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Service Bulletin
This bulletin has been developed to familiarize customers, salespersons, service personnel, and other interested
persons with the Cummins ISB (4 cylinder) and ISB e (4 and 6 cylinder) diesel engines.
The midrange ISB ( 4 cylinder) and ISB e (4 and 6 cylinder) Series engines are fully electronic diesel engines featuring
many enhanced design concepts for continued simplicity and compactness.
An understanding of the information contained in this bulletin will help to identify the components, maintain the engine
properly, and troubleshoot the various systems.
BULLETIN CONTENTS
Engine Diagrams
Engine Protection
Features
Diagnostic Fault Codes
Engine Diagrams
The following illustrations show the locations of the major external engine components, filters, and other service and
maintenance points. Some external components will be at different locations for different engine models.
1. Turbocharger wastegate
2. Flywheel housing
3. Crankcase breather
4. Air compressor cooling connection
5. Intake manifold pressure/temperature sensor
6. Air compressor
7. Fuel rail
8. High-pressure supply line (pump to rail)
9. Fuel rail pressure sensor
10. High-pressure fuel lines
11. Oil fill cap
12. Engine speed sensor (crankshaft)
13. Tone wheel
14. Coolant temperature sensor
15. Vibration damper
16. Coolant outlet
17. Alternator
18. Oil pressure/temperature sensor
1. Air inlet
2. Fan drive
3. Electronic control module
4. Engine speed sensor (crankshaft)
5. Dipstick
6. Fuel filter
7. Vibration damper
8. Fan or PTO drive flange mounting
9. Starter
10. Water pump
11. Coolant inlet
12. Belt tensioner
13. Alternator
14. Coolant outlet
15. Coolant temperature sensor.
1. Coolant outlet
2. Alternator
3. Oil pressure/temperature sensor
4. Coolant inlet
5. Oil filter
6. Oil pan drain plug
7. Turbocharger exhaust outlet
8. Starter
9. Flywheel housing
10. Turbocharger compressor inlet.
1. Turbocharger wastegate
2. Starter
3. Crankcase breather
4. Air compressor cooling connection
5. Air compressor
6. Intake manifold pressure/temperature sensor
7. High-pressure supply line (pump to rail)
8. Fuel rail pressure sensor
9. Fuel rail
10. High-pressure fuel lines
11. Oil fill cap
12. Engine speed sensor (crankshaft)
13. Tone wheel
14. Vibration damper
15. Coolant temperature sensor
16. Coolant outlet
17. Alternator
18. Oil pressure/temperature sensor
19. Exhaust manifold.
1. Air inlet
2. Fan drive
3. Electronic control module
4. Engine speed sensor (crankshaft)
5. Dipstick
6. Fuel filter
7. Vibration damper
8. Fan or PTO drive flange mounting
9. Starter
10. Water pump
11. Coolant inlet
12. Belt tensioner
13. Alternator
14. Coolant outlet
15. Coolant temperature sensor.
1. Coolant outlet
2. Alternator
3. Oil pressure/temperature sensor
4. Coolant inlet
5. Oil filter
6. Oil pan drain plug
7. Turbocharger exhaust outlet
8. Starter
9. Flywheel housing
10. Turbocharger compressor inlet.
ISB (4
cylinder) and
ISB e (4 and 6
cylinder)
Series
Engines
Horsepower
(hp) or
Emissions
Engine Power Torque rpm
Status
Speed (PS)
Advertised
Nm ft-lb
135 PS @
500 369 1500 European
2500 rpm
Four-cylinder 145 hp @ United
569 420 1600
3.9-liter 2600 rpm States
170 hp @ United
569 420 1600
2600 rpm States
185 PS @
700 517 1500 European
2500 rpm
220 PS @
820 605 1500 European
Six-cylinder 2500 rpm
5.9-liter 250 PS @
950 700 1500 European
2500 rpm
275 PS @
950 700 1500 European
2500 rpm
Four-cylinder
engine: The
engine
displacement
is 3.9 liters
[238 C.I.D.].
The bore is
102 mm [4.02
in] and the
stroke is 120
mm [4.72 in].
The firing
order is
1-3-4-2.
Six-cylinder
engine: The
engine
displacement
is 5.9 liters
[360 C.I.D.].
The bore is
102 mm [4.02
in] and the
stroke is 120
mm [4.72 in].
The firing
order is
1-5-3-6-2-4.
