Scene Number: 0041 1000 Audio All numbers and specifications listed in this program are used for illustration purposes only. Current information can be found in the Service Manuals located on QuickServe Online. Scene Number: 0041 1010 Audio Upon completion of this course the learner will be capable of: Describing the source of the engine name. Describing the reason for the engine's introduction. Demonstrating knowledge of the available service information. Demonstrating knowledge of the base engine specifications. Identifying the engines. Identifying dataplate locations. Demonstrating knowledge of engine features or components. Scene Number: 0041 1020 Audio The ISBe4 engine name is derived from many sources: The IS portion of the name represents the Interact System. The Interact System is Cummins automotive/on-highway full-authority electronic engine control system. The B portion of the name represents the engine family. The ISBe4 is part of the B series mid- range engine family. The e4 portion of the name represents the specific market and emissions regulation stage within that market. The ISBe4 is designed for the European stage 4 market. Scene Number: 0041 1030 Audio The ISBe4 engines have been designed for the European market and are certified to meet the requirements of Euro 4 European on-highway emissions legislation. Euro 4 legislation applies to new vehicle type approvals from Oct 2005 and all registrations by Oct 2006. Scene Number: 0041 1040 Audio The ISBe4 engines are supported by: The ISBe4 4.5L and 6.7L (Common Rail Fuel System) Operation and Maintenance Manual ISBe4, ISBe, ISB, and QSB (Common Rail Fuel System) Service Manual The Service Manual replaces the traditional Troubleshooting and Repair Manual, a Shop Manual, and the Alternative Repair Manual. ISBe4 CM850 Electronic Control System Troubleshooting and Repair Manual. ISBe4 with CM850 Electronic Control Module Wiring Diagram This service information is available electronically on QuickServe Online and Intercept and also in hard copy. For more information contact your local Cummins Distributor. Scene Number: 0041 1050 Audio The ISBe4 is available as a 4.5 liter displacement inline 4 or a 6.7 liter displacement inline 6 cylinder engine. The four and six cylinder engines have a common bore and stroke. The inline six cylinder engines have a firing order of 1-5-3-6-2-4 The inline four cylinder engines have a firing order of 1-3-4-2 Scene Number: 0041 1060 Audio The engine dataplate shows specific facts about the engine. The dataplate is typically located on the engine rocker cover, but may be located on the side of the gear housing. The engine serial number and CPL provide data for ordering parts and service. Scene Number: 0041 1070 Audio The ISBe4 engines may be produced at different factories for different markets. The data plates used on engines may differ in appearance and location of information. The dataplate contains the following information: Engine serial number, Control parts list (CPL), Model, and Horsepower and rpm rating. If the engine dataplate is not readable, the engine serial number can be identified on the engine block on top of the lubricating oil cooler housing. Additional engine information is available by reading the ECM dataplate. Scene Number: 0041 1080 Audio The Bosch fuel injection pump dataplate is located on the fuel pump. The dataplate contains the following information: Pump serial number, Cummins part number, Factory code, Bosch part number, Date code. Scene Number: 0041 1090 Audio The electronic control module (ECM) dataplate shows information about the ECM and how the ECM was programmed. The dataplate is located on the ECM. The following information is available on the ECM dataplate: ECM part number (PN) ECM serial number (SN) ECM date code (DC) Engine serial number (ESN) ECM code: Identifies the software in the ECM. Scene Number: 0041 1100 Audio The ISBe4 engines can quickly be distinguished from ISBe engines by: The CM850 ECM with three connectors: A sixty pin engine harness connector. A fifty pin OEM harness connector. A four pin OEM power connector. A high pressure common rail fuel system. An After Treatment Interface Connection in the wiring harness. Scene Number: 0041 1110 Audio The following sections will cover the systems and components of the ISBe4 including: The Fuel system, Air system, Cooling system, Lubrication system, Electronic components, and Mechanicals. Scene Number: 0041 1120 Audio The fuel system contains the following components: The Gear Pump, High Pressure Pump, Fuel Control Valve, Pre Filter, Main Filter, Low Pressure Fuel Lines, High Pressure Fuel Lines, Injectors, Quick Disconnect Fittings, Fuel Return Line, Return Manifold, Fuel Rail, and the Fuel Rail Pressure Relief Valve. Scene Number: 0041 1130 Audio The fuel is pressurized to 6-9 bar in the gear pump. The fuel supplied from the gear pump first flows to the Fuel Return Overflow