer to Procedure 016-006 in Section 16. Measure the flywheel housing bore face alignment. Make sure the runout is within the required specification. Refer to Procedure 016-006 in Section 16.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 REPTO Page 9-21 The PTO shaft must be inserted as straight and central as possible so the oil seal remains intact and in the correct position. Small rotations of the shaft will aid insertion through the seal. NOTE: Make sure the PTO shaft oil seal is not damaged during this process. Make sure the lip on the PTO shaft oil seal does not become folded over or misaligned. Install the retainer clip on the end of the PTO shaft.
Refrigerant Compressor Page 9-22 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Finishing Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Install both rear engine mounts. Refer to Procedure 016-003 in Section 16.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Refrigerant Compressor Page 9-23 Remove Remove the refrigerant compressor mounting capscrew. Remove the refrigerant compressor. Refer to the OEM service manual for information on disconnecting refrigerant lines. Inspect for Reuse Refer to the OEM service manual for refrigerant compressor cleaning and inspection procedures. Install Install the refrigerant compressor and the refrigerant compressor mounting capscrews.
Drive Belt, Refrigerant Compressor Page 9-24 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Finishing Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Install the drive belt.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Drive Belt, Refrigerant Compressor Page 9-25 Remove CAUTION The belt tensioner is spring-loaded and must be pivoted away from the drive belt. Pivoting in the wrong direction can result in damage to the belt tensioner. CAUTION Applying excessive force in the opposite direction of windup or after the tensioner has been wound to the positive stop can cause the tensioner arm to crack or break.
Belt Tensioner, Refrigerant Compressor, Automatic Page 9-26 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Install CAUTION The belt tensioner is spring-loaded and must be pivoted away from the drive belt. Pivoting in the wrong direction can result in damage to the belt tensioner. Lift and hold the belt tensioner. Install the drive belt and release the tensioner. NOTE: Due to the availability of different belt run configurations, this procedure is meant to be generic.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Belt Tensioner, Refrigerant Compressor, Automatic Page 9-27 With the belt on, verify that neither of the tensioner arm stops are in contact with the spring casing stop. If either stop is touching, the drive belt must be replaced. If the tensioner arm stops are still in contact with the spring case stop after replacing the belt, replace the tensioner. Check the location of the drive belt on the belt tensioner pulley.
Belt Tensioner, Refrigerant Compressor, Automatic Page 9-28 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Remove Remove the capscrew and belt tensioner from the mounting location. Install With the belt removed, verify the tensioner arm stop is in contact with the spring casing stop. If these two are not touching, the tensioner must be replaced. Measure the clearance between the tensioner spring casing and the tensioner arm to verify tensioner wear-out and uneven bearing wear.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Belt Tensioner, Refrigerant Compressor, Automatic Page 9-29 Inspect the mating surface for debris. The tensioner can become misaligned if particles are trapped between the mating surfaces. Install Install the belt tensioner and capscrew. Torque Value: 43 N•m [ 32 ft-lb ] Finishing Steps WARNING Batteries can emit explosive gases.
Refrigerant Compressor Mounting Bracket Page 9-30 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Refrigerant Compressor Bracket (009-055) Mounting Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Disconnect the battery.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Refrigerant Compressor Mounting Bracket Page 9-31 Clean and Inspect for Reuse WARNING When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury. WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
Idler Pulley Sea Water Pump Page 9-32 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Finishing Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Install the refrigerant compressor.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Idler Pulley Sea Water Pump Page 9-33 Remove Remove the sea water pump idler pulley mounting capscrew and the idler pulley. Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufactuerer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Some solvents are flammable and toxic.
Idler Pulley Mounting Bracket Page 9-34 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Install Install the idler pulley, mounting capscrew and outer flat washer. Tighten the capscrew. Torque Value: 44 N•m [ 32 ft-lb ] Finishing Steps • Install the sea water pump drive belt. Refer to Procedure 008-126 • Install the belt guard. Refer to Procedure 008-001 Idler Pulley (009-058) Mounting Bracket Preparatory Steps • Remove the belt guard.
ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Idler Pulley Mounting Bracket Page 9-35 Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufactuerer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Some solvents are flammable and toxic. Read the manufactuerer's instructions before using.
Idler Pulley Mounting Bracket Page 9-36 ISB, ISBe and QSB (Common Rail [...] Section 9 - Drive Units - Group 09 Finishing Steps • Install the sea water pump idler pulley. Refer to Procedure 009-057 • Install the sea water pump drive belt. Refer to Procedure 008-126 • Install the belt guard. Refer to Procedure 008-001 Operate the engine and check for leaks. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Page 10-a Section 10 - Air Intake System - Group 10 Section Contents Page Aftercooler Assembly ...............................................................................................................................................10-3 Assemble..................................................................................................................................................................
Page 10-b ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Initial Check............................................................................................................................................................10-20 Charge-Air Cooler (CAC) ........................................................................................................................................10-24 Clean...........................................................................
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Page 10-c Variable Geometry Turbo Actuator .......................................................................................................................10-76 Finishing Steps.......................................................................................................................................................10-77 Install....................................................................................
Page 10-d ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Service Tools Page 10-1 Service Tools Air Intake System The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from a local Cummins® Authorized Repair Location. Tool No.
Service Tools Page 10-2 Tool No. ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Tool Description Tool Illustration Dial Depth Gauge Measure turbocharger axial motion. ST-537 Magnetic Base Indicator Holder 3377399 Used in conjunction with dial indicator, Metric — Part Number 3824564. SAE — Part Number 4918289. Charge Air Cooler Tester Used to pressure test charge air coolers.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Aftercooler Assembly Page 10-3 Aftercooler Assembly (010-005) Initial Check A turbocharger or sea water pump failure can cause damage to the aftercooler assembly. If a turbocharger failure or a sea water pump failure has occurred, remove the aftercooler element and inspect the element and housing for damage. Inspect the zinc anodes to make sure they are still in one piece and have not broken.
Aftercooler Assembly Page 10-4 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Fuel is flammable.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Aftercooler Assembly Page 10-5 Remove NOTE: The rear engine lifting bracket is secured to the engine with the aftercooler mounting capscrews. Loosen the aftercooler mounting capscrews at the flywheel housing (1), the cylinder block (2), and the cylinder head (3). Remove the aftercooler assembly. Disassemble Mark or note the aftercooler inlet and outlet water connection locations.
Aftercooler Assembly Page 10-6 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Inspect the housing and caps for cracks or other damage. Inspect the aftercooler housing for deterioration of the sealing surfaces. Assemble Assemble the aftercooler in a vertical position. Install the aftercooler core into the aftercooler housing. Align the marks so one flat side of the core is facing the air inlet side of the housing. Install a new o-ring around the lower core O.D.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Aftercooler Assembly Page 10-7 Install Loosely install the aftercooler assembly to the flywheel housing first using two mounting capscrews. NOTE: The rear engine lifting bracket is secured by the aftercooler to cylinder head mounting capscrews. The aftercooler bracket must be installed on top of the lifting bracket. Install the upper capscrews first. Be sure the aftercooler bracket is installed on top of the lifting bracket.
Air Cleaner Assembly (Engine Mounted) Page 10-8 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Finishing Steps • Install the fuel cooler lower molded sea water hose to the aftercooler. • Install the fuel cooler clip and mounting capscrew. • If removed, install the fuel drain flex hoses at the fuel cooler. • Connect the aftercooler air inlet connection from the turbocharger.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Cleaner Assembly (Engine Mounted) Page 10-9 Remove CAUTION Use caution when disconnecting or removing oil lines, or replacing filters, so that oil is not drained into the bilge area. Do not drop or throw filter elements into the bilge area. The oil and filters must be discarded in accordance with local environmental regulations. Release the clamp and remove the air cleaner element.
Air Crossover Page 10-10 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 NOTE: Do not use automatic transmission fluid, motor oil, diesel fuel, WD-40® lubricant, or any other light weight oil. Use approved filter oil. After cleaning the air filter, always re-oil the filter element with oil before using. The effectiveness of the air filter is greatly reduced if it is used without oiling. Sparingly squeeze small amounts of oil out of a bottle across the top of each pleat.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Crossover Page 10-11 Remove the air crossover. Loosen the air crossover hose clamps. Remove the air crossover tube. Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Some solvents are flammable and toxic.
Air Crossover Page 10-12 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Inspect the air connection ends for nicks, burrs or other damage. Inspect the hose connections for damage or cuts. Replace if necessary. Check the crossover tube for cracks, holes, and worn sections. If any damage is found, replace the air crossover and mounting components.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Inlet Connection Page 10-13 Finishing Steps Operate the engine and check for leaks. Air Inlet Connection (010-022) General Information The air inlet connection connects the turbocharger air inlet to the OEM air inlet piping. Remove Loosen the clamps which hold the air inlet connection to the turbocharger air inlet and the OEM air inlet piping. Remove the air inlet connection.
Air Inlet Connection Page 10-14 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Use skin and eye protection when handling caustic solutions to reduce the possibility of personal injury.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Intake Manifold Page 10-15 Air Intake Manifold (010-023) General Information The air intake manifold is the part(s) that connect to the cylinder head intake downstream of the cold starting aid. Some engines use a one-piece air intake manifold while other engines use a two-piece air intake manifold. Preparatory Steps WARNING Batteries can emit explosive gases.
Air Intake Manifold Page 10-16 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Remove NOTE: Keep the gasket material, and any other material out of the air intake. Remove the six capscrews that hold the upper part of the intake manifold to the lower part. CAUTION There is a captive capscrew (1) in this manifold, the captive capscrew must be removed after the other five capscrews have been removed, to prevent damage to the intake manifold.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Intake Manifold Page 10-17 Clean and Inspect for Reuse NOTE: Keep the gasket material and any other material out of the air intake. Clean all air intake manifold sealing surfaces with a gasket scraper and a clean rag. Clean the cylinder head sealing surfaces where the intake manifold seals. NOTE: Engines equipped with EGR have a corrosion resistant green Teflon™ coating on the inside surfaces of the intake manifold.
Air Intake Manifold Page 10-18 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Install NOTE: Remove the tape from the intake manifold opening before continuing with the installation process. Install the lower part of the intake manifold with a new gasket. Apply a light coating of thread sealant, Part Number 3824041, to the capscrews before installation. Only install the capscrews finger tight at this time. Install the upper part of the intake manifold with a new gasket.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Intake Manifold Page 10-19 Install the air intake manifold and capscrews. Apply a light coating of thread sealant, Part Number 3824041, to the capscrews before installation. If the air intake manifold was originally equipped with a gasket, replace the gasket. If the air intake manifold was originally equipped with sealant, re-seal the intake with RTV sealant, Part Number 3164070, or equivalent.
Air Leaks, Air Intake and Exhaust Systems Page 10-20 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Operate the engine and check for leaks.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Leaks, Air Intake and Exhaust Systems Page 10-21 Replace damaged pipes and tighten loose clamps, if necessary, to make sure the air inlet system does not leak. Torque Value: 10 N•m [ 89 in-lb ] Check for corrosion of the inlet system piping under the clamps and hoses. Corrosion can allow corrosive products and dirt to enter the intake system. Disassemble and clean as required.
Air Leaks, Air Intake and Exhaust Systems Page 10-22 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Charge Air Cooler Tubing or Connection Hoses Inspect the hose and tubing for damage. Refer to Procedure Procedure 010-019 Tighten loose clamps. Refer to the equipment manufacturer's specifications for the correct torque value. Intake Manifold Connection Inspect for damage. Tighten loose clamps. Replace the connection clamp, if necessary.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Leaks, Air Intake and Exhaust Systems Page 10-23 Compressor Housing Sealing Surface Inspect for damage. Clean surface with a clean cloth. Exhaust System Leaks in the exhaust system will cause the turbocharger to operate at a lower speed, reducing the amount of air going to the cylinders during engine operation. Operate the engine at full throttle and rated rpm with maximum load.
Charge-Air Cooler (CAC) Page 10-24 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 • Turbocharger mounting gaskets • Turbine housing sealing surface. • EGR component gaskets (if equipped). Charge-Air Cooler (CAC) (010-027) Preparatory Steps WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. Use compressed air to clean debris from the outside of the charge air cooler.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Charge-Air Cooler (CAC) Page 10-25 Initial Check Inspect the charge air cooler for cracks, holes, and damage. Inspect the tubes, fins, and welds for tears, breaks, or other damage. If any damage causes the charge air cooler to fail the air leak check, the charge air cooler must be replaced. Inspect the charge air cooler plumbing for cracks and damage. Remove Remove the charge air cooler. Refer to the OEM service manual.
Charge-Air Cooler (CAC) Page 10-26 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. CAUTION The charge air cooler must be rinsed, dried, and cleaned of solvent, oil, and debris, or engine damage will result.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Charge-Air Cooler (CAC) Page 10-27 Leak Test WARNING To reduce the possibility of injury if either plug blows off during the test, secure safety chains on the test plugs to any convenient capscrew on the radiator assembly. This test must not be performed without securely fastened safety chains. To check the charge air cooler for cracked tubes or header, remove the inlet and outlet hoses from the cooler.
Charge-Air Cooler (CAC) Page 10-28 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 If the pressure drop is greater than 48 kPa [7 psi] in 15 seconds, the charge air cooler must be replaced. Refer to the OEM service manual for replacement instructions. NOTE: Charge air coolers are not designed to be 100percent leak free. If the pressure drop is less than 48 kPa [7 psi] in 15 seconds, then the charge air cooler does not need to be replaced.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Charge-Air Cooler (CAC) Page 10-29 Temperature Differential Test Inspect the charge air cooler fins for obstructions to airflow. Remove obstructions such as a winterfront or debris. Manually lock shutters in the open position, if equipped. Lock the fan drive in the ON mode to prevent erratic test results. This can be done by installing a jumper wire across the temperature switch.
Cold Starting Aid Page 10-30 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Charge-Air Piping (010-028) Maintenance Check Inspect the charge-air piping and hoses for leaks, holes, cracks, or loose connections. Tighten the hose clamps if necessary. Refer to the vehicle or equipment manufacturer's specifications for the correct torque value. Cold Starting Aid (010-029) General Information There are three types of cold starting aids used on ISB, ISBe, and QSB engines.
ISB, ISBe and QSB (Common Rail [...
Cold Starting Aid Page 10-32 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Figure 2: ISBe CM800 Preheat Time in Seconds ISBe CM800 post-heat cycle information (intake manifold heater optional): After a cold start, the grid heater could be activated during warm-up, which is termed “post-heat”. The post-heat schedule is determined by the average of the intake manifold temperature at key on. Post-heat is deactivate at vehicle speeds greater than 16.1 kph [10 mph].
ISB, ISBe and QSB (Common Rail [...
Cold Starting Aid Page 10-34 Table 3: ISBe CM850 Post-heat Operation Parameters Intake Manifold Temperature at Key On One -20 to -16°C [-4 to 3°F] One -16 to -11°C [3 to 13°F], rpm < 1076 One -16 to -11°C [3 to 13°F], rpm > 1076 One -10 to -6°C [14 to 22°F], rpm < 1076 One -10 to -6°C [14 to 22°F], rpm > 1076 One -5 to -0.6°C [23 to 31°F], rpm < 1076 One -5 to -0.6°C [23 to 31°F], rpm > 1076 One > 0°C [32°F] ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Cold Starting Aid Page 10-35 Remove the electrical supply terminal. Remove the nylon isolating spacer from the electrical supply terminal. Disconnect the cold starting aid wiring. Remove the ground strap capscrew from the air intake manifold and remove the ground strap. Remove the cylindrical cold starting aid assembly from the air intake manifold. Brick Type Disconnect the cold starting aid wiring.
Cold Starting Aid Page 10-36 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 If the cold starting aid is to be removed for any length of time, apply tape over the hole to keep debris out of the air intake. Integral Type Disconnect the cold starting aid wiring. Removal of the intake manifold temperature/pressure sensor is not necessary. Remove the air intake manifold. • Refer to Procedure 010-023 (Air Intake Manifold) in Section 10.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Cold Starting Aid Page 10-37 If the intake cover will be off for a prolonged period of time, apply tape over the hole to keep debris out of the air intake. Clean and Inspect for Reuse Keep the gasket material and any other materials out of the air intake manifold. On engines equipped with EGR, it is not uncommon to see evidence of soot buildup on the cold starting aid heating elements.
Cold Starting Aid Page 10-38 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Install Cylindrical Type Fit the cold starting aid into the intake manifold. Rotate the cold starting aid to align the electrical supply terminal with the machined hole in the top of the air intake manifold. Insert the electrical supply terminal through the air intake manifold hole. Install the nylon isolating spacer onto the electrical supply terminal.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Cold Starting Aid Page 10-39 NOTE: Some engines have EGR. Connect the EGR pressure differential sensor and the EGR temperature sensor. Refer to Procedure 100-002 (Engine Diagrams) In Section E for sensor location. Install the EGR connection tube v-band clamp. • Refer to Procedure 011-025 (EGR Connection Tubes) in Section 11. Torque Value: 11 N•m [ 97 in-lb ] Tighten the four mounting capscrews.
Cold Starting Aid Page 10-40 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Install the air intake manifold. • Refer to Procedure 010-023 (Air Intake Manifold) in Section 10. Connect the cold starting aid wiring. Finishing Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Intake Restriction Page 10-41 Test WARNING Avoid touching the cold starting aid with your hands while the cold starting aid is operating. Connect INSITE™ electronic service tool. From the list of ECM diagnostic tests, select “Intake Air Heater Override”. Follow the on-screen instructions to determine if the cold starting aid and cold starting aid circuitry are functioning properly.
Turbocharger Page 10-42 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 • Inspect the air inlet piping for damage. Refer to the equipment manufacturer's repair instructions. Remove the test equipment. Turbocharger (010-033) Initial Check • Remove the inlet pipe and air inlet connection from the turbocharger. Refer to Procedure 010-022 in Section 10. • Inspect the turbocharger compressor impeller blades for damage. • Replace the turbocharger if damage is found.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Turbocharger Page 10-43 Wastegate Check • Inspect the lever pin. • Replace the turbocharger if the lever pin is bent or worn excessively. See the Remove and Install sections in this procedure. • Inspect the valve and valve seat for cracks or erosion. NOTE: On some turbochargers, removal of the turbine exhaust outlet cover may be necessary to inspect the valve and valve seat.
