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Application

Engineering
Bulletin
Subject This AEB is for the following applications:
QSB Tier 3/Stage III
Industrial Technical Package Automotive Industrial Power Generation

Date Jun 2004 Page 1 of 25 AEB Number 10.113

Engine Models included: QSB6.7 (D313001CX03), QSB4.5 (D323001CX03)


Fuel Systems included: Bosch HPCR full authority electronic

This document contains updates from the April 2004 version


Introduction
The Tier 3 QSB electronic Industrial product line is designed to meet worldwide government emission regulations
on diesel engines used in off-road applications (EPA/CARB Tier 3, EU Stage III). The product line offers a variety
of ratings ranging from 82 kW to 205 kW (110 to 275 horsepower) in both 4 cylinder and 6 cylinder configurations.

Major Changes for Tier 3


• Increased displacement, 6.7L for QSB6, 4.5L for QSB4
• Rear Gear train
¾ Overall length increases approximately 43 mm
¾ Cummins must supply flywheel housing with engine (no customer supplied flywheel housings)
¾ Accessory drive rotation is opposite from Tier 2B engines
¾ Starter motor locations only on the right hand (turbo) side of engine
• CM850 controller
• Bosch High Pressure Common Rail Fuel System
• Exclusively Charge Air Cooled
• 25 Micron pre-filter required in addition to the 3 micron Fuel filters

This package includes information regarding technical data required to install the engine and information about
options that can be applied to the engine.

An Option Information eBook describing available options and engine specifications is available on the Cummins
GCE (Global Customer Engineering) Internet. Production Launch is scheduled for 01Jul05 (QSB6) and 01Jan06
(QSB4).

It is a requirement that the “Industrial Installation Quality Assurance (IQA) Procedure” (AEB 20.12) is followed for
each new QSB Tier 3 machine application to insure that this application meets or exceeds Cummins’ and the
OEM’s installation requirements. This process is in concurrence with the Installation Quality Assurance (IQA)
Standard Work. All information in this AEB is subject to change. If you have questions concerning this
information, please contact Industrial Application Support.

Author: Steve Beem

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Table of Contents
Introduction .......................................................................................................................................1

Table of Contents .............................................................................................................................2

Emissions Summary .........................................................................................................................3

Ratings Information...........................................................................................................................4

Product Summary ......................................................................................................................... 4-6

Fuel System......................................................................................................................................6

Electronic System ......................................................................................................................... 7-9

Cooling System........................................................................................................................... 9-13

Lubrication System ................................................................................................................... 13-14

Air Handling Systems .....................................................................................................................15

Application Specific Major Hardware........................................................................................ 15-16

Option Strategy...............................................................................................................................17

Product Specifications .............................................................................................................. 17-18

Installation Recommendations ................................................................................................. 18-19

Appendix (Tier 2 vs Tier 3 Overlays) ........................................................................................ 19-24

Change Log ....................................................................................................................................25

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MOBILE OFF-HIGHWAY EMISSIONS REGULATIONS SCHEDULES
NOx / HC / CO / PM (g/kW-hr) [Conversion: (g/kW-hr) x 0.7457 = g/bhp-hr]
(NOx+HC) / CO / PM (g/kW-hr) [Conversion: (g/kW-hr) x 0.7457 = g/bhp-hr]

U.S. EPA (Tier 4 requirements were proposed April 2003. Final rule for Tier 4 expected April 2004)

kW (HP) 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
0-7 (0 - 10) ( 10.5 ) / 8.0 / 1.0 ( 7.5 ) / 8.0 / 0.80
( 7.5 ) / 6.6 / 0.40
8 - 18 (11 - 24) ( 9.5 ) / 6.6 / 0.80 ( 7.5 ) / 6.6 / 0.80

19 - 36 (25 - 48) ( 9.5 ) / 5.5 / 0.80 ( 7.5 ) / 5.5 / 0.60 ( 7.5 ) / 5.0 / 0.30 ( 4.7 ) / 5.0 / 0.03
37 - 55 (49 - 74) ( 4.7 ) / 5.0 / 0.30 Note 7 Note 7
9.2 / -- / -- / -- ( 7.5 ) / 5.0 / 0.40
56 - 74 (75 - 99) ( 4.7 ) / 5.0 / 0.40
3.3 / 0.19 / 5.0 / 0.02 0.40 / 0.19 / 5.0 / 0.02
75 - 129 (100 - 173) 9.2 / -- / -- / -- ( 6.6 ) / 5.0 / 0.30 ( 4.0 ) / 5.0 / 0.30

130 - 224 (174 - 301) 9.2 / 1.3 / 11.4 / 0.54 ( 6.6 ) / 3.5 / 0.20 ( 4.0 ) / 3.5 / 0.20

225 - 449 (302 - 602) 9.2 / 1.3 / 11.4 / 0.54 ( 6.4 ) / 3.5 / 0.20 Note 6 ( 4.0 ) / 3.5 / 0.20 2.0 / 0.19 / 3.5 / 0.02 0.40 / 0.19 / 3.5 / 0.02