Valve. Scene Number: 0041 1140 Audio The high pressure fuel pump assembly on the ISBe4 is similar to the high pressure fuel pump assembly used on previous common rail equipped B series engines. The assembly contains a gear pump, an EFC valve with associated wiring and external plumbing. Scene Number: 0041 1150 Audio At engine shutdown, the ECM causes the electronic fuel control valve to shut off the flow of fuel to the fuel rail. Scene Number: 0041 1160 Audio Due to the closer tolerances of a High Pressure Common Rail fuel system, an additional 25 micron pre-filter is required to be mounted by the OEM between the fuel tank and the gear pump, which is mounted on the high pressure fuel pump assembly. Scene Number: 0041 1170 Audio Filtering is provided by a 3 micron primary fuel filter mounted on the pressure side of the gear pump. Scene Number: 0041 1180 Audio A new style quick disconnect low pressure fuel line connector is used at several locations on the low pressure side of the fuel system. Scene Number: 0041 1190 Audio The quick disconnect is removed by pressing the two tabs inward that are located on the connector. This allows the internal white clip ring to expand around the shoulder on the fuel line fitting. The fuel line quick disconnect can then be pulled from the shouldered fuel line fitting.
Scene Number: 0041 1200
Audio The high-pressure fuel lines connect the fuel rail to the individual fuel connectors. Scene Number: 0041 1220 Audio An all-in-one drain line from the fuel rail, the injector drain and the fuel pump drain is used to route the drain fuel to the fuel return manifold and onto the tank. Scene Number: 0041 1230 Audio The fuel rail stores fuel and prevents pressure fluctuations by utilizing the elasticity of the volume of fuel contained in the rail to dampen pressure spikes.
Scene Number: 0041 1240
Audio The high pressure fuel rail is a laser welded forging equipped with a pressure relief valve cartridge. Scene Number: 0041 1250 Audio The air system contains the following components: Turbocharger, Wastegate Controller, Intake Manifold, Intake Air Inlet, Exhaust Manifold, Charge Air Cooler, Charge Air tubing. Scene Number: 0041 1260 Audio The ISBe4 utilizes a Holset wastegated turbocharger. Scene Number: 0041 1270 Audio The wastegated turbocharger's actuator is mounted on the compressor housing. This means the turbine housing to compressor housing angular relationship is fixed. Scene Number: 0041 1280 Audio The intake manifold is a two-piece design with a captive capscrew. The intake manifold also provides a mounting location for the Intake Temperature Manifold Pressure (TMAP) Sensor. Scene Number: 0041 1290 Audio The air intake manifold uses a circular inlet with a circular grid heater element, as well as a rotating elbow. Scene Number: 0041 1310 Audio Turbocharging causes an increase in the temperature of the intake air. The charge air cooler mounted in front of the radiator reduces the temperature of the intake air. Scene Number: 0041 1320 Audio Hot intake air flows to the charge air cooler from the turbocharger compressor outlet, through the charge air cooler, and to the intake manifold.
Scene Number: 0041 1330
Audio The cooling system contains the following components: Water Pump, Integral Thermostat Housing, Water Inlet, Water Outlet. Scene Number: 0041 1340 Audio The water pump is belt driven and installs in the integral volute in the engine block. Scene Number: 0041 1350 Audio The integral thermostat housing, located in the cylinder head, provides a location for mounting the thermostat vertically in the cooling system. This orientation of the thermostat provides for better de-aeration of the cooling system. Scene Number: 0041 1360 Audio Various style water inlets are available. One water inlet has a provision for an alternator, tensioner, and idler pulley mounting. Scene Number: 0041 1370 Audio The water outlet installs over the thermostat. Alternative water outlet connections are available. Scene Number: 0041 1380 Audio The lubrication system contains the following components: Lube Oil Fill Locations, Dipstick, Turbocharger Feed Line, Turbocharger Drain Line, Crankcase Breather, Crankcase Breather Drain line, Oil Pan, Lube Oil Filter, Lube Oil Filter Head, Lube Oil Cooler, Piston Cooling Nozzles, Lube Oil Pump. Scene Number: 0041 1390 Audio The oil fill is through the top of the valve cover. An alternative fill location is in a low position on the front gear cover. This provides access for fill tubes at convenient vehicle locations. The six cylinder engine has an additional oil fill access hole on the left side of the block. Scene Number: 0041 1400 Audio Optional dipstick mounting locations are available to provide access in various installations. Scene Number: 0041 1410 Audio Once the oil is cooled and filtered, oil flow is divided, with a portion of the oil flowing through the Turbocharger oil supply line to the turbocharger.
