Cummins ISB, ISBe, ISBe4, QSB4.5, QSB5.9, QSB6.7 Engines (Common Rail Fuel System) Service Repair Manual
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Service Manual
ISBe, ISB, and QSB (Common Rail Fuel
System) Series Engines
Volume 2
Service Manual
ISBe, ISB, and QSB (Common Rail Fuel
System) Series Engines
Volume 2
Copyright© 2006
Cummins Inc.
All rights reserved
Bulletin 4021271
Printed 27-JULY-2006
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.
The manual is organized to guide a service technician through the logical steps of identifying and correcting problems
related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment
manufacturer for repair procedures.
A series of specific service manuals (for example: Shop, Specifications, and Alternative Repair) are available and can
be ordered by Contacting your local area Cummins Regional office. A Cummins Regional office listing is located in
Service Literature (Section L).
The repair procedures used in this manual are recommended by Cummins Inc. Some service procedures require the
use of special service tools. Use the correct tools as described.
Cummins Inc. encourages the user of this manual to report errors, omissions, and recommendations for improvement.
Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for communicating
your comments.
The specifications and rebuild information in this manual are based on the information in effect at the time of printing.
Cummins Inc. reserves the right to make any changes at any time without obligation. If differences are found between
your engine and the information in this manual, contact a Cummins Authorized Repair Location or call 1-800-DIESELS
(1-800-343-7357) toll free in the U.S. and Canada.
The latest technology and the highest quality components are used to manufacture Cummins engines. When
replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts.
Table of Contents
Section
Injectors and Fuel Lines - Group 06 ................................................................................................................ 6
Lubricating Oil System - Group 0 7 .................................................................................................................. 7
Cooling System - Group 08 .............................................................................................................................. 8
Drive Units - Group 09 ....................................................................................................................................... 9
Air Intake System - Group 10 ........................................................................................................................... 10
Exhaust System - Group 11 .............................................................................................................................. 11
Compressed Air System - Group 12 ................................................................................................................ 12
Electrical Equipment - Group 13 ...................................................................................................................... 13
Engine Testing - Group 14 ................................................................................................................................ 14
Mounting Adaptations - Group 16 ................................................................................................................... 16
Miscellaneous - Group 17 ................................................................................................................................. 17
Vehicle Braking - Group 20 .............................................................................................................................. 20
Service Literature ............................................................................................................................................... L
Component Manufacturers ............................................................................................................................... M
Specifications ..................................................................................................................................................... V
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..................................................................................................................................................... 6-5
Test.............................................................................................................................................................................. 6-5
3.9L and 5.9L Without Fuel Filter Diagnostic Test Ports........................................................................................ 6-5
With Fuel Filter Diagnostic Test Ports and With an Electric Lift Pump................................................................. 6-6
With Fuel Filter Diagnostic Test Ports and Without an Electric Lift Pump............................................................ 6-7
ECM Cooling Plate, Fuel Cooled ................................................................................................................................6-8
Assemble................................................................................................................................................................... 6-12
Without Electric Lift Pump..................................................................................................................................... 6-12
With Electric Lift Pump...........................................................................................................................................6-12
Marine Applications................................................................................................................................................ 6-13
Clean and Inspect for Reuse.................................................................................................................................... 6-12
Disassemble...............................................................................................................................................................6-11
Without Electric Lift Pump..................................................................................................................................... 6-11
With Electric Lift Pump...........................................................................................................................................6-11
Marine Applications................................................................................................................................................ 6-12
Finishing Steps.......................................................................................................................................................... 6-14
Without Electric Lift Pump..................................................................................................................................... 6-14
With Electric Lift Pump...........................................................................................................................................6-14
Marine Applications................................................................................................................................................ 6-15
General Information..................................................................................................................................................... 6-8
Initial Check................................................................................................................................................................. 6-8
Install.......................................................................................................................................................................... 6-13
Automotive and Industrial...................................................................................................................................... 6-13
Marine Applications................................................................................................................................................ 6-13
Preparatory Steps........................................................................................................................................................ 6-8
Without Electric Lift Pump....................................................................................................................................... 6-8
With Electric Lift Pump............................................................................................................................................. 6-9
Marine Applications................................................................................................................................................ 6-10
Prime.......................................................................................................................................................................... 6-16
With Electric Lift Pump...........................................................................................................................................6-16
With Hand Priming Pump...................................................................................................................................... 6-17
Remove...................................................................................................................................................................... 6-11
Automotive and Industrial...................................................................................................................................... 6-11
Marine Applications................................................................................................................................................ 6-11
Fuel Connector (Head Mounted) ..............................................................................................................................6-83
Clean and Inspect for Reuse.................................................................................................................................... 6-91
General Information................................................................................................................................................... 6-83
Initial Check............................................................................................................................................................... 6-89
