CUMMINS Diesel Engine ISB QSB Repair Workshop Manual

Service Manual ISB e , ISB, and QSB (Common Rail Fuel System) Volume 1

To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com Service Manual ISB e , ISB, and QSB (Common Rail Fuel System) Volume 1 Copyright© 2014 Bulletin 4021271 Cummins Inc. Printed 29-OCTOBER-2014 All rights reserved

To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com 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.

To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com Table of Contents Section Introduction ........................................................................................................................................................ i Engine and System Identification .................................................................................................................... E Familiarization .................................................................................................................................................... F Troubleshooting Symptoms ............................................................................................................................. TS Troubleshooting Symptoms (New Format) ..................................................................................................... TT Engine Disassembly - Group 00 ....................................................................................................................... DS Engine Assembly - Group 00 ............................................................................................................................ AS Product - Group 00 ............................................................................................................................................ 0 Cylinder Block - Group 01 ................................................................................................................................. 1 Cylinder Head - Group 02 .................................................................................................................................. 2 Rocker Levers - Group 03 ................................................................................................................................. 3 Cam Followers/Tappets - Group 04 ................................................................................................................. 4 Back .................................................................................................................................................................... back

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ISB, ISBe and QSB (Common Rail [...] Section i - Introduction Page i-a To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com Section i - Introduction Section Contents Page About the Manual .........................................................................................................................................................i-1 General Information.....................................................................................................................................................i-1 Acronyms and Abbreviations ...................................................................................................................................i-17 General Information...................................................................................................................................................i-17 General Cleaning Instructions ..................................................................................................................................i-12 Abrasive Pads and Abrasive Paper...........................................................................................................................i-12 Definition of Clean......................................................................................................................................................i-12 Fuel System...............................................................................................................................................................i-15 Gasket Surfaces........................................................................................................................................................ i-13 Plastic Bead Cleaning................................................................................................................................................i-14 Solvent and Acid Cleaning.........................................................................................................................................i-13 Steam Cleaning......................................................................................................................................................... i-14 General Repair Instructions ......................................................................................................................................i-10 General Information...................................................................................................................................................i-10 Welding on a Vehicle with an Electronic Controlled Fuel System..............................................................................i-11 General Safety Instructions ........................................................................................................................................i-8 Important Safety Notice...............................................................................................................................................i-8 How to Use the Manual ................................................................................................................................................i-2 General Information.....................................................................................................................................................i-2 Illustrations ...................................................................................................................................................................i-7 General Information.....................................................................................................................................................i-7 Symbols ........................................................................................................................................................................ i-3 General Information.....................................................................................................................................................i-3

ISB, ISBe and QSB (Common Rail [...] Page i-b Section i - Introduction This Page Left Intentionally Blank

ISB, ISBe and QSB (Common Rail [...] About the Manual Section i - Introduction Page i-1 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com 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. Some sections contain reference numbers and procedure numbers. Reference numbers provide general information, specifications, diagrams, and service tools where applicable. Procedure numbers are used to identify and reference specific repair procedures for correcting the problem and describe specific rebuild procedures. This manual does not contain fuel systems electronic troubleshooting. Use the troubleshooting trees in this manual, if there are no electronic fault codes. This manual is designed so the troubleshooting trees are used to locate the cause of an engine problem. The troubleshooting trees then direct the user to the correct repair procedure. The repair procedures within a section are in numerical order. However, the repair steps within a given procedure are organized in the order the repair must be performed regardless of the numerical order of the steps. The user must use the contents pages or the index at the back of the manual to locate specific topics when not using the troubleshooting trees.

How to Use the Manual ISB, ISBe and QSB (Common Rail [...] Page i-2 Section i - Introduction To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com 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. The disassemble/assemble sections of this manual is divided into the same group system used for previous manuals and the Cummins' filmcard system. Section 00 is organized into a logical sequence of engine disassemble/assemble, all other sections are in numerical sequence. Refer to the Table of Contents at the front of the book to determine the section that details the desired information. Each section contains the following in sequence: • Table of Contents • Required Service Tool Listings • General Information containing the basic service, maintenance, design and revision information necessary to assist in the rebuild of an engine or a component • Procedure instructions for the disassembly, inspection, maintenance, and assembly that can be required to rebuild an engine; additional procedures that are not necessary during every rebuild, but can be necessary, are included. These procedures depend on the length of time an engine has been in service and the conditions of the parts. All the procedures are identified with a name and a number. Each digit in the procedure number has a specific meaning. The first three digits of the number refer to the specific section that the procedure can be found within the manual. In this example, “001” represents Section 01 - Cylinder Block. This number will range from 000 to 022. The second three digits of the number are unique and refer to a specific subject. In this example, “028” represents Cylinder Liner. This number will range from 001 to 999. Refer to Section V for specifications recommended by Cummins Engine Company, Inc. for your engine. Specifications and torque values for each engine system are given in that section. NOTE: Discharge of oil or oily water into or upon the water is a direct violation of today's laws. Violators are subject to a penalty of various monetary charges. Dispose of these substances in accordance with standards set by the local enviromental governing agency.

ISB, ISBe and QSB (Common Rail [...] Symbols Section i - Introduction Page i-3 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com 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. CAUTION Minor personal injury can result or a part, and assembly, or the engine can be damaged if the caution instructions are not followed. Indicates a REMOVAL or Dissassembly step.

CUMMINS Diesel Engine ISB QSB Repair Workshop Manual

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