Scene Number: 0041 1420
Audio Oil is sent back to the oil pan from the Turbocharger through the Turbocharger Drain Line. Scene Number: 0041 1440 Audio The crankcase breather has internal baffling under the rocker lever cover and exits the rear of the cover. The baffling should not be removed for service. A new breather connection tube from the rocker lever cover to the rear gear housing eliminates the need for a separate drain. Scene Number: 0041 1450 Audio The standard oil pan is a suspended oil pan design that is isolated to reduce engine noise. Typical capacities are 17 liters for the 6 cylinder and 11.4 liters for the 4 cylinder. An optional 14.2 liter capacity oil pan can be utilized on the 6 cylinder engine. Scene Number: 0041 1460 Audio The oil filter is a full flow spin-on element. Scene Number: 0041 1470 Audio The oil flows up the center of the filter and into the filter head. Scene Number: 0041 1480 Audio Oil is cooled as it moves through the oil cooler element plates as coolant is circulated around the outside of the plates. The actual number of plates will vary depending on application and horsepower. Scene Number: 0041 1490 Audio All ISBe4 engines have J Jet piston cooling nozzles. These engines also use a gallery cooled piston design. Oil from the J Jet piston cooling nozzles is directed into an oil gallery in the piston crown. This design allows oil to absorb additional heat from the piston crown when compared to other piston cooling methods. Scene Number: 0041 1500 Audio The suction tube delivers oil to the Gerotor type lubricating oil pump. The Gerotor type lubricating oil pump is mounted at the front of the cylinder block and gear driven from the front of the crankshaft. The oil pump is driven through a straight cut spur gear. The ISBe4 is a dump to sump, unlike the ISBe3, which was a dump to pump. Scene Number: 0041 1510 Audio The electronic components contain the following: CM850 Engine Control Module OEM Connector, Engine Connector, OEM Power Connector, ECM Air-Cooling Plate, Engine Wiring Harness, Aftertreatment Interface Connection, Sensors. Scene Number: 0041 1520 Audio The CM850 ECM contains three outboard facing ports for the individual wiring harness connections. Scene Number: 0041 1530 Audio The OEM Connector is a 50 pin OEM harness connector. Scene Number: 0041 1540 Audio The Engine Connector is a 60 pin engine harness connector. Scene Number: 0041 1550 Audio The OEM Power Connector is a 4 pin power connector. Scene Number: 0041 1560 Audio The new style air cooled ECM cooling plate utilizes a three bolt mounting yoke. This yoke contains soft shock mounting hardware. Scene Number: 0041 1570 Audio The wiring harness connects the ECM to the various electrical components. Scene Number: 0041 1580 Audio The Aftertreatment Interface Connection is a SCR 14-pin Connector. Scene Number: 0041 1590 Audio The electrical components contain the following sensors: Fuel Rail Pressure Sensor, Intake Manifold Pressure/Temperature Sensor, Ambient Air Pressure Sensor, Engine Speed Sensor (Camshaft), Engine Speed Sensor (Crankshaft), Coolant Temperature Sensor, Oil Pressure Switch. Scene Number: 0041 1610 Audio The signal from the Fuel Rail Pressure Sensor is used by the ECM to determine the fuel pressure in the rail. Scene Number: 0041 1620 Audio The Intake Manifold Pressure/Temperature Sensor is a combination sensor. The Intake Manifold pressure input is used for air/fuel control. The ECM uses the intake manifold temperature input for engine protection and for fan clutch control. Scene Number: 0041 1640 Audio Information from the Ambient Air Pressure Sensor allows the ECM to determine the atmospheric pressure. This information is used for Air/Fuel control and altitude derate capabilities. Scene Number: 0041 1660 Audio The Camshaft speed sensor is located on the front gear cover. Scene Number: 0041 1670 Audio Engine speed is sensed by the Engine Speed Sensor from a disc on the crankshaft pulley.