Install.......................................................................................................................................................................... 6-92
Remove...................................................................................................................................................................... 6-91
Setup.......................................................................................................................................................................... 6-84
Low Mount Fuel Drain Manifold............................................................................................................................. 6-84
High Mount Fuel Drain Manifold with Two Banjo Fittings.................................................................................... 6-85
High Mount Fuel Drain Manifold with One Banjo Fitting...................................................................................... 6-86
Marine Applications................................................................................................................................................ 6-87
Gear Housing Fuel Drain....................................................................................................................................... 6-88
Test........................................................................................................................................................................... 6-90
Fuel Cooler ............................................................................................................................................................... 6-106
Clean and Inspect for Reuse.................................................................................................................................. 6-107
Finishing Steps........................................................................................................................................................ 6-108
Install........................................................................................................................................................................ 6-107
Preparatory Steps.................................................................................................................................................... 6-106
Remove.................................................................................................................................................................... 6-106
Fuel Drain Line Restriction .......................................................................................................................................6-18
General Information................................................................................................................................................... 6-18
Initial Check............................................................................................................................................................... 6-21
Automotive and Industrial...................................................................................................................................... 6-21
Marine Applications................................................................................................................................................ 6-21
Setup.......................................................................................................................................................................... 6-18
Low Mount Fuel Return Manifold.......................................................................................................................... 6-18
Marine Applications Without Fuel Cooler.............................................................................................................. 6-19
Marine Applications With Fuel Cooler................................................................................................................... 6-19
Gear Housing Fuel Return Manifold...................................................................................................................... 6-20
High Mount Fuel Return Manifold..........................................................................................................................6-20
Marine Applications................................................................................................................................................ 6-21
Fuel Drain Lines ......................................................................................................................................................... 6-22
Finishing Steps.......................................................................................................................................................... 6-28
General Information................................................................................................................................................... 6-22
Initial Check............................................................................................................................................................... 6-23
Inspect for Reuse.......................................................................................................................................................6-26
White Tang Fitting.................................................................................................................................................. 6-26
Two Button Fitting.................................................................................................................................................. 6-26
Banjo Fitting............................................................................................................................................................ 6-26
Install.......................................................................................................................................................................... 6-26
Automotive and Industrial...................................................................................................................................... 6-26
Marine Applications................................................................................................................................................ 6-28
Preparatory Steps...................................................................................................................................................... 6-24
Remove...................................................................................................................................................................... 6-24
Automotive and Industrial...................................................................................................................................... 6-24
Marine Applications................................................................................................................................................ 6-25
Fuel Filter (Spin-On Type) ........................................................................................................................................ 6-29
General Information................................................................................................................................................... 6-29
Initial Check............................................................................................................................................................... 6-30
With Electric Lift Pump........................................................................................................................................... 6-30
Without Electric Lift Pump......................................................................................................................................6-31
Marine Applications................................................................................................................................................ 6-33
Install.......................................................................................................................................................................... 6-35
Prime.......................................................................................................................................................................... 6-35
With Electric Lift Pump........................................................................................................................................... 6-35
Without Electric Lift Pump......................................................................................................................................6-36
Marine Applications................................................................................................................................................ 6-38
Remove...................................................................................................................................................................... 6-34
Setup.......................................................................................................................................................................... 6-29
With Fuel Filter Diagnostic Test Ports................................................................................................................... 6-29
Without Fuel Filter Diagnostic Ports...................................................................................................................... 6-30
Fuel Filter Head .......................................................................................................................................................... 6-38
Assemble................................................................................................................................................................... 6-41
Automotive and Industrial...................................................................................................................................... 6-41
Marine Applications................................................................................................................................................ 6-42
Clean and Inspect for Reuse.................................................................................................................................... 6-41
Disassemble...............................................................................................................................................................6-41
Automotive and Industrial...................................................................................................................................... 6-41