The ISB (4 cylinder) and ISB e (4 and 6 cylinder) Series engines are
designed to metric unit specifications throughout. The only deviation
is the use of SAE standard pipe fittings and plugs in some
applications. Unit specifications for optional accessory equipment
will vary with supplier. Service publications list metric values along
with their SAE equivalents for comparison.
The cylinder block has many innovative design features. The block
casting includes provisions for:
Ribbing and block stiffener have been added to strengthen the block
and reduce noise.
The control system uses inputs from the operator and the sensors to
determine the fueling and timing required to operate at the desired
engine speed.
Exhaust valve
Exhaust manifold
Dual-entry turbocharger
Turbocharger exhaust outlet.
Valve crossheads allow the two rocker levers to actuate the four
valves. A new rocker lever design has been implemented to reduce
valve train wear. This design consists of a ball-and-socket-type end
where the rocker lever contacts the valve crosshead. The valve train
consists of the following:
The connecting rod is an angle split design. This design allows for
the largest possible connecting rod crankshaft bore for increased
strength and durability. The angle cut design also allows for the use
of the connecting rod with a larger bearing surface, thereby
improving wear characteristics. The pin bore bushing is lubricated by
the piston cooling nozzle spray.
The surface between the connecting rod and the cap is no longer
machined. The connecting rod cap and rod are separated by a
process known as fractured splitting. The cap is separated by
high-momentum force, resulting in unique surface on every
connecting rod cap. The surface of the connecting rod and cap
must be protected against damage. Any damage to the fractured
surface will result in an improper torque on the connecting rod bolts.
The ISB (4 cylinder) and ISB e (4 and 6 cylinder) Series engines use
steel-backed trimetal connecting rod bearings on the upper bearing
shell. An aluminum alloy is used on the lower bearing shell.
The ISB (4 cylinder) and ISB e (4 and 6 cylinder) Series engines use
new piston s with centered, rather than offset, combustion bowls.
The diagram illustrates the oil flow through the lubrication system as
follows:
The pump (1) then delivers the oil through an internal drilling in the
cylinder block to the oil cooler cover (2) and the pressure regulator
(3). Through the inner channels of the cover, the oil flows from the
bottom to the top of the oil cooler (4) and through the oil filter (5).
When oil pressure from the pump exceeds 449 kPa [65 psi], the
pressure regulator opens, uncovering the dump port and allowing
some oil to drain back to the oil pump inlet. The remaining oil flows
to a cast passage in the oil cooler cover leading to the oil cooler
element. The flow diagram consists of the following:
Oil flowing through the cast passage in the oil cooler cover
continues through the oil cooler element, where it is cooled by
engine coolant passing around the plates of the element. The oil
then continues through another cast passage in the oil cooler cover
to the oil filter, which is a new Fleetguard StrataPore lubrication
filter on the ISB (4 cylinder) and ISB e (4 and 6 cylinder) Series
engines. The flow diagram consists of the following:
The filtered oil flows up the center of the filter and across to the back
of the oil cooler cover. At the oil cooler cover, oil flow is divided. A
portion flows to the turbocharger; the rest passes down a cast
passage to a cross-drilling in the block. The flow diagram consists of
the following:
Once the oil has been cooled and filtered, a cross drilling between
the number 1 and number 2 cylinders carries it across the block to
an angle drilling that intersects the main oil rifle. The main oil rifle
runs the length of the block and carries oil to the overhead and main
bearings through individual transfer drillings. The flow diagram
consists of the following:
The transfer drilling connected to the main oil rifle supplies oil to a
groove in the upper main bearing shells. Oil is then supplied to the
piston cooling nozzles, seated in the upper main bearing saddles,
and the cam bores through short radial drillings. The piston pins
are splash lubricated by piston cooling nozzle spray. The flow
diagram consists of the following:
From the main bearings, oil enters the crankshaft and lubricates the
connecting rod bearings through internal cross-drillings.
From the main oil rifle the oil flows up and over through a transfer
slot in the bottom of the rocker lever support, and then up through a
vertical drilling around the outside diameter of the rocker lever
capscrew. Oil leakage past the top of the cylinder head capscrew is
controlled by the flanged head on the capscrew. The flow diagram
consists of the following:
1. Coolant inlet
2. Pump impeller
3. Coolant flow past oil cooler
4. Coolant flow past cylinders
5. Coolant flow from cylinder block to cylinder head.
A portion of the coolant flowing into the head is routed across the
exhaust port. The balance of the coolant flows across the valve
bridges, around the injector nozzles, and down through two orifices
for each cylinder. The orifices balance the flow of coolant around the
cylinders. The flow diagram consists of the following:
Coolant flows through a cast opening, for each cylinder, to the lower
water manifold cavity and on to the thermostat.