450 - 560 (603 - 751) 9.2 / 1.3 / 11.4 / 0.54 ( 6.4 ) / 3.5 / 0.20 Note 6 ( 4.0 ) / 3.5 / 0.20

>560 (>751) 9.2 / 1.3 / 11.4 / 0.54 ( 6.4 ) / 3.5 / 0.20 3.1 / 0.19 / 3.5 / 0.10 0.40 / 0.19 / 3.5 / 0.02
Tier 1 Tier 2 Tier 3 Tier 4 Interim Tier 4 Final

EUROPE (Stages IIIA, IIIB, and IV set by EU Parliament and Council October 2003. Final publication expected Q1 2004.)

kW (HP) 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
18 - 36 (24 - 48) 8.0 / 1.5 / 5.5 / 0.8 ( 7.5 ) / 5.5 / 0.6

37 - 55 (49 - 74) ( 4.7 ) / 5.0 / 0.025


9.2 / 1.3 / 6.5 / 0.85 7.0 / 1.3 / 5.0 / 0.4 ( 4.7 ) / 5.0 / 0.4
56 - 74 (75 - 99) 3.3 / 0.19 / 5.0 / 0.025
0.4 / 0.19 / 5.0 / 0.025
75 - 129 (100 - 173) 9.2 / 1.3 / 5.0 / 0.70 6.0 / 1.0 / 5.0 / 0.3 ( 4.0 ) / 5.0 / 0.3 3.3 / 0.19 / 5.0 / 0.025

130 - 560 (174 - 751) 9.2 / 1.3 / 5.0 / 0.54 6.0 / 1.0 / 3.5 / 0.2 ( 4.0 ) / 3.5 / 0.2 2.0 / 0.19 / 3.5 / 0.025 0.4 / 0.19 / 3.5 / 0.025
Stage I Stage II Stage IIIA Stage IIIB Stage IV

JAPAN (Tier 1 standards applicable by application. Tier 2 and Tier 3 applicable by power category. Introduction dates October of year listed.)

kW (HP) 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
19 - 36 (25 - 48) Tier 1 application specific stds. 8.0 / 1.5 / 5.0 / 0.8 6.0 / 1.0 / 5.0 / 0.40

37 - 55 (49 - 74) 9.2 / 1.3 / 5.0 / --, Tier 1 standards are application 4.0 / 0.7 / 5.0 / 0.30 Tier 4 not yet proposed.
7.0 / 1.3 / 5.0 / 0.4
56 - 74 (75 - 99) specific and apply to engines 30 - 260kW. 4.0 / 0.7 / 5.0 / 0.25 Tier 4 standards/dates not yet proposed.

75 - 129 (100 - 173) Tier 1 application specific standards. 6.0 / 1.0 / 5.0 / 0.3 3.6 / 0.4 / 5.0 / 0.20 Tier 4 standards/dates not yet proposed.

130 - 560 (174 - 751) Tier 1 application Specific standards. 6.0 / 1.0 / 3.5 / 0.2 3.6 / 0.4 / 3.5 / 0.17 Tier 4 standards/dates not yet proposed.
Tier 1 Tier 2 Tier 3 Tier 4 Tier 4
Notes:
1. Generally, effect dates of standards are for engines built on or after 1 January of the respective year, except where noted.
2. All standards are based upon ISO 8178 C1 8-mode test for variable-speed engines and D2 5-mode test for constant-speed engines. Transient test required beginning with 2011 phase-in.
3. Separate NOx and HC standards separated by a "/". Combined NOx and HC standards denoted in parenthesis "( )".
4. Smoke requirements: U.S: On-highway federal test procedure. Europe - None, but some OEM's require R24.03 certification. Japan has unique smoke standard and procedure.
5. Generator sets in Europe are required to meet Stage II standards beginning 1 January 2007.
6. The U.S. on-highway consent decree includes a one year pull ahead to 2005 of the nonroad Tier 3 requirements for engines 300 - 749 hp. Note slight power range discrepancy.
7. In U.S., optional 0.30 g/kW-hr PM standard for engines 37-55kW at Tier 3. This would allow a 1 year delay of Tier 4 implementation from 2012 to 2013.
8. CANADA - MOU with Cummins requires Tier 1 engines built on or after 1 January 2000. Draft proposal to require EPA compliant engines beginning in 2006.
9. KOREA - U.S. EPA Tier 1 and Tier 2 equivalent standards phased in beginning in 2004 and 2005 respectively for engines 19 - 560kW. Vehicle certification rather than engine certification.