Marine Applications................................................................................................................................................ 6-41
General Information................................................................................................................................................... 6-38
Install.......................................................................................................................................................................... 6-42
Low Mount Fuel Filter............................................................................................................................................. 6-42
High Mount Fuel Filter............................................................................................................................................ 6-43
Marine Applications................................................................................................................................................ 6-43
Preparatory Steps...................................................................................................................................................... 6-39
Prime.......................................................................................................................................................................... 6-44
With Electric Lift Pump........................................................................................................................................... 6-44
Without Electric Lift Pump......................................................................................................................................6-45
Marine Applications................................................................................................................................................ 6-46
Remove...................................................................................................................................................................... 6-39
Low Mount Fuel Filter............................................................................................................................................. 6-39
High Mount Fuel Filter............................................................................................................................................ 6-40
Marine Applications................................................................................................................................................ 6-40
Fuel Filter Head Bracket ........................................................................................................................................... 6-46
Assemble................................................................................................................................................................... 6-47
ISB, ISBe and QSB (Common Rail [...]
Page 6-b Section 6 - Injectors and Fuel Lines - Group 06
Disassemble............................................................................................................................................................... 6-47
Inspect for Reuse.......................................................................................................................................................6-47
Install.......................................................................................................................................................................... 6-47
Remove...................................................................................................................................................................... 6-46
Fuel Inlet Restriction ................................................................................................................................................. 6-50
General Information................................................................................................................................................... 6-50
Initial Check............................................................................................................................................................... 6-53
Prime.......................................................................................................................................................................... 6-54
With Electric Lift Pump...........................................................................................................................................6-54
With Hand Priming Pump...................................................................................................................................... 6-55
Setup.......................................................................................................................................................................... 6-51
Gear Pump Inlet with White Tang Fitting.............................................................................................................. 6-51
Automotive and Industrial Applications with Electric Lift Pump........................................................................... 6-51
Gear Pump Inlet with Banjo Fitting........................................................................................................................ 6-52
Gear Pump Inlet with Two ButtonFitting................................................................................................................ 6-52
Marine Applications................................................................................................................................................ 6-53
Fuel Manifold (Combined) .........................................................................................................................................6-48
Assemble................................................................................................................................................................... 6-49
Disassemble...............................................................................................................................................................6-49
Finishing Steps.......................................................................................................................................................... 6-50
Inspect for Reuse.......................................................................................................................................................6-49
Install.......................................................................................................................................................................... 6-50
Preparatory Steps...................................................................................................................................................... 6-48
Remove...................................................................................................................................................................... 6-49
Fuel Pressure Relief Valve ....................................................................................................................................... 6-99
Finishing Steps........................................................................................................................................................ 6-104
3.9L and 5.9LEngines........................................................................................................................................ 6-104
4.5L and 6.7LEngines........................................................................................................................................ 6-104
General Information................................................................................................................................................... 6-99
Initial Check............................................................................................................................................................. 6-100
Install........................................................................................................................................................................ 6-103
Preparatory Steps.................................................................................................................................................... 6-102
3.9L and 5.9LEngines........................................................................................................................................ 6-102
4.5L and 6.7LEngines........................................................................................................................................ 6-103
Prime........................................................................................................................................................................ 6-105
Remove.................................................................................................................................................................... 6-103
3.9L and 5.9LEngines........................................................................................................................................ 6-103
4.5L and 6.7LEngines........................................................................................................................................ 6-103
Setup........................................................................................................................................................................ 6-100
White Tang Fitting on Pressure Relief Valve..................................................................................................... 6-100
3.9L and 5.9L with Banjo Fitting on Pressure Relief Valve............................................................................ 6-101
4.5L and 6.7L with Banjo Fitting on Pressure Relief Valve............................................................................ 6-101
Two Button Fitting on Pressure Relief Valve..................................................................................................... 6-101
Test.......................................................................................................................................................................... 6-102
Fuel Rail ...................................................................................................................................................................... 6-93