As the block and head are filled, coolant flows into the lower water
manifold cavity, into the head, and through the round hole in the
back of the oil cooler cavity; however, the primary purpose of the
hole is to provide a drain for the lower manifold when all coolant is to
be drained from the system.
Coolant for an in-cab heater is best taken from the lower water
manifold cavity at the T-fitting. If a coolant block heater is used,
install the heater in one of the large cup plugs on the exhaust side
of the engine.
Exhaust gases flow through the exhaust manifold and into the
divided-entry turbine housing of the turbocharger to drive the turbine
wheel. The exhaust system consists of the following:
1. Exhaust valve
2. Exhaust manifold
3. Dual-entry turbocharger
4. Turbocharger exhaust outlet.
The base functions of the control system include fueling and timing
controls, limiting the engine speed operating range between the low-
and high-idle set points, and reducing exhaust emissions while
optimizing engine performance.
The ISB (4 cylinder) and ISB e (4 and 6 cylinder) Series engines are
equipped with a high-pressure fuel pump. The high-pressure fuel
pump is electronically controlled by a electronic control module
(ECM) that utilizes Cummins software.
The fuel pump is mounted to the rear gear housing and is driven by
the rear gear train.
The three pumping chambers in the fuel pump contain piston s that
pressurize the fuel. The fuel exits the chamber and passes through
a check valve that maintains fuel pressure on the exit side of the
pump as the piston in the chamber draws in more fuel.
The fuel exits the fuel pump and travels through a fuel line to the
high-pressure common rail.
This valve reduces the possibility of over fueling of the engine in the
event of a fuel pressure sensor malfunction or a fuel pump
malfunction.
The ECM performs diagnostic tests on most of its circuits and will
activate a fault code if a problem is detected in one of these circuits.
Along with the fault code identifying the problem, a snapshot of
engine operating parameters at the time of fault activation is also
stored in memory.
The ECM communicates with service tools and some other vehicle
controllers (i.e., transmissions, antilock brake system, antislip
reduction, etc.) through an SAE J1939 datalink.
Engine Protection
The engine protection feature monitors critical system temperatures, pressures, and fluid levels. These readings are
compared to calibrated limits based on engine speed and/or engine load. If an out-of-range condition exists and engine
derate action is to be initiated, the operator will be alerted by an in-cab WARNING lamp. The WARNING lamp will blink
or flash when out-of-range conditions continue.
NOTE: Engine power and speed will be gradually reduced, depending on the level of severity of the observed
condition. The engine protection system will not shut down the engine unless the engine protection shutdown
feature has been enabled.
Depending on how the engine protection feature is set up, the engine protection system will initiate an engine
shutdown and prevent an engine restart from the following set points:
Coolant level
Coolant temperature
Oil pressure
Oil temperature
Intake manifold temperature
Engine overspeed.
When engine protection shutdown is enabled using the electronic service tool, it can cause the engine to shut down
when an engine parameter becomes critically out of range. This feature can be enabled or disabled using the electronic
service tool.
The engine can be restarted after an automatic shutdown, in order to move the vehicle to a safe location. The engine
will continue to monitor engine parameters and another shutdown will occur when an engine parameter becomes
critically out of range.
Restart derate prevents the user from defeating an active torque or speed derate. If the user stops and restarts the
engine, the torque or speed derate will still be active.
When engine protection shutdown override is enabled using the electronic service tool, it will allow the operator to
override an impending engine shutdown caused by the engine protection feature. The intended market for this feature
is the transit industry, in which an application such as a bus will possibly need to move to a safe location before engine
shutdown takes effect.
To override engine protection shutdown, the operator depresses an OEM-supplied button during the 30-second engine
protection warning period (WARNING lamp flashes). This will restart the 30-second shutdown warning timer, giving the
driver an extra 30 seconds to move the vehicle to a safe location. Each time the button is depressed, the 30-second
warning period is restarted.
The engine protection feature provides protection against progressive engine damage by comparing data gathered at
engine protection sensors and calibrated minimum and maximum limits. If a value is found to be out of range, an
engine protection fault code is recorded.
The engine protection feature is not adjustable with the electronic service tool. The engine protection derate can occur
in two ways:
A torque derate limits the available engine torque to a calibrated maximum value (Nm/ft-lb).
An engine speed derate limits engine speed to maximum engine speed (rpm).
Engine protection values are stored in the electronic control module (ECM) every time an engine protection fault code is
set.