Turbocharger Page 10-44 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 • Push the rotor assembly toward the gauge and record the reading. HE221W, HE211W, and HE201W - Axial Clearance mm in 0.010 MIN 0.0004 0.076 MAX 0.0030 HX40, H1E, HY30W, HX35W, and HY35W - Axial Clearance mm in 0.038 MIN 0.0015 0.093 MAX 0.0037 HX27/25W - Axial Clearance mm 0.057 MIN 0.103 MAX in 0.0022 0.0040 Variable Geometry, HY35V - Axial Clearance mm in 0.038 MIN 0.0015 0.093 MAX 0.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 • If heavy deposits and/or streaks of oil are present only in the discharge side, install the air inlet and charge-air cooler piping to check the air restriction indicator. Reference the equipment manufacturer service information. • Check for air intake restriction. Refer to Procedure 010-031 in Section 10. • If no intake restriction is found, replace the turbocharger. See the Remove and Install sections in this procedure.
Turbocharger Page 10-46 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 • If oil is found on the turbine housing, remove the oil drain line, and check for restrictions. Refer to Procedure 010-045 in Section 10. • Clear any restrictions found. • Install the drain line and new o-ring seals into the engine block. Refer to Procedure 010-045 in Section 10. NOTE: On automotive engines the exhaust catalyst must be inspected. Refer to Procedure 011-056 in Section 11.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 • Install the exhaust pipe to the turbocharger turbine outlet. • Install the intake pipe to the turbocharger compressor inlet. Turbocharger Page 10-47 Preparatory Steps Automotive and Industrial WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries.
Turbocharger Page 10-48 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Marine Applications WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Do not remove the pressure cap from a hot engine.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Turbocharger Page 10-49 Remove Automotive and Industrial • Remove the exhaust piping. • Remove the turbocharger compressor air inlet connection. Refer to Procedure 010-022 in Section 10. WARNING This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly. .
Turbocharger Page 10-50 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Clean and Inspect for Reuse • Clean the turbocharger and exhaust manifold gasket surfaces. • Inspect the turbocharger and exhaust manifold gasket surfaces, and the mounting studs for cracks or other damage. • Replace the turbocharger if any cracks are found in the mounting flange surfaces. See the Remove and Install sections in this procedure.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Turbocharger Page 10-51 NOTE: On automotive and industrial engines, if the engine experiences a turbocharger damage or any other event in which oil or debris is introduced into the charge air system, the charge air system must be inspected and cleaned. Refer to Procedure 010-027 in Section 10.
Turbocharger Page 10-52 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 • Install the turbocharger compressor outlet elbow, Vband clamp, and a new o-ring seal on the turbocharger compressor discharge outlet, if applicable. • Tighten the clamp. Torque Value: 8 N•m [ 71 in-lb ] • Rotate the compressor housing to fit the intake pipes, if necessary. NOTE: Use the snap ring or loosen the V-band clamp to make necessary adjustments.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Turbocharger Page 10-53 Prime • Install and tighten the turbocharger oil drain line. Refer to Procedure 010-045 in Section 10. • Lubricate the bearings by pouring 60 to 90 cc's [2 to 3 oz] of clean 15W-40 engine oil in the turbocharger oil supply line fitting. • Rotate the turbine wheel to allow oil to enter the bearing housing. Finishing Steps Automotive and Industrial WARNING Batteries can emit explosive gases.
Turbocharger Coolant Hoses Page 10-54 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Marine Applications WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Install the oil supply line. Refer to Procedure 010-046 in Section 10.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Turbocharger Coolant Hoses Page 10-55 Remove NOTE: All lines and banjo screws used in the coolant plumbing have increased annulus ports. Always use the correct Cummins part number and do not use standard lines or banjo screws as a substitute. Remove the supply and return coolant lines that attach to the variable geometry turbine bearing housing. Discard the seals.
Turbocharger Coolant Hoses Page 10-56 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Install NOTE: All lines and banjo screws used in the coolant plumbing have increased annulus ports. Do not use standard lines or banjo screws as a substitute. NOTE: Three of the connections are banjo fittings. The connection from the block to the turbocharger at the block location is a quick-disconnect fitting. Push the quickdisconnect fitting to install it onto the block fitting.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Turbocharger Oil Drain Line Page 10-57 Install the coolant vent line to the top of the turbocharger turbine housing with the banjo bolt. Torque Value: 24 N•m [ 212 in-lb ] Install the coolant vent line to the rear of the coolant expansion tank and tighten. Torque Value: 24 N•m [ 212 in-lb ] Finishing Steps WARNING Coolant is toxic. Keep away from children and pets.
Turbocharger Oil Drain Line Page 10-58 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Clean and Inspect for Reuse Clean the gasket sealing surfaces. Clean the o-ring seating bore, and make sure it is free of dirt and debris. CAUTION A restricted oil drain line can cause the turbocharger bearing housing to be pressurized, causing oil to leak past the seal rings, which can cause component damage. Inspect the line for cracks, wear, and damage.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Turbocharger Oil Supply Line Page 10-59 Marine Applications Install a new o-ring on the turbocharger oil drain line connection (cylinder block end), if applicable. Apply a light film of lubricating oil to the o-ring. Push the connection into the cylinder block until the o-ring is completely seated. Install the hose connection over the end of the drain line connection. Install two hose clamps over the oil drain hose.
Turbocharger Wastegate Actuator Page 10-60 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Inspect for Reuse Inspect the line for cracks, wear, and damage. NOTE: Some turbocharger oil supply line fittings may seal with copper sealing washers, others may seal with o-ring seals. Discard the old copper seal washers or o-ring seals. Install CAUTION Maintain a minimum distance of 10 mm [0.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Turbocharger Wastegate Actuator Page 10-61 CAUTION A bent wastegate mounting bracket, actuator rod, or lever can cause improper operation. Inspect the wastegate mounting bracket, actuator rod, and lever for damage. If the wastegate mounting bracket, actuator rod, or lever is bent, it must be replaced. Remove NOTE: In some applications, the turbocharger must be removed in order to remove the wastegate actuator.
Turbocharger Wastegate Actuator Page 10-62 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 CAUTION Be careful not to bend the control lever. Air Regulator with Pressure Gauge Part Number 3823799 Disconnect the boost capsule actuator rod end from the turbocharger wastegate lever. This can be accomplished by slowly applying regulated air pressure to the boost capsule until the control rod is activated. Disconnect the control rod from the turbocharger wastegate lever pin.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Turbocharger Wastegate Actuator Page 10-63 If the actuator rod shows no sign of movement, remove the actuator rod retaining clip and disconnect the actuator rod from the turbocharger wastegate pin. Reapply air pressure to the wastegate capsule and check for actuator rod movement. If there is no movement, replace the wastegate actuator.
Turbocharger Wastegate Actuator Page 10-64 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Fit the end-link over the turbocharger wastegate lever pin. With the spine of the spacer visible and the turbocharger wastegate lever pushed toward the rod, lay the actuator alongside the mounting bracket. NOTE: Do not fit the two studs into the mounting holes at this time.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Turbocharger Wastegate Valve Body Page 10-65 Tighten the control rod jam nut against the end-link. Cut the tie wrap and remove tie wrap and spacer piece. Discard tie wrap. Continue turning jam nut in the same direction, and tighten against end-link. Torque Value: 8 N•m [ 71 in-lb ] Refit the air supply hose to the actuator using the new hose clamp provided.
Boost Pressure Page 10-66 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Actuate the lever by hand to verify that the shaft rotates freely and is not seized. Check for excessive movement between the shaft and bushing. Replace the turbine housing if the shaft and bushing are damaged or seized. Refer to the Turbocharger Master Repair Manual, Bulletin 3380555.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Intake Connection Page 10-67 Air Intake Connection (010-080) Preparatory Steps Without EGR WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Disconnect the batteries.
Air Intake Connection Page 10-68 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Remove Automotive and Industrial Remove the mounting capscrews, air intake connection, top gasket, cold starting aid, and bottom gasket. NOTE: Some air intake connections may not have an EGR connection as shown. NOTE: Be sure not to tape over all manifold edges so the mounting surfaces can be properly cleaned.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Intake Connection Page 10-69 Clean and Inspect for Reuse Automotive and Industrial NOTE: Keep the gasket material and any other debris out of the air intake. Remove old gasket material from the air intake connection, cold starting aid (if equipped), and intake manifold cover sealing surface. Remove the pipe plugs from the cross-drillings.
Air Intake Connection Page 10-70 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Remove the tape or rag from the intake manifold. Inspect the intake manifold cover, cold starting aid, and air intake connection sealing surfaces for cracks or other damage. NOTE: Some air intake connections may not have an EGR connection as shown. Marine Applications WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Intake Connection Page 10-71 NOTE: The EGR measurement venturi (1) is a nonserviceable part. The air intake connection must be purchased with the EGR measurement venturi preinstalled. Position the cold starting aid (if equipped) using new gaskets. Refer to Procedure 010-029 in Section 10. Install the air intake connection and four mounting screws.
Air Intake Connection Page 10-72 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Marine Applications Install the rear connection on the aftercooler assembly with a new gasket and the four mounting capscrews. Tighten the capscrews. Torque Value: 15 N•m [ 133 in-lb ] Install the front portion of the air intake connection and the four capscrews. Tighten the capscrews. Torque Value: 15 N•m [ 133 in-lb ] Tighten the hose clamps.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Intake Connection Page 10-73 Finishing Steps With EGR WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Install the EGR mixer. Refer to Procedure 011-021 in Section 11.
Air Intake Manifold Cover Page 10-74 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Intake Manifold Cover (010-108) Preparatory Steps • Remove the air intake connection. Refer to Procedure 010-080 • Remove the injector supply lines. Refer to Procedure 006-051 • Remove the fuel rail. Refer to Procedure 006-060 Remove Remove the mounting capscrews and the intake cover. Tape off the intake manifold opening to prevent debris from entering the intake system.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Intake Manifold Cover Page 10-75 Remove the tape. Inspect the intake manifold for cracks or other damage. NOTE: When inspecting the intake manifold for oil or debris from an air system failure, also inspect the cylinder head for oil and debris. Install Install the cover and new gasket. Torque Value: 24 N•m [ 212 in-lb ] Finishing Steps • Install the air intake connection.
Variable Geometry Turbo Actuator Page 10-76 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Variable Geometry Turbo Actuator (010-113) Preparatory Steps WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. Remove, drain, or disconnect the following: • Variable geometry turbocharger if necessary to access and service the actuator. Refer to Procedure 010-033 • Coolant.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Intake Connection Adapter Page 10-77 Finishing Steps CAUTION The position sensor pins can be bent if the engine harness connector is mated to the sensor connector at an angle. Therefore, the engine harness connector must be inserted straight into the position sensor connector to avoid damaging the pins. Bent pins will result in poor engine performance and intermittent fault codes. Install, connect, and fill the following.
Air Intake Connection Adapter Page 10-78 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Remove the charge air piping between the air intake connection adapter and the outlet of the charge air cooler. Refer to Procedure Procedure 010-019 Remove Remove the v-band clamp, the elbow piece of the air intake connection adapter, and the seal.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Air Intake Connection Adapter Page 10-79 Remove the v-band clamp, seal, and air intake connection adapter. Remove the air compressor intake line from the adapter (if applicable). Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
Air Intake Connection Adapter Page 10-80 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Tighten the three capscrews. Torque Value: 24 N•m [ 212 in-lb ] Install the air compressor intake line from the adapter (if applicable). Install the seal, air intake connection adapter elbow, and V-band clamp. Tighten the V-band clamp. Torque Value: 8 N•m [ 71 in-lb ] Install the seal, air intake connection adapter, and v-band clamp. Tighten the v-band clamp.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Turbocharger Compressor Outlet Connection Page 10-81 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Connect the batteries. Operate engine and check for leaks.
Turbocharger Compressor Outlet Connection Page 10-82 ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Remove Loosen the clamp holding the turbocharger compressor outlet connection to the turbocharger. Remove the turbocharger compressor outlet connection and seal, taking care not to drop the seal or any foreign matter into the turbocharger. Clean and Inspect for Reuse WARNING Wear appropriate eye and face protection when using compressed air.
ISB, ISBe and QSB (Common Rail [...] Section 10 - Air Intake System - Group 10 Turbocharger Compressor Outlet Connection Page 10-83 Finishing Steps Reconnect the charge air piping to the turbocharger compressor outlet connection. Refer to Procedure Procedure 010-019. Refer to the OEM manual for the torque specification on the clamp. WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries.
Turbocharger Compressor Outlet Connection Page 10-84 ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Page 11-a Section 11 - Exhaust System - Group 11 Section Contents Page Aftertreatment Diesel Exhaust Fluid Dosing Unit ................................................................................................11-40 Finishing Steps.......................................................................................................................................................11-43 General Information......................
Page 11-b ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Clean and Inspect for Reuse..................................................................................................................................11-16 Finishing Steps.......................................................................................................................................................11-17 Install..................................................................................
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Service Tools Page 11-1 Service Tools Exhaust System The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from a local Cummins® Authorized Repair Location. Tool No. Tool Description Tool Illustration Pressure Gauge Used to measure exhaust restriction.
Exhaust Manifold, Dry Page 11-2 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Exhaust Manifold, Dry (011-007) Preparatory Steps Without EGR Disconnect the turbocharger air inlet and exhaust piping. Disconnect the charge-air cooler Procedure 010-019 in Section 10. piping. Refer to Remove the turbocharger. Refer to Procedure 010-033 in Section 10. With EGR Disconnect the turbocharger air inlet and exhaust piping.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Exhaust Manifold, Dry Page 11-3 WARNING When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury. WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. Use steam to clean the exhaust manifold. Dry with compressed air. Clean the two-piece sealing joint.
Exhaust Manifold, Dry Page 11-4 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Install Apply high-temperature anti-seize compound to the exhaust manifold capscrew threads. Install the exhaust manifold, new gaskets, spacers, and lockplates. Follow the tightening sequence shown in the illustration. NOTE: To aid in alignment of the exhaust manifold, two capscrew passages have a smaller diameter than other passages. The location of these varies with manifold configuration.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Exhaust Manifold, Dry Page 11-5 With EGR Install the EGR cooler inlet tube. Refer to Procedure 011-024 in Section 11. Install the turbocharger. Refer to Procedure 010-033 in Section 10. Install the EGR valve. Refer to Procedure 011-022 in Section 11. Install the exhaust pressure sensor line. Refer to Procedure 011-027 in Section 11. Connect the turbocharger air inlet and exhaust piping. Connect the charge air cooler piping.
Exhaust Manifold, Wet Page 11-6 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Exhaust Manifold, Wet (011-008) Preparatory Steps WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. WARNING Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Exhaust Manifold, Wet Page 11-7 Remove WARNING This assembly weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this assembly. Remove the coolant supply line. Loosen two capscrews and leave them in place to hold the weight of the exhaust manifold. Remove the remaining 10 exhaust manifold mounting capscrews.
Exhaust Manifold, Wet Page 11-8 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Some solvents are flammable and toxic. Read the manufacturer's instructions before using. WARNING Wear appropriate eye and face protection when using compressed air.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Exhaust Restriction Page 11-9 Finishing Steps WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. • Install the coolant vent lines. Refer to Procedure 008-017 NOTE: If the turbocharger and exhaust manifold were removed as an assembly, then continue on with the following steps. If not, Refer to Procedure 011-008 to install the turbocharger.
Exhaust Outlet Connection Page 11-10 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 If exhaust pressure exceeds the specification, inspect the exhaust piping for damage. Refer to the equipment manufacturer's repair instructions. Remove the test equipment. Install a pipe plug into the pressure tap port, if applicable. Exhaust Outlet Connection (011-017) General Information NOTE: This procedure applies to marine applications.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Exhaust Outlet Connection Page 11-11 Preparatory Steps CAUTION Before disconnecting the exhaust outlet piping, be sure to fasten the piping above the water level to prevent the vessel from taking on water and possibly sinking. CAUTION Vessels installed with integrated drive systems must be removed from the water to reduce the possibility of the vessel from taking on water and possibly sinking.
Exhaust Outlet Connection Page 11-12 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Loosen the hose clamps. Remove all hose connections. Remove the exhaust tube. Clean and Inspect for Reuse Inspect all the sealing surfaces and gasket for damage or other indications of leakage. Inspect the inside of the connection to make sure the water passages are not blocked. Inspect the inside of the exhaust tube passages for pitting. Inspect the pod exhaust flange for damage.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Exhaust Outlet Connection Page 11-13 Remove the sealing grommet from the exhaust elbow and inspect for damage. Replace the grommet if damaged. Inspect the exhaust elbow for pitting or corrosion. Inspect the exhaust tube for cracks and other damage to the lamination. Install Install a new gasket and the exhaust outlet connection to the turbocharger. Tighten the four mounting capscrews.
Exhaust Outlet Connection Page 11-14 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Install the sealing grommet inside the exhaust elbow until the grommet is even with the edge of the exhaust elbow. NOTE: Use soapy water on the outside of the grommet to aid in installation. Use clamp rings to install the exhaust elbow. Leave the clamp ring capscrews finger tight to allow the elbow pivots to align with the exhaust tube.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Exhaust Gas Recirculation Cooler Page 11-15 Finishing Steps • Install the exhaust piping to the exhaust outlet connection. Refer to the OEM service manual. • Place the vessel back into the water. • Open the sea water supply valve(s). Refer to the OEM service manual. • Operate the engine and check for leaks. Exhaust Gas (011-019) Recirculation Cooler Preparatory Steps WARNING Coolant is toxic.