Clean and Inspect for Reuse.................................................................................................................................... 6-96
Finishing Steps.......................................................................................................................................................... 6-98
General Information................................................................................................................................................... 6-93
Initial Check............................................................................................................................................................... 6-94
Install.......................................................................................................................................................................... 6-96
Preparatory Steps...................................................................................................................................................... 6-94
Automotive and Industrial...................................................................................................................................... 6-94
Marine Applications................................................................................................................................................ 6-95
Remove...................................................................................................................................................................... 6-95
Fuel Return Overflow Valve ..................................................................................................................................... 6-79
Clean.......................................................................................................................................................................... 6-80
Initial Check............................................................................................................................................................... 6-79
Inspect for Reuse.......................................................................................................................................................6-79
Install.......................................................................................................................................................................... 6-80
Remove...................................................................................................................................................................... 6-79
Fuel Supply Lines ...................................................................................................................................................... 6-56
Clean and Inspect for Reuse.................................................................................................................................... 6-60
White Tang Fitting.................................................................................................................................................. 6-60
ISB, ISBe and QSB (Common Rail [...]
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-c
Two Button Fitting.................................................................................................................................................. 6-61
Banjo Fitting............................................................................................................................................................6-61
Straight O-Ring Thread.......................................................................................................................................... 6-61
Marine Applications................................................................................................................................................ 6-61
Finishing Steps.......................................................................................................................................................... 6-65
Marine Applications................................................................................................................................................ 6-65
General Information................................................................................................................................................... 6-56
Initial Check............................................................................................................................................................... 6-57
Install.......................................................................................................................................................................... 6-62
Without Electric Lift Pump..................................................................................................................................... 6-62
With Electric Lift Pump...........................................................................................................................................6-62
Marine Applications................................................................................................................................................ 6-63
Preparatory Steps...................................................................................................................................................... 6-58
Marine Applications................................................................................................................................................ 6-58
Prime.......................................................................................................................................................................... 6-65
With Electric Lift Pump...........................................................................................................................................6-65
With Hand Priming Pump.......................................................................................................................................6-66
Remove...................................................................................................................................................................... 6-58
Without Electric Lift Pump..................................................................................................................................... 6-58
With Electric Lift Pump...........................................................................................................................................6-58
Marine Applications................................................................................................................................................ 6-59
Injector ........................................................................................................................................................................ 6-67
Clean and Inspect for Reuse.................................................................................................................................... 6-75
Finishing Steps.......................................................................................................................................................... 6-78
General Information................................................................................................................................................... 6-67
Initial Check............................................................................................................................................................... 6-72
Install.......................................................................................................................................................................... 6-76
Remove...................................................................................................................................................................... 6-74
Setup.......................................................................................................................................................................... 6-67
Low Mount Fuel Drain Manifold............................................................................................................................. 6-67
High Mount Fuel Drain Manifold with Two Banjo Fittings.................................................................................... 6-68
High Mount Fuel Drain Manifold with One Banjo Fitting...................................................................................... 6-69
Marine Applications................................................................................................................................................ 6-70
Gear Housing Fuel Drain....................................................................................................................................... 6-71
Test.............................................................................................................................................................................6-73
Injector Supply Lines (High Pressure) .................................................................................................................... 6-81
Finishing Steps.......................................................................................................................................................... 6-83
General Information................................................................................................................................................... 6-81
Initial Check............................................................................................................................................................... 6-81
Inspect for Reuse...................................................................................................................................................... 6-82
Install.......................................................................................................................................................................... 6-82
Remove...................................................................................................................................................................... 6-81
Service Tools ................................................................................................................................................................ 6-1
Injectors and Fuel Lines.............................................................................................................................................. 6-1
ISB, ISBe and QSB (Common Rail [...]