The engine protection shutdown, engine protection restart, and engine protection shutdown override are adjustable with
the electronic service tool.
Features
Accelerator Interlock
The accelerator interlock feature is intended to keep the engine at idle speed by using an interlock switch that is usually
attached to the vehicle's door. Most buses use this feature to disable the accelerator pedal and PTO operation while the
bus door is open; thus the engine remains idle while the door is open.
Altitude Derate
At high altitudes, the turbocharger speed can exceed its design limit if achieving typical boost pressure(s). The air is
less dense and can cause the turbocharger to overspeed; therefore, the electronic control module (ECM) derates the
fueling to limit exhaust flow. The ECM uses the ambient air pressure sensor to determine when to derate fueling. The
fueling derate starts to occur when the engine is operated above the following sea levels.
Setup Information
The altitude derate is a basic feature in the calibration. It is not customer adjustable.
NOTE: In some worldwide territories, road speed governing is subject to local laws that dictate road speed
governor lower droop be disabled. For these territories, road speed governor lower droop is disabled within the
engine calibration and can not be enabled with an electronic service tool.
NOTE: Due to local regulations limiting maximum road speed, this feature will possibly not be available in some
areas of the world.
To adjust the maximum vehicle speed limit, the cruise control on/off switch must be off and the coast/accel switch can
be used to raise or lower the preset limit.
NOTE: The maximum speed limit can not be adjusted above the predefined maximum vehicle speed in top gear
limit.
Cruise Control
Cruise control maintains vehicle speed at a driver-selectable km/h [mph]. With cruise control, vehicle speed control is
more precise, resulting in improved fuel economy. It is similar to an automobile cruise control where the driver/operator
has the ability to adjust and maintain a desired road speed.
Upper Droop - This feature allows the actual vehicle speed to decrease slightly from the set cruise control speed
under heavy-load conditions (i.e., ascending a hill). When this feature is trimmed to its maximum of 5 km/h [3
mph], better fuel economy will result, especially in hilly or rolling terrain. When this feature is trimmed to its
minimum of 0 km/h [0 mph], perceived engine performance will be improved.
Lower Droop - This feature allows the actual vehicle speed to increase slightly from the set cruise control speed
under light-load conditions (i.e., descending a hill). When this feature is trimmed to its maximum of 5 km/h [3
mph], vehicle momentum is preserved and should result in better fuel economy. When this feature is trimmed to
its minimum of 0 km/h [0 mph], vehicle speed is maintained.
NOTE: Due to local regulations limiting maximum road speed, this feature will possibly not be available in some
areas of the world.
The three operation modes include off, standby, and active. These are determined by the switch positions of the on/off
switch and the set/resume switch. The cruise control on/off switch allows the driver to turn the feature on and off. The
set/resume switch allows the driver to set, resume, or adjust the set vehicle speed (increase or decrease mph).
Off Mode
When the cruise control switch is in the OFF position, cruise control does not affect engine operation, nor can it be
activated.
Standby Mode
When the cruise on/off switch is in the ON position, cruise control will remain on standby until a request for activation is
made by the driver using the cruise set/resume switch.
Active Mode
If the driver activates cruise control by using the set position of the set/resume switch, then the cruise control will
maintain the vehicle speed at that set vehicle speed. When the driver activates cruise control by using the resume
position of the set/resume switch, the engine will then maintain vehicle speed at the last set vehicle speed the driver
commanded.
Maintenance Monitor
NOTE: The maintenance monitor is designed to alert the operator of the need for a routine maintenance stop.
Maintenance records must still be maintained for historical purposes.
NOTE: The maintenance monitor uses data received from the vehicle speed sensor (VSS) to determine distance
and data from the ECM to determine the amount of fuel burned. Whenever a VSS or battery voltage fault has
occurred, the maintenance monitor data can be inaccurate.
The maintenance monitor is an electronic program contained in the ECM for monitoring oil drain intervals. Benefits to
the customer include the ability to track drain intervals automatically in one of three modes. The maintenance monitor
can replace the standard manual methods for oil drain intervals.
NOTE: The diagnostic switch must be in the OFF position for the flashing sequence to occur.
Viewing maintenance monitor data is done through the electronic service tool and the following data can be printed
from the ECM:
Trip Information
The trip information system constantly monitors and records various engine and operating data necessary to track both
engine and driver/operator performance. The data can be viewed using the electronic service tool. If any faults occur
that can corrupt the trip data, the system will caution the user when viewing the data.