Exhaust Gas Recirculation Cooler Page 11-16 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Some solvents are flammable and toxic. Read the manufacturer's instructions before using.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Exhaust Gas Recirculation Cooler Page 11-17 Finishing Steps WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations. • Install the EGR valve coolant return line. Refer to Procedure 011-030 (EGR Valve Coolant Lines) in Section 11. • Install the EGR cooler connection tube. Refer to Procedure 011-024 (EGR Cooler Connection) in Section 11.
EGR Mixer Page 11-18 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Cap off one of the coolant connections and connect a regulated air supply hose to the other coolant connection. Place the EGR cooler into a tank of heated water (60°C [140°F]). The EGR cooler must be completely submerged in the water. Apply air pressure of 310 kPa [45 psi]. Inspect for air bubbles coming from the cooler. Observe the cooler for a minimum of 2 minutes under water.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 EGR Mixer Page 11-19 Remove Remove the mixer and o-ring seal from the air intake connection. Clean and Inspect WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Wear appropriate eye and face protection when using compressed air.
EGR Valve Page 11-20 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Finishing Steps Install the two-piece air intake connection adapter. Refer to Procedure Procedure 010-131 Install the charge-air piping/hose. Refer to Procedure Procedure 010-019 EGR Valve (011-022) Preparatory Steps WARNING Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 EGR Valve Page 11-21 Clean and Inspect for Reuse Clean the EGR valve marmon flange and the mounting surfaces of the EGR valve with a Scotch-Brite™ pad. Clean the exhaust manifold with a Scotch-Brite™ pad. Inspect the EGR valve for cracks, leaks, corrosion, restriction, and debris. Inspect the exhaust transfer tube for cracks, corrosion, and plugging.
EGR Valve Page 11-22 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Inspect the V-band clamps for signs of overextension. The band must not be bent or damaged. Inspect the V-band clamp threads for damage. Replace the V-band clamp if damage is found. Install Before installing the V-band clamp, coat the clamping surface with high temperature anti-seize compound. Position the V-band clamp and new gasket onto the exhaust transfer tube.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 EGR Cooler Connection Page 11-23 Position the exhaust transfer tube V-band connection on the EGR valve. Tighten the V-band clamp. Torque Value: 11 N•m [ 100 in-lb ] Tighten the capscrews. three upper vertical EGR mounting Torque Value: 43 N•m [ 32 ft-lb ] Tighten the upper horizontal EGR mounting capscrews. Torque Value: 43 N•m [ 32 ft-lb ] Finishing Steps WARNING Coolant is toxic. Keep away from children and pets.
EGR Cooler Connection Page 11-24 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Remove the two V-band clamps, tube, and gaskets. Discard the gaskets. Inspect for Reuse Inspect the tube for cracks, restrictions, plugging, and damage. Inspect the V-band clamps for signs of overextension. The band must not be bent or damaged. Inspect the V-band clamp threads for damage. Replace the V-band clamp if damage is found.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 EGR Connection Tubes Page 11-25 Place new gaskets onto the tube. Install the tube. Position the V-band clamps. Coat the P-clip capscrew(s) with high-temperature antiseize compound. Loosely install the capscrew(s) for the P-clip(s). Tighten the V-band clamps. Torque Value: 11 N•m [ 100 in-lb ] Tighten the P-clip capscrew(s). Torque Value: 24 N•m [ 212 in-lb ] Operate the engine and check for boost and exhaust leaks.
EGR Connection Tubes Page 11-26 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Remove the two V-band clamps, tube, and gaskets. Discard the gaskets. Inspect for Reuse Inspect the tube for cracks, restrictions, plugging, and damage. Inspect the V-band clamps for signs of overextension. The band must not be bent or damaged. Inspect the V-band clamp threads for damage. Replace the V-band clamp if damage is found.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 EGR Connection Tubes Page 11-27 Place new gaskets onto the tube. Position the tube, gasket, and V-band clamp on the cooler and intake cover marmon flange connections. Check for proper alignment. Loosely install the capscrews for the tube support brace. CAUTION Do not force the tube to fit the intake cover or EGR cooler marmon flanges. Force fitting the tube will result in undesirable stress in the tube and possible tube failure.
EGR Valve Coolant Lines Page 11-28 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Exhaust (011-027) Pressure Sensor Tube Remove Remove the capscrew from the tube bracket. Loosen the tube nuts at the exhaust manifold and the sensor adapter. Remove the tube. Clean and Inspect WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 EGR Valve Coolant Lines Page 11-29 Remove NOTE: All lines and banjo screws used in the water plumbing have increased annulus ports. Do not use standard lines or banjo screws as a substitute. Remove the supply and return coolant lines for the EGR valve actuator. Discard the banjo seals. Inspect for Reuse Inspect the lines for debris, clogging and pinched areas. Inspect the banjo fittings for damage.
EGR Cooler Coolant Lines Page 11-30 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Finishing Steps • Fill the engine cooling system. Refer to Procedure 008-018 EGR Cooler Coolant Lines (011-031) Preparatory Steps Drain the coolant. Refer to Procedure 008-018 Remove Remove the nut holding the steel coolant inlet tube bracket to the exhaust manifold. Remove the clamps and hoses from each end and remove the coolant inlet tube.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 EGR Cooler Coolant Lines Page 11-31 Remove the clamps and hoses from each end of the coolant return tube on top of the cooler and remove the tube. Clean and Inspect Inspect the hoses and tubes for cracks, plugging, restrictions, and pinched areas. Install Install the clamps and hoses to each end of the coolant return tube on top of the cooler and install the tube.
EGR Cooler Coolant Lines Page 11-32 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Install the nut holding the steel coolant inlet tube bracket to the exhaust manifold. Torque Value: 45 N•m [ 33 ft-lb ] Finishing Steps Fill the engine with coolant. Refer to Procedure 008-018 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Aftertreatment Selective Catalytic Reduction (SCR) Cata [...] Page 11-33 Aftertreatment Selective Catalytic Reduction (SCR) Catalyst (011-036) General Information WARNING The exhaust and exhaust components can remain hot after the vehicle stopped moving.
Aftertreatment Selective Catalytic Reduction (SCR) Cata [...] Page 11-34 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Remove WARNING The catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of California to cause cancer. Always wear protective gloves, dust mask, and eye protection when handling the catalyst assembly. Do not get the catalyst material in your eyes.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Aftertreatment Selective Catalytic Reduction (SCR) Cata [...] Page 11-35 Inspect exhaust catalyst for: • Loose paint • Excess Corrosion • Damage to the body of exhaust catalyst, i.e. splits or cracks to the body of the exhaust catalyst or connecting pipework. Inspect exhaust catalyst for signs of catalyst solution leaks. Check/inspect all fittings and supports brackets before reuse.
Aftertreatment Nozzle Page 11-36 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Finishing Steps WARNING The catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State of California to cause cancer. In the event the catalyst is being replaced, dispose of in accordance with local regulations. Do not cut open the catalyst assembly. • Install and connect the exhaust gas temperature sensors.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Aftertreatment Nozzle Page 11-37 Initial Check Visually check the pipework going to and coming from the aftertreatment diesel exhaust fluid dosing unit for any signs of a leak. Diesel exhaust fluid leaks will leave a white deposit around the fittings. Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries.
Aftertreatment Nozzle Page 11-38 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Clean and Inspect for Reuse WARNING The diesel exhaust fluid contains urea. Do not get the substance in your eyes. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of contact, immediately wash skin with soap and water. Do not swallow internally.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Connect the diesel aftertreatment nozzle. exhaust fluid Aftertreatment Nozzle Page 11-39 supply to the Finishing Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Connect the batteries.
Aftertreatment Diesel Exhaust Fluid Dosing Unit Page 11-40 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Aftertreatment Diesel Exhaust Fluid Dosing Unit (011-058) General Information WARNING DEF contains urea. Do not get the substance in your eyes. In case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes. Do not swallow. In the event the DEF is ingested, contact a physician immediately.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Aftertreatment Diesel Exhaust Fluid Dosing Unit Page 11-41 Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Disconnect the batteries.
Aftertreatment Diesel Exhaust Fluid Dosing Unit Page 11-42 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Test WARNING DEF contains urea. Do not get the substance in your eyes. In case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes. Do not swallow. In the event the DEF is ingested, contact a physician immediately. Reference the materials safety data sheet (MSDS) for additional information.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Aftertreatment Diesel Exhaust Fluid Dosing Unit Page 11-43 Install WARNING DEF contains urea. Do not get the substance in your eyes. In case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes. Do not swallow. In the event the DEF is ingested, contact a physician immediately. Reference the materials safety data sheet (MSDS) for additional information.
Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter Page 11-44 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter (011-060) General Information WARNING Diesel exhaust fluid (DEF) contains urea. Do not get the substance in your eyes. In case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes. Do not swallow. In the event the DEF is ingested, contact a physician immediately.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter Page 11-45 Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. NOTE: Do not power wash or steam clean this unit.
Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter Page 11-46 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Inspect for Reuse WARNING Diesel exhaust fluid (diesel exhaust fluid) contains urea. Do not get the substance in your eyes. In case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes. Do not swallow. In the event the diesel exhaust fluid is ingested, contact a physician immediately.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Sid [...] Page 11-47 Finishing Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Connect the batteries. Refer to the OEM service manual.
Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Sid [...] Page 11-48 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Initial Check Locate the DEF dosing unit on the vehicle. The DEF dosing unit dataplate is located either on the top or the side of the unit, as shown in the illustration (1). Check the pipework going to and returning from the DEF dosing unit for any signs of a leak. DEF leaks will leave a white deposit around the fittings.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Sid [...] Page 11-49 Flush CAUTION Fluid can attempt to force through the solenoid exhaust port on the doser. Damage to the selective catalytic reduction (SCR) dosing unit can occur. The DEF dosing unit must be wiped with a clean damp cloth and/or a wash bottle with mild detergent. This will remove any contamination and reduce the risk of debris entering the DEF dosing unit.
Aftertreatment Diesel Exhaust Fluid Dosing Unit Air Sid [...] Page 11-50 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 • Connect one end of the coiled PTFE pipe to the dosing pump air supply port (1), and the opposite end to the regulated vehicle air supply (2), using the barrel connector from service tool kit, Part Number 5296510.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Aftertreatment Diesel Exhaust Fluid Tank Filter Page 11-51 Finishing Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Connect the batteries. Refer to the OEM service manual.
Aftertreatment Diesel Exhaust Fluid Tank Filter Page 11-52 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Remove WARNING Diesel exhaust fluid (DEF) contains urea. Do not get the substance in your eyes. In case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes. Do not swallow. In the event the DEF is ingested, contact a physician immediately. Reference the materials safety data sheet (MSDS) for additional information.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Aftertreatment Diesel Exhaust Fluid Line Restriction Te [...] Page 11-53 Finishing Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. • Connect the batteries. Refer to the OEM service manual.
Aftertreatment Diesel Exhaust Fluid Line Restriction Te [...] Page 11-54 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Initial Check Visually check the DEF supply and return lines and fittings for signs of damage, leaks, or faulty connectors. DEF leaks will leave a white deposit around the fittings. A hand vacuum pump is required for this procedure. Check the performance of the hand vacuum pump prior to carrying out this test.
ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Aftertreatment Diesel Exhaust Fluid Line Restriction Te [...] Page 11-55 Test WARNING DEF contains urea. Do not get the substance in your eyes. In case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes. Do not swallow. In the event the DEF is ingested, contact a physician immediately. Reference the materials safety data sheet (MSDS) for additional information.
Aftertreatment Diesel Exhaust Fluid Line Restriction Te [...] Page 11-56 ISB, ISBe and QSB (Common Rail [...] Section 11 - Exhaust System - Group 11 Supply Line Restriction 1 Connect the male J2044 line from the vacuum test kit to the DEF supply line to dosing unit connector. 2 Gradually operate the vacuum pump while observing the clear pipe lines that leads to the collection cup.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Page 12-a Section 12 - Compressed Air System - Group 12 Section Contents Page Air Compressor .......................................................................................................................................................12-22 Assemble................................................................................................................................................................
Page 12-b ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Compressed Air System...........................................................................................................................................12-1 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Service Tools Page 12-1 Service Tools Compressed Air System The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from a local Cummins® Authorized Repair Location. Tool No. Tool Description Tool Illustration Dial Bore Gauge Used to measure the cylinder bores.
Air Compressor Carbon Buildup Page 12-2 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor (012-003) Carbon Buildup Initial Check WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause bodily injury. Shut the engine OFF. Open the drain cock on the wet tank to release the compressed air from the system. WARNING Air discharge lines can be very hot.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Carbon Buildup Page 12-3 WARNING The air discharge line must be capable of withstanding extreme heat and pressure to prevent the possibility of personal injury and property damage. Refer to the OEM service manual for specifications. NOTE: If the total carbon deposit thickness exceeds specification, remove and clean, or replace, the air discharge line.
Air Compressor Carbon Buildup Page 12-4 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Park vehicle on a level surface and in an area where it is safe to idle for an extended period of time. Chock the vehicle wheels, and completely drain the vehicle air system. Remove the air compressor discharge line (1), air compressor intake line (2), and air governor signal line (3) at the air compressor.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Carbon Buildup Page 12-5 Place the discharge line into a 19 liter [5 gal] bucket and cover with several oil absorption pads. Pour 89 ml [3 fluid ounces] of automatic transmission fluid into the dispensing bottle. Install the dispensing bottle onto the dispensing hose assembly. NOTE: For best results, use Dexron III automatic transmission fluid or equivalent.
Air Compressor Carbon Buildup Page 12-6 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Pour 89 ml [3 fl oz] of automatic transmission fluid into the dispensing bottle, and install back onto the dispensing hose assembly. Toggle the ‘Unloader’ switch (2) on to apply air pressure to the unloader signal port. Do not relieve pressure at the unloader valve at this time. Start the engine.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Carbon Buildup Page 12-7 Verify constant suction at the air compressor cylinder head intake port when the air compressor is loaded (Unloader switch OFF), and fluctuating air flow when unloaded (Unloader switch ON). If constant suction is not present in a loaded state, repeat the cleaning process one additional time.
Air Compressor Carbon Buildup Page 12-8 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Off-Engine Repair WARNING Use skin and eye protection when handling caustic solutions to reduce the possibility of personal injury. WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. CAUTION Do not use a sharp object to remove carbon. The sealing surfaces can be damaged.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Carbon Buildup Page 12-9 Remove carbon from the compressor head and valve assembly components with a non-abrasive solvent and a non-metallic brush. NOTE: Using an abrasive solvent like carburetor cleaner can lead to further lubrication loss in the air compressor head. Blow out passages with compressed air. Verify the unloader slider plate is fully closed when at rest.
Air Compressor Coolant Lines Page 12-10 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Using an engraving pen, mark the number 2 next to the CH marking already engraved on the cylinder head. Install the compressor head and valve assembly. Install the compressor head and valve assembly. Refer to Procedure 012-007 in Section 12. Perform the Air Compressor Diagnostic Test to verify the air compressor is functioning properly.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Cylinder Head, Single Cylinder Page 12-11 Remove Remove the coolant lines from the air compressor (does not apply to air-cooled compressors). Inspect for Reuse Inspect the drive clips or connectors for damaged threads. Inspect the coolant hoses and coolant lines for restriction of coolant flow.
Air Compressor Cylinder Head, Single Cylinder Page 12-12 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Do not remove the pressure cap from a hot engine.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Cylinder Head, Single Cylinder Page 12-13 Remove Remove the capscrews. four air compressor head mounting Remove the air compressor head and gasket. Discard the gasket. Clean and Inspect for Reuse NOTE: Do not use an abrasive cleaning tool on any surface of the air compressor cylinder head or damage may occur. Inspect the air compressor cylinder bore for damage.
Air Compressor Cylinder Head, Single Cylinder Page 12-14 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Inspect the cylinder head for signs of coolant leaks. A coolant leak can be recognized by looking for places where the engine paint on the compressor has been washed away. White crystalline clusters of material are not a sign of a coolant leak. If a coolant leak is found, the cylinder head should be rebuilt using a gasket kit.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Cylinder Head, Single Cylinder Page 12-15 Inspect the sealing surface on both halves of the cylinder head for damage. If damage is found, the cylinder head must be replaced. Assemble NOTE: The assembly process is not required for new air compressor cylinder head kits. These kits include a cylinder head with all of the gaskets assembled and ready for installation on the air compressor crankcase.
Air Compressor Cylinder Head, Single Cylinder Page 12-16 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Make sure the intake valve is oriented so the governor signal channel of the cylinder head is exposed by four holes (1). Install the air compressor intake reed valve. The intake reed valve has larger diameter holes on one side than the other to assist in proper orientation.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Cylinder Head, Single Cylinder Page 12-17 Finishing Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Coolant is toxic. Keep away from children and pets.
Air Compressor Cylinder Head, Two Cylinder Page 12-18 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Cylinder Head, Two Cylinder (012-008) Preparatory WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Cylinder Head, Two Cylinder Page 12-19 Clean and Inspect for Reuse Inspect the compressor housing for cracks or other damage. Clean the piston crown. Gasket sealing surfaces must be clean and free of all old gasket material, carbon, rust, and other buildup. Surfaces must be free of scratches, gouges, burrs, and other deformities.
Air Compressor Oil Drain Line Page 12-20 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor (012-009) Oil Drain Line Initial Check Inspect the air compressor oil drain line for cracks, cuts, or collapsing (if equipped). Remove If equipped, remove the air compressor oil drain line at the compressor. Remove the air compressor oil drain line on the side of the engine block. Inspect for Reuse Check the flexible lines for splits, cracks, or hardening.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Unloader and Valve Assembly Page 12-21 Operate the engine and check for leaks and proper operation of the air compressor. Air Compressor Unloader and Valve Assembly (012-013) Initial Check WARNING Air pressure must be released from the system before removing the air governor. The governor can be under pressure and cause personal injury.
Air Compressor Page 12-22 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Connect the original equipment manufacturer (OEM) air governor signal line to the air compressor unloader port. Operate the engine to activate the air compressor. Verify that the system still builds pressure properly. If the air system pressure continues to build beyond the governed point, the air governor is malfunctioning. • Refer to Procedure 012-018 in Section 12.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Page 12-23 Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Coolant is toxic. Keep away from children and pets.