Page 6-d Section 6 - Injectors and Fuel Lines - Group 06
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 your local Cummins Authorized
Repair Location.
Tool No. Tool Description Tool Illustration
3164325
Fuel System Leak Tester
Used to cut off the fuel supply to the injector to diagnose it for leakage
or other malfunction. Used on fuel rails with 14 mm threads.
3823208
Torque Wrench - Injector Terminal Nuts
This 13 in-lb torque wrench is used to tighten the injector terminal
nuts.
3823705
Graduated Beaker
Used to measure fuel return flows.
3164617
Fuel Return Flow Hose (fuel rail pressure relief valve)
This tool uses a special fitting to measure return flow from the
pressure relief valve on the fuel rail (engines with EGR only).
3164618
Fuel Return Flow Hose (injector and fuel pump)
This tool uses a special fitting to connect to the fuel return circuits to
measure return flow from the injectors and fuel pump (engines with
EGR only).
3164583
Fuel Line Cap
This tool is used to cap a quick-connect fuel line that has been
disconnected from the engine. This prevents back-flow out of the line.
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This is a comprehensive Service Repair Manual for the Cummins ISB, ISBe, ISBe4, QSB4.5, QSB5.9, QSB6.7 Engines with a Common Rail Fuel System. It contains detailed service and repair procedures, including assembly, disassembly, and wiring diagrams.
The manual provides in-depth information, electrical and hydraulic diagrams, as well as real photo illustrations and schemes for complete step-by-step operations on repair, servicing, technical maintenance, and troubleshooting procedures for your machine. It offers all the necessary information for repairing your machine, enabling you to identify issues and understand how to maintain and repair it without the need for professional service.
The Table of Contents includes:
- Section i - Introduction
- Section E - Engine and System Identification
- Section F - Familiarization
- Section TS - Troubleshooting Symptoms
- Section TT - Troubleshooting Symptoms (New Format)
- Section DS - Engine Disassembly
- Section AS - Engine Assembly
- Section 0 - Complete Engine
- Section 1 - Cylinder Block
- Section 2 - Cylinder Head
- Section 3 - Rocker Levers
- Section 4 - Cam Followers/Tappets
- Section 5 - Fuel System
- Section 6 - Injectors and Fuel Lines
- Section 7 - Lubricating Oil System
- Section 8 - Cooling System
- Section 9 - Drive Units
- Section 10 - Air Intake System
- Section 11 - Exhaust System
- Section 12 - Compressed Air System
- Section 13 - Electrical Equipment
- Section 14 - Engine Testing
- Section 16 - Mounting Adaptations
- Section 17 - Miscellaneous
- Section 20 - Vehicle Braking
- Section L - Service Literature
- Section V - Specifications
Model Specification: Cummins ISB, ISBe, ISBe4, QSB4.5, QSB5.9, QSB6.7 Engines (Common Rail Fuel System)
Language: English
File Format: PDF
Requirements: Adobe Reader
Specifications: Fully Printable & Bookmarked
Compatible: All Versions of Windows & Mac, APP ISO, iPhone, iPad, Android, etc.
This high-quality manual is 100% complete and intact, with no missing or corrupt pages/sections. It is bookmarked and searchable for easy navigation. Detailed illustrations, exploded diagrams, drawings, and photos guide you through every service repair procedure.
The manual can be viewed on any computer, zoomed, and printed. It comes in PDF format, compatible with all PC-based Windows operating systems and Mac. It can be saved to your hard drive and burned to CD-ROM.
Instant access means there are no shipping costs or waiting for a CD or paper manual to arrive in the mail. You will receive this manual today via instant download upon completion of payment via our secure payment processor. We accept all major credit/debit cards and PayPal.
You can perform the repairs yourself and save money.