Mixers
Dry bulk haulers
Dump trucks
Refuse vehicles
Other.
Engine speed for PTO can be set either in cab or remotely, through control switches, where a remote-mounted switch
can be used where a cab switch is not desirable. Also, the cruise control switches are used for the PTO feature.
Clutch Override
PTO, when enabled, will allow the PTO to deactivate when the clutch pedal is depressed.
Brake Override
PTO, when enabled, will allow the PTO to deactivate when the service brake pedal is depressed.
Gear-Down Protection
Gear-down protection has two functions. It gives the driver the performance needed while driving one gear down from
top gear and also yields improved fuel economy by increasing the time in top gear.
European Application
Example: With the maximum vehicle speed in top gear set at 90 km/h [56 mph], the driver can choose to set the heavy
engine load at 87 km/h [54 mph] and the light engine load at 79 km/h [49 mph]. This will create a more significant
performance penalty and will encourage the driver to use the top gear.
Automotive governor
Variable-speed governor.
The automotive governor allows a larger speed variation under varying load conditions given a throttle position (engine
speed varies with load).
The variable-speed (VS) governor maintains a constant engine speed for a given throttle position under varying load
conditions.
The low-idle engine speed parameter is the speed at which the engine will idle. This speed can be adjusted by a cab
switch if the switch is installed and the low-idle adjustment feature is enabled.
Idle Shutdown
When the engine is at idle, the idle shutdown feature will automatically shut down the engine after a specified period of
time, depending on the mode of operation and customer-programmable parameters. This feature is intended to reduce
engine idle time and increase the fuel economy.
NOTE: The parameter will not appear if the idle shutdown feature is turned off.
The idle shutdown warning period lasts for 30 seconds prior to engine shutdown. The yellow WARNING lamp on the
dash will flash during the idle shutdown warning period.
After the idle shutdown feature has been overridden, this feature will not shut off the engine again until the vehicle has
been moved.
Fan Control
The electronic control module (ECM) can control the cooling fan based on inputs from the coolant temperature sensor
and the intake manifold temperature sensor. Some applications will also provide inputs to the ECM for auxiliary device
cooling (i.e., air conditioner pressure, power steering temperature, transmission temperature) or a manual fan switch for
fan control.
This parameter must be adjusted with the electronic service tool to match the fan clutch operation requirements.
Some fans engage with 12 or 24 VDC applied to them and some operate with 0 VDC applied to them.
Water-in-Fuel Warning
The water-in-fuel sensor protects the fuel system by alerting the driver/operator that water has accumulated in the
fuel-water separator and needs to be drained. The operator will be warned of a water-in-fuel condition by illuminating
the MAINTENANCE lamp.
Setup Information
The onboard and offboard fault diagnostics are basic features in the
calibration. These features are not customer adjustable.
The lamps will remain off until a fault code is recorded. The lamps
will remain on if there is an active fault code. An illuminated
WARNING lamp tells the driver there is a fault but the vehicle can be
operated and needs to be serviced as soon as possible. However, an
illuminated STOP lamp alerts the driver to stop the vehicle as soon
as is safely possible and have it serviced.
The electronic service tool can display both active and inactive fault
codes. Only inactive fault codes and associated fault information
can be erased from the ECM memory. Engine monitoring and
special diagnostic tests are also included in the electronic service
tool.
To check for fault codes, turn the keyswitch to the OFF position and
move the diagnostic switch to the ON position. Turn the vehicle
keyswitch to the ON position. If no active fault codes are recorded,
both red and yellow lamps will come on and then go out in
sequence and remain off. If active fault codes are recorded, both
lamps will come on momentarily and then begin to flash the code of
the recorded, active fault codes.
To skip to the next fault code, move the set/resume switch (if
equipped) momentarily to the increment (+) position. The
driver/operator can go back to the previous fault code by
momentarily moving the set/resume switch (if equipped) to the
decrement (-) position. If only one active fault code is recorded, the
same fault code will be displayed continuously when either
increment (+) or decrement (-) switch is toggled.
NOTE: Be sure to turn off the diagnostic switch when the fault
codes are not being flashed out.
When not using the diagnostic system, turn off the diagnostic switch
or remove the shorting plug.
Optional V-belt pulleys are available for the fan hub and crankshaft
pulleys. This bolt-on option can be used to drive additional
accessories. Electric fan clutches can be driven by the engine ECM.
An isolated oil pan is not available for the ISB (4 cylinder) and ISB e
(4 and 6 cylinder) Series engines. The four-cylinder pan is shown in
the illustration.