Air Compressor Page 12-24 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Remove the mounting nut, capscrew, and air compressor. Discard the gasket. Clean and Inspect for Reuse Inspect the air compressor housing for cracks or other damage. Inspect the drive gear for cracks or other damage. Make sure the gasket surfaces of the gear housing and air compressor are clean and not damaged. Remove the air compressor cylinder head if it is not already removed.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Page 12-25 Assemble Wabco™ Air Compressors Install the cylinder block mounting bracket and mounting fasteners. Tighten the mounting fasteners finger-tight. Knorr-Bremse™ Air Compressors NOTE: Make sure the drive gear and air compressor drive shaft nose are clean and free of any oil before installing the gear on the air compressor driveshaft. Install the drive gear onto the air compressor driveshaft.
Air Compressor Page 12-26 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 NOTE: If no TDC mark is present on either the vibration damper or the crankshaft speed indicator ring, align the large gap in the crankshaft speed indicator ring to the 5o'clock position (2). The dowel pin can also be visible in the 9-o'clock position (1). Wabco™ Air Compressors Set the timing mark on the air compressor gear to the 9o'clock position when looking at the gear.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Page 12-27 Install Wabco™ Air Compressors For Wabco™ procedure. air compressors, use the following Prior to installing the air compressor, identify which gasket is going to be installed so that, if necessary, the basekt can be properly oriented.
Air Compressor Page 12-28 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 NOTE: For low mount designs, it is important to make sure of appropriate positioning of the air compressor relative to the engine block in order to minimize gear last. This will help minimize noise from the gear train during normal engine operation. Loosen the six air compressor mounting capscrews.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Page 12-29 CAUTION Air compressor failure can result if any of the mating surfaces are not touching prior to tightening. Verify the air compressor support bracket is contacting the cylinder block support bracket. Adjust the brackets as necessary. If necessary, loosen the cylinder block support bracket to align the components. Tighten the air compressor support bracket mounting capscrews (1).
Air Governor (Air Compressor Will Not Pump) Page 12-30 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Install the four air compressor support bracket mounting capscrews and finger-tighten. Tighten the air compressor support bracket mounting capscrews in the sequence shown. Torque Value: 24 N•m [ 212 in-lb ] Finishing Steps WARNING Batteries can emit explosive gases.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Governor (Air Compressor Pumps Continuously) Page 12-31 Activate the air compressor and allow the air pressure to buildup. If pressure is reading below 125 psi according to the dash gauge, relieve 25 psi of pressure by applying the vehicle brakes to see if the air compressor starts to pump again. If the air compressor only pumps to the level it was before then the air governor needs to be inspected for proper operation.
Air Governor (Air Compressor Pumps Continuously) Page 12-32 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 NOTE: Be sure the air pressure gauge is accurate and the supply lines and fittings are in good condition before performing any air pressure checks. Use a master gauge of known accuracy to check the air pressure gauge. Apply 690-kPa [100-psi] air pressure to the unloader port.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Leaks, Compressed Air System Page 12-33 Operate the engine and check for air leaks. Air Leaks, Compressed Air System (012-019) Initial Check Verify the unused unloader port, if applicable, on the air compressor has a pipe plug installed. Verify all unused ports are plugged with pipe plugs except for the exhaust port on the air governor. The air governor exhaust port must always be ventilated to the atmosphere.
Air Compressor (Oil Carryover) Page 12-34 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor (012-020) (Oil Carryover) Inspect for Reuse Perform this test in conjunction with troubleshooting the air compressor pumping oil into the air system. NOTE: Small oil deposits at the air dryer purge valve are normal. The air compressor is lubricated with engine oil, and small amounts of carryover are to be expected.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor (Oil Carryover) Page 12-35 Connect the oil carryover test tool, Part Number 4918883, to the air compressor cylinder head discharge port. NOTE: If the application presents restricted access to the air compressor, a high temperature flexible hose (minimum 15 mm [0.
Air Compressor (Oil Carryover) Page 12-36 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 NOTE: Compare the test results with the reference results shown below. Time Air Compressor Has Been In Service (Months/ Years): • Less Than 6 Months - Compressor in good condition • 6 Months to 2 Years - Compressor in good condition • Greater Than 2 Years - Compressor in good condition.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Rear Bearing Housing, Two Cylinder Page 12-37 Air Compressor Rear Bearing Housing, Two Cylinder (012-112) General Information Before removing the rear bearing housing of the air compressor, always check to make sure parts are available for the type of air compressor being serviced. If parts are not available, it will be necessary to replace the entire air compressor.
Air Compressor Rear Bearing Housing, Two Cylinder Page 12-38 ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. Remove the o-ring seal. Gasket sealing surfaces must be clean and free of all old gasket material, carbon, rust, and other buildup.
ISB, ISBe and QSB (Common Rail [...] Section 12 - Compressed Air System - Group 12 Air Compressor Rear Bearing Housing, Two Cylinder Page 12-39 Tighten the capscrews in the sequence shown. Torque Value: 22 N•m [ 195 in-lb ] Install the drive adapter and mounting capscrew. NOTE: Loctite™ 638, or equivalent must be applied to the capscrew during installation. Tighten the capscrew. Torque Value: 25 N•m [ 221 in-lb ] Finishing Steps • Install the air compressor. Refer to Procedure 012-014 in Section 12.
Air Compressor Rear Bearing Housing, Two Cylinder Page 12-40 ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Page 13-a Section 13 - Electrical Equipment - Group 13 Section Contents Page Alternator ...................................................................................................................................................................13-2 Finishing Steps.......................................................................................................................................................
Page 13-b ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Service Tools Page 13-1 Service Tools Electrical Equipment The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from a local Cummins® Authorized Repair Location. Tool No.
Alternator Page 13-2 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Alternator (013-001) General Information Due to the number of different alternator brands and configurations, the following procedure has been generalized to cover the most common configurations. Consult the alternator manufacturer for any information that is not covered in this procedure.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Alternator Page 13-3 One Wire System, Typical Alternator (Delco-Remy™) One Wire System, Typical Alternator (Delco-Remy™) 3 GRD* 4 R* 5 6 BAT I* Ground Charge indicator, automatic lockout system, tachometer** Battery Indicator light *Not all alternators have this feature. **Provides voltage pulses at about one-half system voltage at a frequency of one-tenth of generator rpm.
Alternator Page 13-4 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Three Wire System, Typical Alternator (Delco-Remy™) Key Terminal 1 Blade number 1* 2 Blade number 2 3 GRD* 4 R* 5 6 Connected To Indicator light Voltage sense Ground Charge indicator, automatic lockout system, tachometer** Battery Indicator light BAT I* *Not all alternators have this feature. **Provides voltage pulses at about one-half system voltage at a frequency of one-tenth of alternator rpm.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Alternator Page 13-5 Initial Check Check the drive belt and alternator pulley, to be sure the alternator is rotating properly. If any problems exist, check the following: 1 If the drive belt is slipping on the alternator pulley, inspect the drive belt.Refer to Procedure 008-002 in Section 8. Refer to Procedure 008-087 in Section 8. Inspect the belt tensioner. 2 Remove the drive belt. Refer to Procedure 008-002 in Section 8.
Alternator Page 13-6 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Connect a carbon-pile load (battery/alternator tester) across the batteries in one of the battery boxes. Clamp an induction pickup-type ampere-hour meter around the battery cable; or use the digital multimeter, Part Number 3164488 or 3164489, with the clamp-on current probe, Part Number 3164490. WARNING Batteries can emit explosive gases.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Alternator Page 13-7 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To avoid arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Acid is extremely dangerous and can damage the machinery and can also cause serious burns.
Alternator Page 13-8 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Marine Applications WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Acid is extremely dangerous and can damage the machinery and can also cause serious burns.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Alternator Page 13-9 Hinge Mount Remove the alternator link capscrew. Remove the alternator mounting capscrew. Remove the alternator. Marine Applications Remove the capscrew from the top of the alternator and alternator link. Remove the mounting capscrew at the bottom of the alternator and alternator mounting bracket. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.
Alternator Page 13-10 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Typical Delco™ Alternator Wiring System The main function of the indicator (I) terminal is to indicate if the alternator is working correctly. Typically, an indicator light is wired to this terminal. If the alternator is not charging properly, the light turns on. Another function of the indicator (I) terminal is that it can be used to supply up to 1 ampere of output at system voltage.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Alternator Page 13-11 Install Spool Mount Install the alternator and the bottom alternator mounting capscrew and nut. Install the upper alternator link mounting capscrew at the top of the alternator. Tighten the capscrews. Torque Value: Lower Mounting Capscrew Step 1 40 N•m [ 30 ft-lb ] Torque Value: Upper Link Mounting Capscrew Step 1 24 N•m [ 212 in-lb ] Pad Mount Install the alternator.
Alternator Page 13-12 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Marine Applications Spool Mount or Saddle Mount Inspect the water inlet connection. Test fit the alternator link to the water inlet. If the machined area is not sufficient for the link to sit flat as installed, the inlet will need to be replaced. Refer to Procedure 008-082 in Section 8. Install the alternator and alternator mounting capscrew. Install the alternator link.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Alternator Bracket Page 13-13 Marine Applications WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To avoid arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING Acid is extremely dangerous and can damage the machinery and can also cause serious burns.
Alternator Bracket Page 13-14 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Remove the drive belt. Refer to Procedure 008-002. Remove the alternator. Refer to Procedure 013-001. Marine Applications WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Alternator Bracket Page 13-15 Pad Mount Remove the alternator bracket mounting capscrews. Remove the alternator bracket. Marine Applications Remove the two alternator mounting bracket capscrews. Remove the alternator mounting bracket. Clean and Inspect for Reuse WARNING When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury.
Alternator Bracket Page 13-16 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Inspect the alternator brackets for cracks or damage. If any cracks are found on the alternator brackets, they must be replaced. Install Spool Mount NOTE: On some applications, the alternator bracket and water inlet are combined in the same bracket. Refer to Procedure 008-082, where applicable. Install the upper alternator bracket and mounting capscrews. Install the capscrew.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Alternator Bracket Page 13-17 Marine Applications NOTE: The coolant connection tube has two dowel pins used for correctly locating the alternator mounting bracket during installation. Install the alternator mounting bracket over the two dowel pins. Install the two alternator bracket mounting capscrews and tighten. Torque Value: 54 N•m [ 40 ft-lb ] Finishing Steps Automotive and Industrial Install the alternator.
Batteries Page 13-18 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Batteries (013-007) Initial Check If conventional batteries are used, remove the cell caps or covers, and check the electrolyte level. NOTE: Maintenance-free batteries are sealed and do not require the addition of water. Fill each battery cell with distilled water. Refer to the battery manufacturer's specifications.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Battery Cables (013-009) and Starter Magnetic Switch Page 13-19 Connections Initial Check WARNING Batteries can emit explosive gases. To reduce the possibility of severe personal injury, always ventilate the compartment before beginning the servicing of the batteries. Always detach the negative (-) battery cable first, and attach the negative (-) battery cable last.
Starter Magnetic Switch Page 13-20 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Resistance Check WARNING Be sure the starter motor switch is in the OFF position to reduce the possibility of electrical shock and personal injury. Remove the cable connecting the magnetic switch to the starter motor solenoid from the magnetic switch terminal. Connect the leads of the digital multimeter, Part Number 3377161, or equivalent, to the two large switch terminals.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 • Turn the keyswitch to the OFF position. • Remove the multimeter leads, and connect the magnetic switch to the starter motor solenoid wire. Starter Solenoid Page 13-21 Starter Solenoid (013-019) Initial Check Before troubleshooting the starter motor, make sure the battery terminals are not loose or corroded.
Starter Solenoid Page 13-22 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 If the wire connecting the starter solenoid and keyswitch is not loose or damaged and the starter will not operate: • Remove the cable connecting the starter and starter solenoid from the solenoid terminal. • Connect the multimeter positive (+) lead to the solenoid "S" or switch terminal and the negative (-) lead to the chassis or an engine ground location.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 • Check the cable connecting the starter motor to the battery for breaks, and for loose or corroded connections. • If the cables are not loose or damaged, the starter motor is defective and must be replaced.
Starting Motor Page 13-24 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 If the crankshaft does not rotate or requires more than the normal effort to bar, check for an internal malfunction or a problem with the drive unit and/or accessories. If the engine cranking speed is too slow/will not crank at all, and the engine rotates freely: Make sure the wiring connections are clean, tight, and not damaged. Check the battery voltage. Refer to Procedure 013-007 in Section 13.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Starting Motor Page 13-25 WARNING When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury. WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.
Starting Motor Page 13-26 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Measure Using an inside micrometer or a vernier caliper, measure the distance from the starting motor mounting flange to the forward face of the front side of the flywheel ring gear. NOTE: Include any spacers previously removed when completing the measurement. Starting Motor Spacing mm 49.28 MIN 52.32 MAX in 1.94 2.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Starting Motor Page 13-27 Cummins® Branded Starters CAUTION Do not overtighten the electrical connections. Starter damage can result. NOTE: Use the location tags to help identify where each wire connection goes. Connect the electrical connections to the starter motor.
Charging System Indicator Page 13-28 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Charging System Indicator (013-023) Initial Check NOTE: Be positive that the correct terminals are used on the alternator. Refer to the alternator manufacturer's instructions. Trouble with the charging system can be indicated by the indicator lamp or ammeter. Check the indicator lamp for normal operation as shown below.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Key Switch Page 13-29 If the lamp is off when the switch is in the ON position and the engine is not running, there can be an open circuit. Check for a blown fuse, a burned out bulb, defective bulb socket, or an open circuit in number 1 or "D+" lead between alternator and keyswitch. If the lamp is on when the switch is on and the engine is running, disconnect the lead to the alternator.
Key Switch Page 13-30 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 Turn the keyswitch to the START position. The multimeter must indicate system voltage. If there is no voltage: • Turn the key switch to the OFF position. • Check for supply voltage to the keyswitch by connecting the multimeter positive (+) lead to the key switch terminal having a wire connecting the keyswitch to the starter motor solenoid "B" terminal. Turn the keyswitch to the START position.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 ECM Unswitched Blocks (013-047) Power ECM Unswitched Power Terminal Blocks Page 13-31 Terminal General Information In addition to the heavy duty battery connections used for the starter, marine engines equipped with an Electronic Control Module (ECM) and the SmartCraft system use an additional unswitched power supply.
ECM Unswitched Power Terminal Blocks Page 13-32 ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 If for some reason the terminal blocks are damaged, new terminal blocks can be obtained and installed. Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries.
ISB, ISBe and QSB (Common Rail [...] Section 13 - Electrical Equipment - Group 13 ECM Unswitched Power Terminal Blocks Page 13-33 Remove the upper and lower mounting capscrews from the positive or negative terminal blocks. Slide the terminal blocks out the back of the mounting plate. Some plates may have to be removed to complete this operation. Install Install the new positive or negative terminal block through the rear of the mounting plate.
ECM Unswitched Power Terminal Blocks Page 13-34 ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Page 14-a Section 14 - Engine Testing - Group 14 Section Contents Page Aftertreatment Testing ........................................................................................................................................... 14-54 Regeneration..........................................................................................................................................................
Page 14-b ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Service Tools Page 14-1 Service Tools Engine Testing The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from a local Cummins® Authorized Repair Location. Tool No.
Service Tools Page 14-2 Tool No. ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Tool Description Tool Illustration Drivetrain Dynomometer Used to measure engine horse power. 3375710 Engine Control Used to start and control engine speed. 3163890 Harness 3164036 Used to in conjunction with engine control, Part Number 3163890, to connect unit to the ISB (4 cylinder) and ISBe (4 and 6 cylinder) series engines.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Engine Testing Dynamometer) (014-002) Engine Testing (Chassis Dynamometer) Page 14-3 (Chassis Setup The performance of an engine installed in on-highway vehicles can be tested on a chassis dynamometer.
Engine Testing (Chassis Dynamometer) Page 14-4 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 While operating the chassis dynamometer, follow the general safety precautions listed below: • Use tires that have more than 160 km [100 mi] of use. Do not use new tires. • Do not use recapped tires or tires of different sizes or designs. • Make sure the tires are inflated to the manufacturer's specifications.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Engine Testing (Chassis Dynamometer) Page 14-5 WARNING Some exhaust gas constituents may be toxic and/or carcinogenic. Make sure the ventilation hose does not leak. Adjust the vehicle and dynamometer room exhaust system to make sure all the exhaust gases are removed from the room. Read the chassis dynamometer and vehicle manufacturer's recommendations and specifications for testing procedures.
Engine Testing (Chassis Dynamometer) Page 14-6 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Test WARNING Check the coolant level only when the engine is stopped. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Failure to do so can cause personal injury from heated coolant spray.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Engine Testing (Chassis Dynamometer) Page 14-7 The number of instruments and gauges required to perform a chassis dynamometer test will vary according to type and the capability of the test equipment used. See the service tools listed at the beginning of this section. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
Engine Testing (Chassis Dynamometer) Page 14-8 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 To correctly monitor an engine's performance, record the following parameters: • Lubricating oil pressure (vehicle instrument panel) • Engine speed (rpm) (vehicle instrument panel) • Wheel horsepower (whp) (dynamometer controls) • Blowby: Refer to Procedure 014-010 in Section 14. • Exhaust back pressure: • Use the following procedure in the Service Manual, ISF2.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Engine Run-in Dynamometer) (014-003) Engine Run-in (Chassis Dynamometer) Page 14-9 (Chassis Test NOTE: Refer to Procedure 014-002 before operating the engine to avoid internal component damage. NOTE: Refer to Procedure 014-005 for general operating procedures and safety precautions. NOTE: Operate the vehicle in a gear that produces a road speed of 90 to 95 km/h [56 to 59 mph].