Scene Number: 0041 1680
Audio The Coolant Temperature Sensor is located at the front right side of the cylinder head, near the thermostat. The input from this sensor allows the ECM to determine the coolant temperature. Coolant temperature input is used for: Controlling the operation of the fan, varying the fueling for starting, controlling injection timing and the engine protection system. Scene Number: 0041 1690 Audio The Engine Oil Pressure switch is installed on the top of the front gear cover above the camshaft speed sensor. This sensor indicates the pressure of the oil as an input to the engine protection system. Scene Number: 0041 1700 Audio The mechanical system contains the following components: Air Compressor, Cylinder Head, Cylinder Block, Flywheel Housing, Rear Gear Housing, Front Gear Cover, Front Gear Housing, Vibration Damper, Tone Wheel, Crankshaft, Belt Tensioner, Flywheel, Connecting Rods, Main Bearings, Rod Bearings, Pistons.
Scene Number: 0041 1710
Audio The ISBe4 utilizes a Knorr Bremse twin Reed single-cylinder air compressor. It is very important that this compressor be timed to the engine at TDC
Scene Number: 0041 1720
Audio The cylinder head is a one-piece, cross flow design. Scene Number: 0041 1730 Audio The new cylinder blocks for the four and six cylinder engines are sculpted and stiffened for noise reduction. Scene Number: 0041 1740 Audio The standard flywheel housing is an aluminum SAE 2 gravity die casting with vertical side mounting pads. This housing has a 219.6 mm starter center distance which is compatible with a new 132 tooth ring gear. The flywheel housing also serves as the rear gear cover. Scene Number: 0041 1760 Audio The front gear cover provides a mounting location for the front crankshaft oil seal, the Crankshaft Speed Sensor, the Camshaft Position Sensor and the Oil Pressure Switch. Scene Number: 0041 1780 Audio Six cylinder engines have a viscous damper and four cylinder engines may be equipped with a rubber element damper or no damper device.
Scene Number: 0041 1790
Audio The tone wheel sensor window is used to locate Top Dead Center for some service procedures. Scene Number: 0041 1800 Audio The crankshaft drives the camshaft, which drives the fuel pump, and accessory gear. Scene Number: 0041 1810 Audio The engine design incorporates a spring loaded automatic belt tensioner. Scene Number: 0041 1830 Audio The connecting rods utilize a fractured rod cap. With this manufacturing technique, the rod and cap are manufactured as a unit and then separated by a controlled fracture. This provides the rod and cap with a matched mating face that has virtually no gap. For this reason the rod and cap must be assembled as matched pairs. Scene Number: 0041 1840 Audio The block is machined to accept seven main bearings with thrust bearings located at the number 6 main bearing location. Scene Number: 0041 1850 Audio The upper and lower connecting rod bearings are made from different materials. Make certain that the correct part number rod bearings are used in their respective location. Scene Number: 0041 1860 Audio The cast aluminum piston utilizes an improved swirl design combustion chamber and a piston cooling gallery. Scene Number: 0041 1865 Audio You are about to leave the Virtual Classroom and take the assessment. Select "Next" to continue to the assessment. Select "Back" to return to the Virtual Classroom or click on the Program Guide icon to view the program guide. Note: If you are in Review Mode selecting "Next" will either return you to the Main Menu if you have completed all of the modules in your Play List, or it will take you to the next module in your Play List. Scene Number: 0041 1870 Audio The IS portion of the name ISBe4 represents what? Scene Number: 0041 1890 Audio Which of these is not listed on the engine dataplate? Scene Number: 0041 1900 Audio The CM850 ECM engine harness connector is Scene Number: 0041 1910 Audio What micron pre-filter is used on the ISBe4 engine? Scene Number: 0041 1920 Audio How is the thermostat mounted in the cooling system? Scene Number: 0041 1930 Audio What is the typical capacity of the 6 cylinder engine oil pan? Scene Number: 0041 1940 Audio The Gerotor type lubricating oil pump is mounted at the front of the cylinder block is? Scene Number: 0041 1950 Audio The Aftertreatment Interface Connection is a Scene Number: 0041 1960 Audio True or False: The 6 cylinder engines may be equipped with a rubber element damper or without a damper device. Scene Number: 0041 1970 Audio Where are the thrust bearings located?