Engine Run-in (Without Dynamometer) Page 14-10 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Operate the engine at torque peak rpm and full load for 4 minutes. Check the gauges and record the readings. NOTE: Refer to the engine data sheet for the torque peak rpm of the engine model being tested. CAUTION Do not shut off the engine immediately after the run-in is completed.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Engine Testing (Engine Dynamometer) Page 14-11 NOTE: Do not idle the engine for more than 5 minutes at any one time during the first 160 km [99 mi] of operation. Engine Testing (Engine Dynamometer) (014-005) Setup Use engine lifting fixture, Part Number 3822512, to remove the engine from the chassis. Refer to Procedure 000-001 Install the engine to the test stand. Align and connect the dynamometer.
Engine Testing (Engine Dynamometer) Page 14-12 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Fill the cooling system with coolant to the bottom of the fill neck in the radiator fill (or expansion) tank. Refer to Procedure 008-018 Inspect the engine for coolant leaks at connections, fittings, plates, and plugs. Repair as needed. Refer to Procedure 008-020 if any leaks are found. Measure the coolant pressure at a coolant tap on the exhaust side of the cylinder head.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Engine Testing (Engine Dynamometer) Page 14-13 CAUTION Do not attempt to install pipe thread fittings in plastic or rubber intake piping. Damage to the components can occur. Air Inlet Restriction Connect a water manometer, Part Number ST-1111-3, to the turbocharger air inlet pipe to test air restriction.
Engine Testing (Engine Dynamometer) Page 14-14 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 CAUTION Do not attempt to install pipe thread fittings in plastic or rubber intake piping. Damage to the piping can result. If INSITE™ electronic service tool is available, use it to monitor intake manifold pressure during the test. This eliminates the need to install a gauge as shown below.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Engine Testing (Engine Dynamometer) Page 14-15 CAUTION The lubricating oil system must be primed before operating the engine after it has been rebuilt to avoid internal damage. Priming the Lubricating System Remove the plug. To prime the system using external pressure, connect the supply to a tapped hole in the main oil rifle. Use a pump capable of supplying 210 kPa [30 psi] of continuous pressure.
Engine Testing (Engine Dynamometer) Page 14-16 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 • Disconnect the turbocharger lubricating oil supply tube. • Pour 50 to 60 cc [2 to 3 fl oz] of clean 15W-40 oil into the turbocharger oil supply hole. • Connect the oil supply tube to the turbocharger. CAUTION Mechanical overtightening can distort the threads or damage the filter element seal. • Fill the lubricating oil filters with clean 15W-40 oil.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Engine Testing (Engine Dynamometer) Page 14-17 Allow the oil to drain into the oil pan, and measure the oil level with the dipstick. Add oil, as necessary, to bring the level to the high level mark on the dipstick. Lubricate the gasket on the fuel filter with clean 15W-40 oil. Fill the fuel filter with clean fuel. Screw the fuel filter onto the fuel filter head until the gasket contacts the fuel filter head surface.
Engine Run-in (Engine Dynamometer) Page 14-18 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Inspect the voltage rating on the starter motor before installing the electrical wiring. Attach electrical wires to the starter motor and the batteries, if used, negative (-) cable last. NOTE: If another method of starting the engine is used, follow the manufacturer's instructions to make the necessary connections.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Engine Run-in (Engine Dynamometer) Page 14-19 It is good practice to observe these measurements even if engine performance meets specifications. If engine performance does not meet specifications, these measurements can indicate possible reasons for underperformance. CAUTION Do not crank the engine for more than 30 seconds. Excessive heat will damage the starter motor.
Engine Run-in (Engine Dynamometer) Page 14-20 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 NOTE: Repair all leaks or component problems before continuing the engine run-in. Listen for unusual noises. Watch for coolant, fuel, and lubricating oil leaks. Check for correct engine operation in general. Move the throttle to obtain 1200 rpm engine speed, and set the test load to 25 percent of the rated load.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Engine Run-in (Engine Dynamometer) Page 14-21 Move the throttle lever to its fully opened position, and increase the dynamometer load until the engine speed is at torque peak rpm. Operate the engine at this speed and load level for 10 minutes or until the blowby becomes stable within specifications. Check all gauges, and record the data. Reduce the dynamometer load until the engine speed increases to the engine's rated rpm.
Engine Run-in (Engine Dynamometer) Page 14-22 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Engine Dynamometer Test - Performance Check Make sure the air compressor will be unloaded during the performance check. CAUTION Do not crank the engine for more than 30 seconds. Excessive heat will damage the starter motor. Crank the engine and observe the oil pressure when the engine starts.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Engine Run-in (Engine Dynamometer) Page 14-23 Make sure the engine is at operating temperature (71.1°C [160°F] minimum coolant temperature). Move the throttle pedal to 100-percent throttle. Adjust the dynamometer load until the engine maintains the rated rpm. Allow the readings to stabilize. Read the horsepower.
Engine Testing (In Chassis) Page 14-24 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Remove all test instrumentation. Remove the engine from the dynamometer. NOTE: If the engine is to be stored temporarily and does not have permanent-type antifreeze, it is necessary to drain all coolant. Refer to the Operation and Maintenance Manual, ISB (4 cylinder) and ISBe (4 and 6 cylinder) Engines Bulletin . Prepare the engine for engine painting.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Engine Testing (In Chassis) Page 14-25 Refer to the INSITE™ service tool user's manual for detailed setup for dynamometer instructions. Automated Cylinder Performance Test The automated cylinder performance test is the most thorough test of cylinder performance (versus the singlecylinder cutout test, which tests the performance of individual cylinders only).
Engine Testing (In Chassis) Page 14-26 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Refer to the INSITE™ service tool user's manual for detailed automated cylinder performance test instructions. After Running the Automated Cylinder Performance Test It is normal for the engine rpm to vary during the test, but if the engine rpm goes to high idle for more than 5 seconds at a time, shut off the engine. Once the test is complete, make sure to: 1 Shut off engine.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Crankcase Blowby, Measure Page 14-27 Crankcase Blowby, Measure (014-010) General Information Excessive crankcase blowby can indicate an engine or engine-related component malfunction that allows combustion gases or air to enter the crankcase. This results in the buildup of higher than normal crankcase pressure, which results in increased levels of blowby.
Crankcase Blowby, Measure Page 14-28 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 It is important to note that the terms blowby and carryover (oil out of the breather tube) are commonly used interchangeably. When measuring blowby, and there is an excessive amount of oil coming out of the breather tube, the quantity of oil can affect the blowby measurement. The blowby measurement is affected by the oil collecting on the orifice of the blowby measurement service tool.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Crankcase Blowby, Measure Page 14-29 The tools used to measure blowby are similar in design. The difference between the tools is in the size of the orifice. Different size orifices are available to more accurately measure blowby by accommodating the wide variety of engine configurations and ratings. This is due to the fact that engine blowby is dependent on the volume of intake airflow.
Crankcase Blowby, Measure Page 14-30 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 The following charts show the relationship of measured pressure to flow rate, depending on the blowby tool used. Blowby Conversion Table (5.61-mm [0.221-in] orifice, Blowby Tool, Part Number 3822476) mm [in] of H2O Liter [cfm] per Minute 25.4 [1] 50.8 [2] 76.2 [3] 101.6 [4] 127 [5] 152.4 [6] 177.8 [7] 203.2 [8] 228.6 [9] 254 [10] 279.4 [11] 304.8 [12] 330.2 [13] 355.6 [14] 381 [15] 406.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Crankcase Blowby, Measure Page 14-31 Blowby Conversion Table (7.67-mm [0.302-in] orifice, Blowby Tool, Part Number 3822566) mm [in] of H2O Liter [cfm] per Minute 228.6 [9] 254 [10] 279.4 [11] 304.8 [12] 330.2 [13] 355.6 [14] 381 [15] 406.4 [16] 431.8 [17] 457.2 [18] 482.6 [19] 508 [20] 533.4 [21] 558.8 [22] 584.2 [23] 609.6 [24] 172 [6.074] 180 [6.357] 187 [6.604] 193 [6.816] 200 [7.063] 206 [7.275] 211 [7.451] 217 [7.
Crankcase Blowby, Measure Page 14-32 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 If internal engine damage is suspected to be the cause of the excessive blowby condition, other steps can be taken to confirm this. The steps include: • Confirm engine maintenance practices • Cut the oil filter open and check for debris • Take an oil sample and inspect for contamination.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Crankcase Blowby, Measure Page 14-33 MidRange Blowby Specifications Chart Blowby Specification For New or Rebuild Blowby Specification For Troubleshooting mm [in] H2O mm [in] H2O Engine Model A1400 and A1700 (Naturally Aspirated) A2000 and A2300 (Naturally Aspirated) A2000 and A2300 (Turbocharged) ISF2.8 ISF3.8 B3.3 Tier 1, 2 B3.3, QSB3.3 Tier 3 B3.3, QSB3.3 Tier 4 Interim (Less than 74 HP) B3.9, QSB3.9-30, B4.5, QSB4.
Crankcase Blowby, Measure Page 14-34 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Initial Check NOTE: The location and type of crankcase breathers vary by engine configuration (Front Gear Train or Rear Gear Train) and/or engine application (Marine, Industrial, and Automotive). Prior to measuring blowby pressure, check the crankcase breather tube for obstructions. • Use the following procedure in the C Series Engines Troubleshooting and Repair Manual, Bulletin 3666003.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Crankcase Blowby, Measure Page 14-35 Check the engine oil level and, if necessary, proper calibration of the dipstick. If the level is too high, it can cause a higher than normal blowby pressure and/or excessive carryover. • Use the following procedure in the C Series Engines Troubleshooting and Repair Manual, Bulletin 3666003. Refer to Procedure 007-011 in Section 7. • Use the following procedure in the B3.9, B4.5, B4.
Crankcase Blowby, Measure Page 14-36 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Measure Choose the appropriate blowby measurement service tool to use for the engine being serviced. Reference the MidRange Blowby Specifications Chart in this procedure and determine the appropriate blowby measurement service tool to use, based on engine type and/or horsepower. Blowby Tool Part Number Orifice Size mm [in] 3822476 5.61 mm [0.221 in] 3822566 7.67 mm [0.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Crankcase Blowby, Measure Page 14-37 For ISB CM2150 engines that have the crankcase ventilation filter located on top of the rocker lever cover, use the following steps to connect the blowby measurement tools. • Disconnect the crankcase ventilation line from the turbocharger/original equipment manufacturer (OEM) intake plumbing. If the crankcase ventilation line is connected to the turbocharger housing, remove the inlet fitting.
Crankcase Blowby, Measure Page 14-38 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 For ISB CM2150 engines that have the crankcase ventilation filter located at the rear of the engine, use the following steps to connect the blowby measurement tools. • Disconnect the crankcase ventilation line from the crankcase ventilation filter housing. Plug or cap the crankcase ventilation filter housing.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 • Crankcase Blowby, Measure Page 14-39 Use a suitable fitting to plug the crankcase breather tube. Engine Blowby Contribution: Operate the engine at rated speed and under load by: • For engine run-in, a chassis dynamometer or engine dynamometer. • For engine testing, a chassis dynamometer or engine dynamometer. • A stall speed test (for engines equipped with automatic transmissions only).
Crankcase Blowby, Measure Page 14-40 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Turbocharger Blowby Contribution: NOTE: For engines equipped with dual turbochargers, the Turbocharger Oil Drain Line Isolation Test may need to be conducted twice to determine which turbocharger is contributing high blowby. The first test should be conducted with both turbocharger drain lines isolated.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Crankcase Blowby, Measure Page 14-41 Preferred Turbocharger Isolation Method: Install a hose assembly with two shutoff valves (A and B), as shown in the illustration, between the turbocharger and turbocharger drain line location in the cylinder block. The valves must have a minimum inside diameter of 19 mm [0.75 in]. Place the other hose in a 8 to 9 liter [2 to 3 gal] container.
Crankcase Blowby, Measure Page 14-42 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 WARNING To reduce the possibility of personal injury, keep hands, long hair, jewelry, and loose fitting or torn clothing away from fans and other moving parts. WARNING Troubleshooting presents the risk of equipment damage, personal injury, or death. Troubleshooting must be performed by trained, experienced technicians.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Crankcase Blowby, Measure Page 14-43 Determine the turbocharger blowby pressure contribution by determining the difference in the blowby pressure measurement with the turbocharger drain isolated, valve (A) open, and turbocharger drain not isolated, valve (A) closed.
Crankcase Blowby, Measure Page 14-44 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 If installed, remove the turbocharger oil drain line assembly and shutoff valves. • Use the following procedure in the C Series Engines Troubleshooting and Repair Manual, Bulletin 3666003. Refer to Procedure 010-045 in Section 10. • Use the following procedure in the B3.9, B4.5, B4.5 RGT, and B5.9 Service Manual, Bulletin 3666087. Refer to Procedure 010-045 in Section 10.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Crankcase Blowby, Measure Page 14-45 WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.
Crankcase Blowby, Measure Page 14-46 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 With the regulated shop air pressure line still connected to the air compressor governor/unloader air signal port, regulate the signal pressure so that the air compressor starts pumping (system pressure will begin to rise again at this point). Use the pressure value recorded previously as a set point.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Crankcase Blowby, Measure Page 14-47 Determine the air compressor blowby pressure contribution by determining the difference in the blowby pressure measurement with the air compressor pumping and the air compressor not pumping. Blowby Pressure Differential Air Compressor Contribution Maximum: 30 percent If the air compressor blowby contribution is out of specification, replace the air compressor.
Crankcase Blowby, Measure Page 14-48 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury. With the engine shut off, bleed the vehicle's air system down by opening the drain cock on the wet tank to release compressed air from the system.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Crankcase Blowby, Measure Page 14-49 Also, measure exhaust back pressure during exhaust brake operation. Operate the engine until a steady reading is obtained. NOTE: When measuring blowby, the value can “spike” initially as the engine reaches peak power and rated speed. Wait for the blowby measurement to stabilize before taking a reading.
Crankcase Blowby, Measure Page 14-50 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Valve stem clearance is excessive or the valve stem seals are damaged. • Use the following procedure in the C Series Engines Troubleshooting and Repair Manual, Bulletin 3666003. Refer to Procedure 002-004 in Section 2. • Use the following procedure in the B3.9, B4.5, B4.5 RGT, and B5.9 Service Manual, Bulletin 3666087. Refer to Procedure 002-004 in Section 2.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Crankcase Blowby, Measure Page 14-51 Cylinder head valve guides are excessively worn. • Use the following procedure in the C Series Engines Troubleshooting and Repair Manual, Bulletin 3666003. Refer to Procedure 002-004 in Section 2. • Use the following procedure in the B3.9, B4.5, B4.5 RGT, and B5.9 Service Manual, Bulletin 3666087. Refer to Procedure 002-004 in Section 2. • Use the following procedure in the ISB and QSB5.
Crankcase Blowby, Measure Page 14-52 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Air compressor is malfunctioning. • Use the following procedure in the C Series Engines Troubleshooting and Repair Manual, Bulletin 3666003. Refer to Procedure 012-014 in Section 2. • Use the following procedure in the B3.9, B4.5, B4.5 RGT, and B5.9 Service Manual, Bulletin 3666087. Refer to Procedure 012-014 in Section 12. • Use the following procedure in the ISB and QSB5.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Crankcase Blowby, Measure Page 14-53 Piston or piston rings are worn or damaged. • Use the following procedure in the C Series Engines Troubleshooting and Repair Manual, Bulletin 3666003. Refer to Procedure 001-043 in Section 1. • Use the following procedure in the B3.9, B4.5, B4.5 RGT, and B5.9 Service Manual, Bulletin 3666087. Refer to Procedure 001-043 in Section 1. • Use the following procedure in the ISB and QSB5.
Aftertreatment Testing Page 14-54 ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Aftertreatment Testing (014-013) Regeneration CAUTION Engine systems equipped with exhaust aftertreatment must operate on low sulphur diesel with a maximum sulfur content of 50 parts per million. The use of high sulfur fuel will shorten the life of certain components in the exhaust system, including the diesel oxidation catalyst.
ISB, ISBe and QSB (Common Rail [...] Section 14 - Engine Testing - Group 14 Aftertreatment Testing Page 14-55 this point, the fuel injection sequencing is adjusted and it will be noted that the engine running tone will change. This is normal during the regeneration process. At the end of this elevated speed period, the engine will decelerate to idle for a short cooling phase, whereby the regeneration process will be completed.
Aftertreatment Testing Page 14-56 ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Page 16-a Section 16 - Mounting Adaptations - Group 16 Section Contents Page Engine Drive Shaft ..................................................................................................................................................16-58 Adjust......................................................................................................................................................................
Page 16-b ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Remove.................................................................................................................................................................. 16-31 Flywheel Ring Gear ................................................................................................................................................ 16-45 Assemble.................................................................
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Service Tools Page 16-1 Service Tools Mounting Adaptations The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from a local Cummins® Authorized Repair Location. Tool No. Tool Description Tool Illustration Crack Detection Kit Used to detect cracks in engine components.
Service Tools Page 16-2 Tool No. ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Tool Description Tool Illustration Oil Seal replacer (Rear) 3164660 Used remove/install rear crankshaft seal on engines equipped with unitized seal. Vibration Damper Guide Pin Used to help align the vibration damper. M12 x 1.75 3376638 Accessory Drive Support Guide Pin Used to help align the accessory drive support. M10 x 1.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Engine Lifting Brackets Page 16-3 Engine Lifting Brackets (016-001) Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Disconnect the batteries.
Engine Lifting Brackets Page 16-4 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Clean and Inspect for Reuse WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury. WARNING Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Engine Lifting Brackets Page 16-5 WARNING Four 20 mm, grade 10.9, hex head capscrews must be used to install the front lifting bracket. If shorter capscrews or capscrews of a different grade are used, the engine can fall when lifting the engine. Personal injury and property damage can result. For engines equipped with pad mount alternators, install the capscrews and front bracket. Tighten the capscrews.
Engine Support Bracket, Front Page 16-6 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Engine Support (016-002) Bracket, Front General Information Due to the number of different engine mounting configurations, the following procedure is written to be generic. Some of the illustrations may not represent the actual part being removed and installed. Initial Check CAUTION Damaged engine mounts and brackets can cause engine misalignment.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Engine Support Bracket, Front Page 16-7 Remove WARNING The engine lifting equipment must be designed to lift the engine and transmission as an assembly without causing personal injury. WARNING The component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component. Use a hoist or lifting fixture to support the front of the engine.
Engine Support Bracket, Front Page 16-8 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 WARNING The engine lifting equipment must be designed to lift the engine and transmission as an assembly without causing personal injury. WARNING The component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Engine Support Bracket, Front Page 16-9 Install For Front Mount, install the front mount bracket and capscrews. Torque Value: Grade 8.8 Step 1 80 N•m [ 60 ft-lb ] Torque Value: Grade 10.9 Step 1 115 N•m [ 85 ft-lb ] Torque Value: Grade 12.9 Step 1 125 N•m [ 95 ft-lb ] For Side Mount, install the side mount brackets and capscrews. Torque Value: Grade 8.8 Step 1 80 N•m [ 60 ft-lb ] Torque Value: Grade 10.
Engine Support Bracket, Front Page 16-10 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 NOTE: Make sure to install any shims or spacers in the same location as removed. Install the front engine mounting bolt. Install the hexagonal jam nut and tighten. Torque Value: 350 N•m [ 258 ft-lb ] NOTE: After tightening the engine mounting bolt, inspect for signs of contact between the side brackets and the front engine support bracket.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Engine Support (016-003) Bracket, Engine Support Bracket, Rear Page 16-11 Rear General Information Due to the number of different engine mounting configurations, the following procedure is written to be generic. Some of the illustrations may not represent the actual part being removed and installed. Initial Check CAUTION Damaged engine mounts and brackets can cause engine misalignment.
Engine Support Bracket, Rear Page 16-12 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Remove the rear support capscrews and bracket. Clean and Inspect for Reuse WARNING When using a steam cleaner, wear protective clothing, as well as safety glasses or a face shield. Hot steam can cause serious personal injury. WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturers recommendations for use.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flexplate Page 16-13 Install Install the support bracket and mounting capscrews. Torque Value: 77 N•m [ 57 ft-lb ] NOTE: Make sure to install any shims or spacers in the same location as removed. Lower the rear of the engine. Install the rear engine mount fasteners. Tighten to the specifications. original equipment manufacturer's Remove the lifting fixture or hoist from the rear of the engine.
Flexplate Page 16-14 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING This component or assembly weighs greater than 23 kg [50 lb].
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flexplate Page 16-15 Electrical An electrical issue can typically be identified by seeing damage to the ring gear of the flywheel 360 degrees around the circumference of the ring gear (commonly called 360 degree milling). The following can be causes for electrical issues: 1 The operator is attempting to start engine while engine is already running.
Flexplate Page 16-16 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Remove the flexplate mounting capscrews. Remove the flexplate from the flywheel. Inspect for Reuse Inspect the teeth of the ring gear for chips or uneven wear. Check the flexplate for cracks. Replace the flexplate if any damage is found. Check the flexplate for cracks at the mounting holes, drive splines, and the inner drive plate. Replace the flexplate if any damage is found.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flexplate Page 16-17 Install the flexplate and flexplate mounting capscrews. Tighten the capscrews. Torque Value: 44 N•m [ 32 ft-lb ] If the engine is equipped with a flex-coupling guard plate, install the flex-coupling guard plate onto the flywheel housing. Position the wiring harness connector at the 11 o'clock position, as shown in the illustration. Install a capscrew to hold it in place.
Flywheel Page 16-18 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. WARNING This component or assembly weighs greater than 23 kg [50 lb].
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flywheel Page 16-19 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Disconnect the batteries. Remove the gear drive unit. Refer to the OEM instructions. Remove the flexplate.
Flywheel Page 16-20 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Mechanical A mechanical issue can typically be identified by seeing damage to the ring gear of the flywheel in 3 distinct locations for 6 cylinder engines (commonly called 120 degree milling), and 2 locations for 4 cylinder engines (commonly called 180 degree milling).
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flywheel Page 16-21 Remove NOTE: Use the barring tool, Part Number 3824591, to hold the flywheel to prevent rotation. Remove two capscrews 180 degrees apart. Install two M12 x 1.25 x 90-mm guide pins. NOTE: If a clutch is used in the equipment, the threads in the clutch pressure plate mounting capscrew holes can be metric or standard. Be sure to use the correct capscrews.
Flywheel Page 16-22 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Clean and Inspect for Reuse WARNING When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury. WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flywheel Page 16-23 Inspect the flywheel ring gear teeth for cracks and chips. If the ring gear teeth are cracked or broken, the ring gear must be replaced. Refer to Procedure 016-008 Assemble If removed, install a new pilot bearing. Use a mandrel and hammer to install the pilot bearing. The pilot bearing must be installed evenly with the pilot bore surface. Install Install two M12 x 1.
Flywheel Page 16-24 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Lubricate the threads of the capscrews and the surface of the washers with clean lubricating engine oil. Install the six capscrews. Remove the T-handles and guide pins. Install the remaining capscrews into the holes from which the guide pins were removed. NOTE: Use the barring tool, Part Number 3824591, to hold the flywheel to prevent rotation. Tighten the capscrews in a star pattern.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flywheel Page 16-25 Use the barring tool, Part Number 3824591, to rotate the crankshaft one complete revolution. Flywheel Total Indicator Reading mm 0.127 MAX in 0.0050 WARNING The component weighs 23 kg [51 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift the component.
Flywheel Page 16-26 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 WARNING The component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift the component. • Install the flywheel. • Inspect the bore runout again. • Replace the flywheel if the runout does not meet specifications. Flywheel Bore Runout mm 0.127 MAX in 0.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flywheel Page 16-27 Measure the distance from the center of the flywheel to the contact tip of the indicator (A). Use this measurement to determine which specification to use from the table below. The total indicator reading must not exceed the following specifications: Flywheel Radius (A) mm 101.6 127 152.4 177.8 203.2 228.6 254 Maximum Total Indicator Reading of Flywheel Face in 4 5 6 7 8 9 10 mm 0.140 0.13 0.156 0.
Flywheel Page 16-28 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Connect the batteries. Operate the engine and check for noise or vibration. Install the flexplate.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flywheel Housing Page 16-29 Operate the engine and check for noise or vibration. Flywheel Housing (016-006) Preparatory Steps WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.
Flywheel Housing Page 16-30 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 WARNING This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component. WARNING Support the rear of the engine using the rear support attached to the cylinder head. Failure to support the engine can cause personal injury. NOTE: Use a container that can hold at least 16 liters [27 US qt] of lubricating oil.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flywheel Housing Page 16-31 WARNING This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component. WARNING Support the rear of the engine using the rear support attached to the cylinder head. Failure to support the engine can cause personal injury. Drain the coolant. Refer to Procedure Procedure 008-018 Remove the starter motor.
Flywheel Housing Page 16-32 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Remove the rear support capscrews and bracket. WARNING This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component. Loosen the flywheel housing capscrews, but do not remove. Using a rubber hammer, loosen the flywheel housing so that the seal is broken between the flywheel housing and rear gear housing.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flywheel Housing Page 16-33 While supporting the flywheel housing, use a rubber hammer to loosen the flywheel housing. Remove the flywheel housing. NOTE: Some engines may have an additional rectangular seal between: 1 The flywheel housing and the rear seal carrier 2 The flywheel housing and camshaft journal bore of the block. NOTE: When removing the flywheel housing, note the location of any locating dowel rings.
Flywheel Housing Page 16-34 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Clean and Inspect for Reuse WARNING When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause serious personal injury. WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer's recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flywheel Housing Page 16-35 Inspect the rear face of the gear housing and flywheel housing mounting surface for cleanliness and raised nicks or burrs. Use fine crocus cloth to remove small nicks and burrs. Thoroughly clean the flywheel housing and gear housing mating surfaces. These surfaces must be clean of oil and debris.
Flywheel Housing Page 16-36 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Using the barring tool, Part Number 3824591, slowly rotate the crankshaft. Record the readings at the 3-o'clock (A), 6-o'clock (B) , and 9-o'clock positions (C). The values for A, B, and C could be positive or negative. Continue to rotate the crankshaft until the indicator is at the 12-o'clock position. Check the indicator to make sure the needle points to zero.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flywheel Housing Page 16-37 The maximum allowable total indicator reading determined by the diameter of the housing bore. specifications, replace the housing. NOTE: For rear gear train engines, the rear gear may also be the cause of the TIR being specification. Flywheel Housing Bore and Face Runout SAE Number 00 0 1/2 1 2 3 Bore Diameter mm 784.15 to 784.65 657.45 to 647.95 584.00 to 584.40 510.98 to 511.38 447.55 to 447.
Flywheel Housing Page 16-38 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Slowly rotate the crankshaft. Record the readings obtained at the 9-o'clock, 12-o'clock, and 3-o'clock positions as A, B, and C in the concentricity work sheet. Recheck zero at the 6-o'clock position. If it does not, the readings will be incorrect and the procedure will have to be redone. The values for A, B, and C could be positive or negative.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flywheel Housing Page 16-39 NOTE: Use the corresponding chart for the SAE 1, 2 or 3 flywheel housings being measured. Using the illustration, mark the total horizontal value on the horizontal side of the chart and the total vertical on the vertical side of the chart. Using a straightedge, find the intersection point of the total horizontal and total vertical values.
Flywheel Housing Page 16-40 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 CAUTION Do not remove the dowel rings located in the rear gear housing in an attempt to relocate the flywheel housing. The dowel rings are required to locate the rear gear housing to the cylinder block for proper gear alignment. Improper gear alignment will result in engine damage.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flywheel Housing Page 16-41 Assemble For wet flywheel housings, apply pipe sealant, Part Number 3375066, to any threaded plugs previously removed. Install and tighten the plugs. Refer to Procedure Procedure 017-007 for pipe plug torque values for different plug sizes. Install the access plate and new gasket. Install the capscrews and tighten.
Flywheel Housing Page 16-42 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Install NOTE: Before installing the flywheel housing, make sure any locating dowel rings are in the same position as when the flywheel housing was removed. NOTE: The sealant called for in the following step may appear different than what was originally used to build the engine. Apply a 1.5 to 2.0 mm [0.06 to 0.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flywheel Housing Page 16-43 If previously equipped, install a new rectangular seal for the camshaft journal bore to the back side of the flywheel housing. Apply a small amount of sealant, Part Number 3164067, to hold the seal in place until the flywheel housing is installed. Inspect the rear face of the cylinder block and flywheel housing mounting surface for cleanliness and raised nicks or burrs. Install two guide pins.
Flywheel Housing Page 16-44 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Install the rear engine support bracket and mounting capscrews. Torque Value: 77 N•m [ 57 ft-lb ] NOTE: Make sure to install any shims or spacers in the same location as removed. Lower the rear of the engine. Install the rear engine mount fasteners. Tighten to the OEM specification. Remove the lifting fixture or hoist from the rear of the engine.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Flywheel Ring Gear Page 16-45 WARNING Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last. Connect the batteries. Operate the engine and check for leaks. Install the flexplate/flywheel.
Engine Mounts Page 16-46 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Disassemble WARNING To reduce the possibility of severe eye damage, wear eye protection when you drive the gear from the flywheel. Do not use a steel drift pin or damage to the component can occur. Use the brass drift pin to drive the ring gear from the flywheel. Assemble Heat the new ring gear for 20 minutes in an oven preheated to 127°C [261°F].
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Engine Mounts Page 16-47 system is close to the frequency of the engine vibration. This can result in the mounting system operating at or near resonance, with a resulting magnification of the input vibration. This is obviously an undesirable situation.
Engine Mounts Page 16-48 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Remove WARNING The engine lifting equipment must be designed to lift the engine and transmission as an assembly without causing personal injury. WARNING This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Engine Mounts Page 16-49 Inspect for Reuse CAUTION Damaged engine mounts and brackets can cause engine misalignment. Drivetrain component damage can result in excessive vibration complaints. Inspect all rubber-cushioned mounts for cracks and other damage. Look for interference or contact between metal components. Inspect all mounting brackets for cracks and damaged bolt holes.
Propeller Shaft Page 16-50 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Install NOTE: Make sure to install any shims or spacers in the same location as removed. Align the engine in the chassis. Install the engine mount fasteners and tighten. Refer to the OEM service manual for torque specifications. Remove the lifting fixture or hoist from the engine lifting brackets. Connect all engine and chassis mounted accessories that were removed.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Propeller Shaft Page 16-51 Inspect the strut. Make sure the strut is mounted solidly to the hull. Check that the shaft is aligned with the cutlass bearing, and that the bearing is not worn. If any problems are noted, refer to an authorized OEM service location. A misaligned shaft will cause uneven wear of the cutlass bearing.
Propeller Shaft Page 16-52 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 The couplings must be aligned. A straight edge can be used to help align the couplings Use a feeler gauge (3) to check the alignment of the coupling in four different places, 90 degrees apart. The variation is to be within 0.051 to 0.102 mm [0.002 to 0.004 in]. If the flange is out of alignment the engine mounting will need to be adjusted until the alignment is correct.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Marine Vibration Isolator Page 16-53 Marine Vibration Isolator (016-026) General Information This illustration shows the different types of marine isolators, and the location of the snubber and corresponding gap used to determine loading of the isolator. 1 Top nut 2 Leveling stud 3 Adjusting nut 4 Jam nut 5 Snubber gap.
Marine Vibration Isolator Page 16-54 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Check that the metal parts of the isolator are not damaged, cracked, bent, or warped. If they are, the isolator will need to be replaced. Check for excessive corrosion. If corrosion is enough to weaken the structure or impede the function of the isolator, it will need to be replaced.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Marine Vibration Isolator Page 16-55 If the isolator is out of alignment, the mounting will need to be adjusted. Wedges can be used to shim the base to achieve proper alignment. Shims must be made of a solid material that will not compress under the weight of the engine. Preparatory Steps WARNING Batteries can emit explosive gases.
Marine Vibration Isolator Page 16-56 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Remove WARNING This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly. The engine needs to be supported before removing the isolators. The amount of space available will determine the best method for this support.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Marine Vibration Isolator Page 16-57 Install Set the new isolator in place. Check that the isolator is properly aligned. Reference the Initial Check section in this procedure for alignment information. Set the adjusting nut at the approximate height of the isolator removed. Replace other isolators that need to be changed using the same technique. Install the washer and top nut.
Engine Drive Shaft Page 16-58 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Engine Drive Shaft (016-027) General Information Marine Applications These instructions are for a single unit drive shaft, which attaches to the engine and transmission with flange mount U-joints. Some marine engines are equipped with drive shafts that are various lengths, depending on the boat builder design. This allows the engine to be mounted some distance from the propulsion system drives.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Engine Drive Shaft Page 16-59 WARNING This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly. NOTE: The longer drive shafts can be very heavy. The technician should consider whether two technicians are needed for the procedure.
Engine Drive Shaft Page 16-60 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Make sure the release lever is disengaged when measuring. For drive shafts longer than 254 mm [10 in]: • Insert the indicator line into the holes in the tool blades using the pegs to hold the line tight. • Install line in the tool so not to interfere with free movement of the line. Make sure the line is tight and does not sag.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Engine Drive Shaft Page 16-61 Check the vertical alignment: • Rotate both tools 90 degrees perpendicular to the ground. so they are Read the angles of the pod and engine where the lines cross the scales at the free end of the blades. This gives the operator the vertical angles of the engine and pod. The readings on both scales should be very close to the same. Vertical Alignment: 2 degrees ± 1 degree.
Engine Drive Shaft Page 16-62 ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Install Marine Applications WARNING This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly. NOTE: The longer drive shafts can be very heavy. The technician should consider whether two technicians are needed for this procedure.
ISB, ISBe and QSB (Common Rail [...] Section 16 - Mounting Adaptations - Group 16 Engine Drive Shaft Page 16-63 Driveshafts over 254 mm [10 in] have a grease fitting in the cross member of the U joints (1). These should be lubricated with the specified grease. Use Mercury™ U-joint and Gimbal Bearing Grease, Part Number 92-802870A1, or equivalent. Install the top (1) and bottom (3) drive shaft shields on the transmission end as shown. Coat the capscrew threads with Loctite™ 277, or equivalent.
Engine Drive Shaft Page 16-64 ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section 17 - Miscellaneous - Group 17 Page 17-a Section 17 - Miscellaneous - Group 17 Section Contents Page Cup Plug ....................................................................................................................................................................17-3 Clean and Inspect for Reuse....................................................................................................................................17-3 Install................
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ISB, ISBe and QSB (Common Rail [...] Section 17 - Miscellaneous - Group 17 Service Tools Page 17-1 Service Tools Miscellaneous The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from a local Cummins® Authorized Repair Location. Tool No. Tool Description Tool Illustration Pipe Plug Sealant Used when installing pipe plugs to reduce the possibility of leaks.
Service Tools Page 17-2 Tool No. ISB, ISBe and QSB (Common Rail [...] Section 17 - Miscellaneous - Group 17 Tool Description Tool Illustration Cup Plug Driving Tools (driver head, 11/16-inch nominal) 3823520 Required to install new cup plugs to their proper depth, plus avoiding damage to the cup plug and the surrounding area.
ISB, ISBe and QSB (Common Rail [...] Section 17 - Miscellaneous - Group 17 Cup Plug Page 17-3 Cup Plug (017-002) Remove CAUTION Do not allow metal shavings to fall inside the engine when drilling a hole in the cup plug. Damage to engine components can occur. Use a center punch to mark the cup plugs for drilling. Drill a 1/8-inch hole in the cup plug. Use a dent puller to remove the plug. Discard all used cup plugs. Do not use them again.
Pipe Plug Page 17-4 ISB, ISBe and QSB (Common Rail [...] Section 17 - Miscellaneous - Group 17 Install CAUTION Excessive sealant can run back into the engine and cause damage to other components. Allow the sealant to dry for a minimum of 2 hours before operating the engine. The plug can come out of the bore if the sealant is not dry.
ISB, ISBe and QSB (Common Rail [...] Section 17 - Miscellaneous - Group 17 Pipe Plug Page 17-5 Clean Use spray cleaner, Part Number 3375433, or equivalent, to clean the threads of the pipe plugs and threaded bores. Inspect for Reuse Inspect the threads of the pipe plugs for mutilation or damage. Inspect the threaded bores for damage. Install Apply a film of pipe plug sealant, Part Number 3375066, or equivalent, to the threads. Install the pipe plugs. Tighten the pipe plugs.
Straight Thread Plug Page 17-6 ISB, ISBe and QSB (Common Rail [...] Section 17 - Miscellaneous - Group 17 Straight Thread Plug (017-011) General Information Two types of straight thread plugs are used: 1 Straight thread plug with o-ring 2 Straight thread plug with formed in-place sealant. The two plugs are interchangeable and reusable. The only difference between the two plugs is the installation torque value. See the install step of this procedure.
ISB, ISBe and QSB (Common Rail [...] Section 17 - Miscellaneous - Group 17 Straight Thread Plug Page 17-7 For straight thread plugs with an o-ring, inspect the o-ring for cuts, tears, or deformation. Replace the o-ring if necessary. For straight thread plugs with formed in-place sealant, inspect the sealant for damage. If damaged, replace the entire plug. Install If equipped with a straight thread plug with o-ring, install a new o-ring on the straight-thread plug, if required.
Straight Thread Plug Page 17-8 ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section 20 - Vehicle Braking - Group 20 Page 20-a Section 20 - Vehicle Braking - Group 20 Section Contents Page Engine Exhaust Brake ..............................................................................................................................................20-1 General Information..................................................................................................................................................20-1 Install................
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ISB, ISBe and QSB (Common Rail [...] Section 20 - Vehicle Braking - Group 20 Engine Exhaust Brake Page 20-1 Engine Exhaust Brake (020-016) General Information An engine exhaust brake retards the speed of the engine during motoring conditions to provide additional vehicle braking power and extend the life of the vehicle service brakes. The exhaust brake retards engine speed by creating high exhaust back pressure. This back pressure is obtained by restricting airflow through the exhaust system.
Engine Exhaust Brake Page 20-2 ISB, ISBe and QSB (Common Rail [...] Section 20 - Vehicle Braking - Group 20 Loosen the exhaust clamps on the brake. Remove the brake assembly from the exhaust system. Install Install the brake assembly into the exhaust system. Tighten the exhaust clamps. Torque Value: 9 N•m [ 80 in-lb ] Connect the exhaust brake solenoid. To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
ISB, ISBe and QSB (Common Rail [...] Section L - Service Literature Page L-a Section L - Service Literature Section Contents Page Additional Service Literature .....................................................................................................................................L-1 General Information....................................................................................................................................................L-1 Cummins Customized Parts Catalog .........
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ISB, ISBe and QSB (Common Rail [...
Service Literature Ordering Location Page L-2 ISB, ISBe and QSB (Common Rail [...] Section L - Service Literature Service Literature Ordering Location Contact Information Region United States and Canada All Other Countries Ordering Location Cummins Distributors or Credit Cards at https:// store.cummins.com Cummins Distributors or Dealers To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
ISB, ISBe and QSB (Common Rail [...] Section L - Service Literature Cummins Customized Parts Catalog Page L-3 Cummins Customized Parts Catalog General Information Cummins is pleased to announce the availability of a parts catalog compiled specifically for you. Unlike the generic versions of parts catalogs that support general high volume parts content; Cummins Customized catalogs contain only the new factory parts that were used to build your engine.
Cummins Customized Parts Catalog Page L-4 ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Page V-a Section V - Specifications Section Contents Page Air Intake System ...................................................................................................................................................V-102 Specifications.........................................................................................................................................................
Page V-b ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Water Inlet Connection.............................................................................................................................................V-68 Zinc Anode...............................................................................................................................................................V-67 Cummins®/Fleetguard® Filter Specifications ....................................................
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Page V-c Starting Motor...........................................................................................................................................................V-87 Electrical System ....................................................................................................................................................V-104 Specifications.............................................................................
Page V-d ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Turbocharger Oil Drain Line.....................................................................................................................................V-18 Turbocharger Oil Supply Line...................................................................................................................................V-18 Vibration Damper, Rubber....................................................................................
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Page V-e Lubricating Oil Cooler...............................................................................................................................................V-57 Lubricating Oil Pressure Regulator (Main Rifle).......................................................................................................V-57 Lubricating Oil Pump............................................................................................
Page V-f ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Engine Disassembly - Group 00 - Torque Values Page V-1 Ref.No./ Steps Metric U.S.
Engine Assembly - Group 00 - Specifications Page V-2 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric U.S. Engine Assembly - Group 00 - Specifications Crankshaft (001-016) Crankshaft End Clearance 0.102 mm 0.432 mm MIN MAX 0.004 in 0.017 in 0.10 mm MIN 0.004 in 0.33 mm MAX 0.013 in Piston Protrusion 0.151 mm 0.485 mm MIN MAX 0.006 in 0.019 in Camshaft End Play (A) 0.12 mm 0.50 mm MIN MAX 0.005 in 0.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Engine Assembly - Group 00 - Torque Values Page V-3 Ref.No./ Steps Metric U.S. Engine Assembly - Group 00 - Torque Values Crankshaft (001-016) Torque Value: Step 1 Step 2 Step 3 50 N•m [ 37 ft-lb ] 50 N•m [ 37 ft-lb ] 80 N•m [ 59 ft-lb ] Turn all capscrews through 90 degrees.
Engine Assembly - Group 00 Page V-4 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Gear Housing, Front (001-033) Front Gear Housing Mounting Capscrews Oil Pan To Capscrews Gear Housing Mounting Camshaft (001-008) Camshaft Gear (Camshaft Installed) (001-012) Camshaft Gear Capscrews Metric U.S. .
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Engine Assembly - Group 00 Page V-5 Ref.No./ Steps Lubricating Oil Pan (007-025) Oil Pan Suspended - (Four Cylinder) Capscrew Metric U.S. .
Engine Assembly - Group 00 Page V-6 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. Frnt Gear Train Gear Retaining Nut 105 N•m [ 77 ft-lb ] Front Gear Train Fuel Pump Drive Access Cover.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Engine Assembly - Group 00 Page V-7 Ref.No./ Steps Component or Assembly (Procedure) Fuel Lift Pump Outlet Fuel Line Fittings ECM Mounting Plate (001-103) Ecm Mounting Plate To Cylinder Block Mounting Capscrews. ECM Cooling Plate, Fuel Cooled (006-006) Ecm Cooling Plate Mounting Capscrews Ecm Cooling Plate Assembly Mounting Capscrews Metric U.S.
Engine Assembly - Group 00 Page V-8 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Engine Assembly - Group 00 Page V-9 Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. .
Engine Assembly - Group 00 Page V-10 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Injector Solenoid Wires Nuts. Metric 1.5 N•m U.S. [ 13 in-lb ] Fuel Connector (Head Mounted) (006-052) Torque Value: Fuel Connector (cylinder head-mounted) Step 1 55 N•m [ 41 ft-lb ] Fuel Rail (006-060) 3.9L and 5.9L High-Pressure Supply Line 30 22 4.5L and 6.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Engine Assembly - Group 00 Page V-11 Ref.No./ Steps Component or Assembly (Procedure) Injector Supply Line Brace Capscrews Metric U.S.
Engine Assembly - Group 00 Page V-12 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. Single Piece Air Intake Connection Adapter 10 N•m [ 89 in-lb ] Lubricating Oil Pump (007-031) Lubricating Oil Pump Capscrews Initial Torque 8 N•m 24 N•m [ 70 in-lb ] [ 212 in-lb ] Gear Cover, Front (001-031) Front Cover Capscrew 24 N•m [ 212 in-lb ] Crankshaft Seal, Front (001-023) Front Cover Capscrews.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Engine Assembly - Group 00 Page V-13 Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. .
Engine Assembly - Group 00 Page V-14 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. Injector Wiring Nut 1.5 N•m [ 13 in-lb ] Rocker Lever Cover Capscrews 24 N•m [ 212 in-lb ] Rocker Lever Cover (003-011) Rocker Lever Cover Mounting Nuts. 24 N•m [ 212 in-lb ] Capscrew Mounted Rocker Lever Cover Capscrews.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Engine Assembly - Group 00 Page V-15 Ref.No./ Steps Metric U.S.
Engine Assembly - Group 00 Page V-16 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Engine Assembly - Group 00 Page V-17 Ref.No./ Steps Component or Assembly (Procedure) Crankcase Breather Tube (003-018) Breather Tube Mounting Plate Adapter Capscrews Metric U.S. .
Engine Assembly - Group 00 Page V-18 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Engine Assembly - Group 00 Page V-19 Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. .
Engine Assembly - Group 00 Page V-20 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Alternator Bracket (013-003) Spool Mount Upper And Lower Alternator Bracket Mounting Capscrews M8 Spool Mount Upper And Lower Alternator Bracket Mounting Capscrews M10 Metric U.S. .
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Engine Assembly - Group 00 Page V-21 Ref.No./ Steps Component or Assembly (Procedure) Alternator Link Capscrew Torque Value: Capscrews (1,3) Step 1 44 N•m [ 33 ft-lb ] Torque Value: Capscrew (2) Step 1 [ 26 ft-lb ] 35 N•m Fan Hub, Belt Driven (008-036) Fan Hub Mounting Capscrews Metric U.S.
Engine Assembly - Group 00 Page V-22 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. . Torque Value: Grade 8.8 Step 1 80 N•m [ 60 ft-lb ] Torque Value: Grade 10.9 Step 1 115 N•m [ 85 ft-lb ] Torque Value: Grade 12.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Cylinder Block - Group 01 - Specifications Page V-23 Ref.No./ Steps Metric U.S. Cylinder Block - Group 01 - Specifications Bearings, Main (001-006) Crankshaft End Play Standard Oversize 0.25 mm [0.010 in] Oversize 0.50 mm [0.020 in] Oversize 0.75 mm [0.030 in] Oversize 1.00 mm [0.
Cylinder Block - Group 01 Page V-24 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Camshaft Thrust Plate Thickness (Front Gear Train Engines) Metric U.S. . 9.40 mm MIN 0.370 in 9.60 mm MAX 0.378 in 5.25 mm MIN 0.207 in 5.35 mm MAX 0.211 in Camshaft End Play (A) 0.10 mm 0.36 mm MIN MAX 0.004 in 0.014 in Camshaft Gear Backlash Limits (B) 0.076 mm 0.280 mm MIN MAX 0.003 in 0.011 in Camshaft End Play (A) 0.12 mm 0.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Cylinder Block - Group 01 Page V-25 Ref.No./ Steps Component or Assembly (Procedure) Connecting Rod (001-014) Connecting Rod Piston Diameter Metric U.S. . Pin Bushing Connecting Rod Crankshaft Bore Diameter Bearings Removed Standard Oversize 0.25 mm [0.010 in] 0.50 mm [0.020 in] 0.75 mm [0.030 in] 1.00 mm [0.040 in] Standard Undersize 0.25 mm [0.010 in] 0.50 mm [0.020 in] 0.75 mm [0.030 in] 1.00 mm [0.
Cylinder Block - Group 01 Page V-26 Component or Assembly (Procedure) Crankshaft (001-016) Standard ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric U.S. . 68.987 69.027 MIN MAX 2.7160 2.7176 68.712 68.774 68.462 68.527 68.212 68.274 67.962 68.027 MIN MAX MIN MAX MIN MAX MIN MAX 2.7052 2.7076 2.6954 2.6979 2.6855 2.6879 2.6767 2.6782 0.04 mm MIN 0.002 in 0.12 mm MAX 0.005 in 82.962 83.013 MIN MAX 3.2662 3.2682 82.712 82.763 82.462 82.513 82.212 82.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Cylinder Block - Group 01 Page V-27 Ref.No./ Steps Metric U.S. . 70.61 mm MAX 2.780 in 0.102 mm 0.432 mm MIN MAX 0.004 in 0.017 in Crankshaft Gear, Front (Crankshaft Removed) (001-019) Crankshaft Gear Bore Inside Diameter 70.51 mm 70.55 mm MIN MAX 2.776 in 2.779 in 70.59 mm 70.61 mm MIN MAX 2.779 in 2.780 in 16.000 mm 16.055 mm MIN 0.630 in MAX 0.632 in MIN 3.4639 in MAX 3.4653 in 120.
Cylinder Block - Group 01 Page V-28 Component or Assembly (Procedure) Cylinder Bore Diameter - 3.9L and 5.9L Engines Only (New Cylinder Block) Cylinder Bore Diameter - 3.9L and 5.9L Engines Only (Used Cylinder Block) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric U.S. . 102.010 mm 102.030 mm 102.010 mm 102.050 mm MIN 4.0161 in MAX 4.0169 in MIN 4.0161 in MAX 4.0177 in Out-of-Roundness 0.038 mm MAX 0.0015 in Taper 0.076 mm MAX 0.003 in 106.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Cylinder Block - Group 01 Page V-29 Ref.No./ Steps Component or Assembly (Procedure) Piston (001-043) 3.9L and 5.9L Diameter 4.5L and Diameter 6.7L Metric U.S. . Standard Standard Piston Piston Intermediate Oil control Piston Pin Bore Piston Pin Diameter Skirt Skirt 101.864 mm 101.887 mm MIN 4.0104 in MAX 4.0113 in MIN 4.2078 in MAX 4.2083 in 0.040 0.110 0.040 0.085 MIN MAX MIN MAX 0.0016 0.0043 0.0016 0.0033 40.
Cylinder Block - Group 01 Page V-30 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Piston and Connecting Rod Assembly (001-054) Connecting Rod and Crankshaft Side Clearance Piston Protrusion Crankshaft Speed Indicator Ring (001-071) Crankshaft Speed/Position Sensor Air Gap Metric U.S. . 0.10 mm MIN 0.004 in 0.33 mm MAX 0.013 in 0.151 mm 0.485 mm MIN MAX 0.006 in 0.019 in 0.8 mm 1.5 mm MIN MAX 0.032 in 0.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Cylinder Block - Group 01 - Torque Values Page V-31 Ref.No./ Steps Metric U.S. Cylinder Block - Group 01 - Torque Values Balancer (001-004) Balancer Assembly Cover Capscrews 32 N•m [ 24 ft-lb ] Balancer Installation Torque 48 N•m [ 35 ft-lb ] 50 N•m [ 37 ft-lb ] 10 N•m [ 89 in-lb ] Bearings, Connecting Rod (001-005) Torque Value: Step 1 Step 2 Step 3 30 N•m 60 N•m Rotate 60 degrees.
Cylinder Block - Group 01 Page V-32 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Cylinder Block - Group 01 Page V-33 Ref.No./ Steps Component or Assembly (Procedure) Metric 50 N•m Torque Value: Step 1 Step 2 Step 3 U.S. [ 37 ft-lb ] 50 N•m [ 37 ft-lb ] 80 N•m [ 59 ft-lb ] Turn all capscrews through 90 degrees. Torque Value: Previously Installed Main Bearing Capscrews Step 1 50 N•m [ 37 ft-lb ] Step 2 60 N•m [ 44 ft-lb ] Step 3 80 N•m [ 59 ft-lb ] Step 4 Rotate 90 degrees.
Cylinder Block - Group 01 Page V-34 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. . Gear Cover, Front (001-031) Front Cover Capscrew 24 N•m [ 212 in-lb ] Front Gear Cover Capscrews.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Cylinder Block - Group 01 Page V-35 Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. .
Cylinder Block - Group 01 Page V-36 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Cylinder Head - Group 02 - Specifications Page V-37 Ref.No./ Steps Metric U.S. Cylinder Head - Group 02 - Specifications Cylinder Head (002-004) End-to-End Side-to-Side 0.305 0.076 MAX MAX 0.012 0.003 Injector Protrusion 2.45 mm 3.15 mm MIN MAX 0.096 in 0.124 in Intake Valve Depth (Installed) 0.584 mm 1.092 mm MIN MAX 0.023 in 0.043 in Exhaust Valve Depth (Installed) 0.965 mm 1.
Cylinder Head - Group 02 Page V-38 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric U.S. . Valve Guide Bore Diameter 7.027 mm 7.077 mm MIN MAX 0.2767 in 0.2786 in Valve Stem Diameter 6.96 mm 7.01 mm MIN MAX 0.2740 in 0.2760 in 132.1 152.1 MAX MAX 5.20 5.99 Valve Rim Thickness Limit 0.79 mm MIN 0.031 in Injector Protrusion 2.45 mm 3.15 mm MIN MAX 0.096 in 0.124 in Intake Valve Depth (Installed) 0.584 mm 1.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Cylinder Head - Group 02 - Torque Values Page V-39 Ref.No./ Steps Metric U.S. Cylinder Head - Group 02 - Torque Values Cylinder Head (002-004) Valve Spring Compressor Capscrews.
Cylinder Head - Group 02 Page V-40 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. .
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Rocker Levers - Group 03 - Specifications Page V-41 Ref.No./ Steps Metric U.S. Rocker Levers - Group 03 - Specifications Overhead Set (003-004) Intake Exhaust Rocker Lever (003-008) Rocker Lever Bore Rocker Lever Shaft 0.152 0.381 0.381 0.762 MIN MAX MIN MAX 0.006 0.015 0.015 0.030 22.027 mm MAX 0.867 in 21.965 mm MIN 0.
Rocker Levers - Group 03 - Torque Values Page V-42 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Rocker Levers - Group 03 Page V-43 Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. P-Clip, Breather Oil Drain Back Tube 24 N•m [ 18 ft-lb ] Overhead Set (003-004) Locknut 24 N•m [ 212 in-lb ] 36 N•m [ 27 ft-lb ] 10 N•m [ 89 in-lb ] Rocker Lever Cover Mounting Nuts. 24 N•m [ 212 in-lb ] Capscrew Mounted Rocker Lever Cover Capscrews.
Rocker Levers - Group 03 Page V-44 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. Breather Tube Connections Capscrews 10 N•m [ 89 in-lb ] Open Draft Capscrews Plate 7 N•m 12 N•m [ 62 in-lb ] [ 106 in-lb ] Closed Crankcase Breather System Hose Clamps 6 N•m 12 N•m [ 53 in-lb ] [ 106 in-lb ] Rocker Lever Housing (003-013) Rocker Lever Housing Capscrews 24 N•m [ 212 in-lb ] Injector Wiring Nut 1.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Clamp Plate Capscrews Breather Tube Bearher Tube Adapter Capscrew Rocker Levers - Group 03 Page V-45 Adapter Metric U.S. 24 N•m [ 18 ft-lb ] 24 N•m [ 18 ft-lb ] To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com .
Cam Followers/Tappets - Group 04 - Specifications Page V-46 Component or Assembly (Procedure) Ref.No./ Steps ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Metric U.S. Cam Followers/Tappets - Group 04 - Specifications Tappet (004-015) Valve Tappet Stem Diameter 15.936 mm 15.977 mm MIN 0.627 in MAX 0.629 in To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com .
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Fuel System - Group 05 - Torque Values Page V-47 Ref.No./ Steps Metric U.S.
Fuel System - Group 05 Page V-48 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric U.S. Front Gear Train Fuel Pump Drive Access Cover.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Injectors and Fuel Lines - Group 06 - Specifications Page V-49 Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. Injectors and Fuel Lines - Group 06 - Specifications Fuel Drain Line Restriction (006-012) Allowable Drain Line Restriction 20.0 kPa MAX 2.9 psi 14.0 kPa MAX 4 in Hg 0 kPa MIN 0 psi 79.9 kPa MAX 11.6 psi 0 kPa MIN 0 psi 79.9 kPa MAX 11.6 psi 0 kPa MIN 0 psi 79.9 kPa MAX 11.
Injectors and Fuel Lines - Group 06 Page V-50 Component or Assembly (Procedure) Fuel Pressure Range At Fuel Filter Inlet (Engine Running) Fuel Pressure Drop Across Fuel Filter Fuel Inlet Restriction (006-020) Without Electric Lift Pump With Electric Lift Pump Marine Applications ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric U.S. . 0 kPa MIN 0 psi 79.9 kPa MAX 11.6 psi 34 kPa MAX 5 psi 50.8 20.3 13.5 MAX MAX MAX 15.0 6.0 4.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Injectors and Fuel Lines - Group 06 - Torque Values Page V-51 Ref.No./ Steps Metric U.S.
Injectors and Fuel Lines - Group 06 Page V-52 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Combined Fuel Manifold To Fuel Cooler Drain Line Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Injectors and Fuel Lines - Group 06 Page V-53 Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
Injectors and Fuel Lines - Group 06 Page V-54 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. .
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Injectors and Fuel Lines - Group 06 Page V-55 Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. . Fuel Return Overflow Valve (006-044) Torque Value: Fuel Return Overflow Valve Step 1 20 N•m [ 177 in-lb ] Injector Supply Lines (High Pressure) (006-051) Injector High-Pressure Supply Lines For 3.9L And 5.
Injectors and Fuel Lines - Group 06 Page V-56 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Lubricating Oil System - Group 07 - Specifications Page V-57 Ref.No./ Steps Metric U.S. Lubricating Oil System - Group 07 - Specifications Lubricating Oil Cooler (007-003) Air Pressure Test 449 kPa 518 kPa MIN MAX 65 psi 75 psi MIN MIN 29 25 0.170 mm 0.300 mm MIN MAX 0.007 in 0.012 in Tip Limit 0.178 mm MAX 0.007 in Gerotor Drive/Planetary to Port Plate Limit 0.127 mm MAX 0.
Lubricating Oil System - Group 07 Page V-58 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric U.S. . Lubricating Oil System (007-037) Oil Pressure at Low Idle 69 kPa MIN 10 psi Oil Pressure at Rated Engine Speed 207 kPa MIN 30 psi Marine Oil Pan Drain Plug Torque 50 N•m MIN 37 ft-lb To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Lubricating Oil System - Group 07 - Torque Values Page V-59 Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
Lubricating Oil System - Group 07 Page V-60 Component or Assembly (Procedure) Oil Pan, Capscrew Suspended (Six-Cylinder) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Lubricating Oil System - Group 07 Page V-61 Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. .
Cooling System - Group 08 - Specifications Page V-62 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Water Pump (008-062) Minimum Pressure Gauge Capacity Cooling System - Group 08 Page V-63 Ref.No./ Steps Metric U.S. . 207 kPa MIN 30 psi To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
Cooling System - Group 08 - Torque Values Page V-64 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Cooling System - Group 08 Page V-65 Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
Cooling System - Group 08 Page V-66 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Cooling System - Group 08 Page V-67 Ref.No./ Steps Metric U.S. .
Cooling System - Group 08 Page V-68 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Heat Exchanger Zinc Anode Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Cooling System - Group 08 Page V-69 Ref.No./ Steps Metric U.S. Expansion Tank Fill Line Tube 8 N•m [ 71 in-lb ] Drive Belt, Sea Water Pump (008-126) Sea Water Pump Belt Idler Pulley 45 N•m [ 33 ft-lb ] 10 N•m [ 89 in-lb ] Sea Water Pump Pulley (008-127) Sea Water Pump Pulley Mounting Capscrews To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.
Drive Units - Group 09 - Specifications Page V-70 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric U.S. Drive Units - Group 09 - Specifications Accessory Drive (009-001) Accessory Drive Gear Bore Inside Diameter (Accessory Drive Adapter) Accessory Drive Shaft Outside Diameter (Accessory Drive Adapter) Bearing Bore Inside Diameter (Accessory Drive Adapter) Accessory Drive Gear End Play 38.920 mm 38.945 mm 39.008 mm 39.020 mm 67.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Drive Units - Group 09 - Torque Values Page V-71 Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
Drive Units - Group 09 Page V-72 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric 35 N•m U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Air Intake System - Group 10 - Specifications Page V-73 Ref.No./ Steps Metric U.S. Air Intake System - Group 10 - Specifications Air Intake Restriction (010-031) Air Intake Restriction 635 mm H2O MAX 25 in H2O 0.010 mm MIN 0.0004 in 0.076 mm MAX 0.0030 in 0.038 mm MIN 0.0015 in 0.093 mm MAX 0.0037 in HX27/25W - Axial Clearance 0.057 mm 0.103 mm MIN MAX 0.0022 in 0.
Air Intake System - Group 10 - Torque Values Page V-74 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Turbo Outlet Connection Clamp Torque Air Intake System - Group 10 Page V-75 Ref.No./ Steps Metric U.S.
Air Intake System - Group 10 Page V-76 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Turbocharger Oil Drain Line (010-045) Turbocharger Oil Drain Line Capscrews Air Intake System - Group 10 Page V-77 Ref.No./ Steps Metric U.S. .
Air Intake System - Group 10 Page V-78 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Air Intake System - Group 10 Page V-79 Ref.No./ Steps Metric Turbocharger Compressor Outlet Connection (010-132) Turbocharger Compressor Outlet 10 N•m Connection Clamp. U.S. . [ 89 in-lb ] To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
Exhaust System - Group 11 - Specifications Page V-80 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric U.S. Exhaust System - Group 11 - Specifications Exhaust Manifold, Dry (011-007) Exhaust Manifold Flatness Exhaust Restriction (011-009) Exhaust Restriction 0.20 mm MAX 0.008 in 75 mm Hg MAX 40 in H2O To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com .
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Exhaust System - Group 11 - Torque Values Page V-81 Ref.No./ Steps Metric U.S.
Exhaust System - Group 11 Page V-82 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. . EGR Connection Tubes (011-025) 11 N•m 24 N•m 24 N•m [ 100 in-lb ] [ 212 in-lb ] [ 212 in-lb ] 10 N•m [ 89 in-lb ] EGR Cooler Coolant Lines (011-031) Coolant Line Bracket Nut 45 N•m [ 33 ft-lb ] Aftertreatment Nozzle (011-040) Aftertreatment Nozzle Retaining Nut.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Compressed Air System - Group 12 - Torque Values Page V-83 Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. Compressed Air System - Group 12 - Torque Values Air Compressor Cylinder Head, Single Cylinder (012-007) Torque Value: Step 1 Step 2 25 N•m Rotate 90 degrees [ 221 in-lb ] Torque Value: Step 1 Step 2 6 N•m Rotate 90 degrees.
Compressed Air System - Group 12 Page V-84 Component or Assembly (Procedure) ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Metric Air Compressor Rear Bearing Housing, Two Cylinder (012-112) 25 N•m U.S. . [ 221 in-lb ] To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Electrical Equipment - Group 13 - Specifications Page V-85 Ref.No./ Steps Metric U.S. Electrical Equipment - Group 13 - Specifications Starting Motor (013-020) Starting Motor Spacing 49.28 mm 52.32 mm MIN MAX 1.94 in 2.06 in To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com .
Electrical Equipment - Group 13 - Torque Values Page V-86 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Electrical Equipment - Group 13 Page V-87 Ref.No./ Steps Metric U.S. Alternator Bracket Mounting Capscrews 45 N•m [ 33 ft-lb ] Alternator Mounting Bracket Capscrews 54 N•m [ 40 ft-lb ] Starting Motor (013-020) Starting Motor Mounting Capscrews 43 N•m [ 32 ft-lb ] 5 N•m [ 45 in-lb ] 3.
Engine Testing - Group 14 - Specifications Page V-88 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Engine Testing - Group 14 - Torque Values Page V-89 Ref.No./ Steps Metric U.S. Engine Testing - Group 14 - Torque Values Engine Testing (Engine Dynamometer) (014-005) Main Oil Rifle Plug 6 N•m [ 53 in-lb ] To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com .
Mounting Adaptations - Group 16 - Specifications Page V-90 Component or Assembly (Procedure) Ref.No./ Steps ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Metric U.S. Mounting Adaptations - Group 16 - Specifications Flywheel (016-005) Flywheel Total Indicator Reading 0.127 mm MAX 0.0050 in Flywheel Bore Runout 0.127 mm MAX 0.005 in To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com .
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Mounting Adaptations - Group 16 - Torque Values Page V-91 Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
Mounting Adaptations - Group 16 Page V-92 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Marine Front Engine Mounting Capscrews Support Bracket Engine Support Bracket, Rear (016-003) Support Bracket Capscrew Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Mounting Adaptations - Group 16 Page V-93 Ref.No./ Steps Component or Assembly (Procedure) Metric U.S. .
Miscellaneous - Group 17 - Torque Values Page V-94 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Ref.No./ Steps Component or Assembly (Procedure) Metric U.S.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Component or Assembly (Procedure) Vehicle Braking - Group 20 - Torque Values Page V-95 Ref.No./ Steps Metric U.S. Vehicle Braking - Group 20 - Torque Values Engine Exhaust Brake (020-016) Exhaust Clamp 9 N•m [ 80 in-lb ] To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com .
General Engine Page V-96 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications General Engine Specifications Automotive and Industrial Listed below are the general specifications for the engines covered by this manual. Horsepower................................................................................................................................Refer to engine dataplate Bore and Stroke for 3.9 liters [238 C.I.D] and 5.9 liters [360 C.I.D] Engines..................................
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications General Engine Page V-97 NOTE: The engine features a no-adjust overhead. The valve train is designed such that adjustment of the valve lash is not required for normal service, until the first overhead set adjustment recommended under the Maintenance Schedule in Section 2 of this manual. The valve train operates acceptably within the limits of 0.152- to 0.381-mm [0.006- to 0.015-in] intake valve lash and 0.381- to 0.762-mm [0.015- to 0.
Fuel System Page V-98 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Fuel System Specifications Automotive and Industrial For performance and fuel rate values, refer to the Engine Data Sheet. Maximum Fuel Inlet Restriction With gear pump only (no engine mounted electric fuel lift pump) (at gear pump inlet)..................50.7 kPa [15 in-Hg] With engine mounted electric fuel lift pump (at electric fuel lift pump inlet)......................................20.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Lubricating Oil System Page V-99 Lubricating Oil System Specifications Automotive and Industrial Oil Pressure: Low idle (minimum allowed)..................................................................................................................69 kPa [10 psi] At rated (minimum allowed).................................................................................................................
Lubricating Oil System Page V-100 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Total System...............................................................................................................................26.4 liters [27.9 qt] High to Low (on dipstick)................................................................................................................7.4 liters [7.8 qt] Maximum Oil Temperature: Without EGR for 3.9 liters [238 C.I.D.] and 5.9 liters [360 C.I.D.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Cooling System Page V-101 Cooling System Specifications Automotive and Industrial Coolant Capacity (four-cylinder engine only)..........................................................................................8.5 liters [2.2 gal] Coolant Capacity (six-cylinder engine only) Without EGR.......................................................................................................................................10 liters [2.
Air Intake System Page V-102 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Air Intake System Specifications Automotive and Industrial Maximum Intake Restriction (clean air filter element).................................................................254 mm H2O [10 in H2O] Maximum Intake Restriction (dirty air filter element)...................................................................
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Exhaust System Page V-103 Exhaust System Specifications All Applications Except Marine Maximum Back Pressure from Piping and Silencer (combined): Hg..............................................................................................................................................................76 mm [3 in] H2O............................................................................................................................
Electrical System Page V-104 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Electrical System Specifications Recommended Battery Capacity System Voltage 12 VDC VDC 2 24 The number of plates within a given battery size determines reserve capacity. Reserve capacity is the length of time for which a battery at 27°C [81°F] can supply 25 amperes at 10.5 VDC or greater. Cold cranking amp ratings are based on two 12-VDC batteries in series.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Cummins®/Fleetguard® Filter Specifications Page V-105 Cummins®/Fleetguard® Filter Specifications General Information Cummins Filtration Inc. is a subsidiary of Cummins Inc. Cummins Filtration™ filters are developed through joint testing at Cummins Inc. and Cummins Filtration Inc.. Fleetguard® filters are standard on new Cummins® engines. Cummins Inc. recommends their use.
Drive Belt Tension Page V-106 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Drive Belt Tension Tension Chart SAE Belt Size Belt Tension Gauge Part No. Click-type Burroughs 0.380 in 3822524 0.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Capscrew Markings and Torque Values Page V-107 Capscrew Markings and Torque Values General Information CAUTION When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew being replaced. Using the wrong capscrews can result in engine damage. Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface of the nuts. U.S.
Capscrew Markings and Torque Values Page V-108 Body Size Diamet er mm 8 10 12 14 16 18 20 ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Fraction, Decimal, Millimeter Conversions Page V-109 Fraction, Decimal, Millimeter Conversions Conversion Chart Fraction 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 inch 0.0156 0.0313 0.0469 0.0625 0.0781 0.0938 0.1094 0.1250 0.1406 0.1563 0.1719 0.1875 0.2031 0.2188 0.2344 0.2500 0.2656 0.2813 0.2969 0.3125 0.3281 0.
Newton-Meter to Foot-Pound Conversions Page V-110 ISB, ISBe and QSB (Common Rail [...
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Pipe Plug Torque Values Page V-111 Pipe Plug Torque Values Torque Table Thread Size Actual Thread O.D. in 1/16 1/8 1/4 3/8 1/2 3/4 1 1-1/4 1-1/2 in 0.32 0.41 0.54 0.68 0.85 1.05 1.32 1.66 1.
Tap-Drill Chart - U.S. Customary and Metric Page V-112 ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Tap-Drill Chart - U.S. Customary and Metric General Information NOTE ON SELECTING TAP-DRILL SIZES: The tap drill sizes shown on this card give the theoretical tap drill size for approximately 60% and 75% of full thread depth. Generally, it is recommended that drill sizes be selected in the 60% range as these sizes will provide about 90% of the potential holding power.
ISB, ISBe and QSB (Common Rail [...] Section V - Specifications Weights and Measures - Conversion Factors Page V-113 Weights and Measures - Conversion Factors Conversion Chart Quantity U.S. Customary Unit Name sq. inch Abbreviation in2 Area sq. foot Fuel Consumption Fuel Performance Force Length Power Pressure Temperature Torque Velocity Volume: liquid displacement pounds per horsepower hour miles per gallon gallons per mile pounds force inch foot horsepower pounds force per sq.
Weights and Measures - Conversion Factors Page V-114 ISB, ISBe and QSB (Common Rail [...
Index Page X-1 About the Manual ................................................................................................i-1 General Information...........................................................................................i-1 Accessory Drive .................................................................................................9-1 Assemble..........................................................................................................9-4 Clean and Inspect for Reuse....
Index Page X-2 Remove.........................................................................................................10-16 Air Intake Manifold Cover ..............................................................................10-74 Clean and Inspect for Reuse........................................................................10-74 Finishing Steps.............................................................................................10-75 Install............................................
Index Page X-3 Drive Belt, Sea Water Pump ..........................................................................8-122 Finishing Steps.............................................................................................8-125 Inspect for Reuse..........................................................................................8-123 Install.............................................................................................................8-123 Preparatory Steps........................
Index Page X-4 Install...............................................................................................................8-61 Preparatory Steps...........................................................................................8-58 Remove...........................................................................................................8-59 Fan Shroud Assembly .....................................................................................8-62 Inspect for Reuse................
Index Page X-5 Fuel System ......................................................................................................V-98 Specifications.................................................................................................V-98 General Cleaning Instructions .........................................................................i-12 Abrasive Pads and Abrasive Paper.................................................................i-12 Definition of Clean.................................
Index Page X-6 Torque Table................................................................................................V-111 Propeller Shaft ................................................................................................16-50 General Information......................................................................................16-50 Out of Water..................................................................................................16-50 Alignment.............................
Index Page X-7 Finishing Steps.............................................................................................8-108 Initial Check..................................................................................................8-103 Install.............................................................................................................8-107 Preparatory Steps.........................................................................................8-104 Remove..........................
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Cummins Inc. Box 3005 Columbus, Indiana, U.S.A., 47202 Registered Office Cummins Ltd. 49 - 51 Gresham Road, Staines, Middlesex TW18 2BD, England Registration 573951 England Copyright© 2014 Cummins Inc. Bulletin 4021271 Printed in U.S.A.