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Rating Information (Check the GCE Performance Curves and Datasheets web site for latest performance
information)
¾ 193.9KW (260Hp) and 205.1 KW (275 Hp) ratings are not JMLIT certified
¾ Turbocharger Hardware changes below 164.1 KW (220Hp) @ 2500 RPM (separate power match zone
above and below this boundary)
¾ An additional turbo charger hardware change occurs at 115.6KW (155HP)@2000 rpm. At this rating and
below the turbo’s are non-wastegated
¾ Rated speeds of 2200 rpm and higher require a viscous damper, a rubber damper is used below 2200
rpm (QSB6.7, no Damper for QSB4.5)
¾ Max Wheel Loader ratings are capped at 153 KW (205 Hp) @ 2000 rpm or 149KW (200 HP) @ 2100
rpm. Wheel Loaders require special performance hardware (turbo’s) and cannot use standard ratings
(see chart below for current planned Wheel Loader ratings)

Color Key
Key Power Match Nodes Wheel loader ratings Turbo split Non-waste gated Continuous Rating

Altitude Derate
The electronic fuel system for the QSB Tier 3 is capable of derating automatically (the design includes a standard
ambient air pressure sensor). Check the Fuel Rating data sheet for altitude capability for a specific rating.

Product Summary
Product Summary QSB6 QSB4
Configuration D313001CX03 D323001CX03
Aspiration Charge Air Cooled Charge Air Cooled
Displacement 6.7 Liter 4.5 Liter
Gear Train Rear Rear
Weight (dry) 475 Kg 371 Kg
Cylinder Configuration Inline 6 Inline 4
Fuel System Bosch HPCR Bosch HPCR

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Product Changes (comparison to Tier 2 QSB)


Feature Comparison Tier 2B Tier 3B
FFOB to FH mounting Front Gear train QSB6 = 748, QSB4 Rear Gear Train approximately 43 mm
surface mm = 508 longer
Oil pan Height below QSB6 = 296, QSB4 = 291 QSB6 = 306 , QSB4 = 282
Crank Centerline mm
Aspiration CAC, and T Engines available, CAC QSB6, QSB4 CAC
at higher Hp for each engine type

Coolant flow (@2500 rpm) QSB VP44 220 l/m, QSB5.9 185 l/m, QSB6 227 l/m, QSB4 tbd
QSB4.5 202 l/m
Oil change interval and 500 Hour (CAC engines above 500 Hour all engines, 18.2 Qt QSB6,
pan capacity 100Hp, all below 100Hp), 15Qt (6B), 11.6Qt QSB4. Deep sump pans will be
10 Qt (4B) available (24L QSB6, 15L QSB4)
Electronic Features and Standard between all QSB tier 2 QSB T3 will have all the primary features of
OEM (electronic) products (VP44 or VP30). For Tier 2 the current Tier 2 QSB. Differences in the
Connections the ECM was 2 50 pin connectors wiring and the ECM. For Tier 3 the
and the 23 OEM connector. ECM has a 4 pin power connector, a 60
pin engine connector, and a 50 pin OEM
connector. There is no 23 pin OEM
connector.
Fuel Systems VP44, VP30 HPCR
Altitude capability No ambient air pressure sensor Ambient air pressure sensor standard
capability on QSB6 and QSB4. Zero fueling
Derate to 10,000 feet
Cold Start capability VP30 and VE control injection timing HPCR controls injection timing during
during cranking (VP44 does not) cranking. Grid heaters optional.

Heat Rejection to Coolant HP/Rpm dependent, see GCE 0-5% higher than Tier 2 equivalent
depending on rating
Heat Rejection to CAC Calculated based Compressor outlet 10-15% higher than Tier 2 equivalent
temp and Charge air flow (see GCE) depending on rating
Maximum Top Tank 212F (100C) 225F (107C)
Temperature
Accessory Drive Capability 105 ft-lb (142 N-m) 180 ft-lb (244 N-m)

Engine Envelope
Tier 1 6BTA Tier 2 Tier 3 QSB6
HMRO QSB5.9-30-T HMRO
(3170326) HMRO (3170561)
(3170525)
Overall Height above the Centerline 647 mm 650 mm 654 mm
of Crankshaft
Overall Length 1005 mm 1017 mm 1059 mm
Overall Width at widest point 683.6 mm 681 mm 725 mm

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Tier 1 4BTA Tier 2 Tier 3 QSB4


HMRO QSB4.5-30-T HMRO
(3170323) HMRO (3170613)
(3170526)
Overall Height above the Centerline 608.6 mm 610 mm 596 mm
of Crankshaft
Overall Length 777.1 mm 777 mm 818 mm
Overall Width at widest point 652 652 mm 713 mm
Note: Dimensions for Tier 3 are from Alpha level installation drawings and will be updated for production Bill of
Material when available

Cylinder Block
The cylinder block released for the Tier 3 QSB has a sculpted/ribbed block for high rigidity, an integral ladder
frame and an enclosed tappet cavity. These features improve noise capability as well as durability. The block has
commonality of some taps and bosses with previous B/QSB designs, however there are several new bosses and
profile changes. Internal coolant passages have been re-engineered to increase coolant flow over previous Tier
2B or ISB02 block designs (both four and six cylinider).

Cylinder Head
The head is 4 valve QSB (VP44)-style. Valve seat inserts are standard. The injector is vertical and centralized on
cylinder centerline. The exhaust valves springs and train have capability for exhaust brake operation to 4.3 bar
(60 psi).

Rear Gear Housing


The die cast aluminum gear housing is at the rear, sandwiched between the block and the flywheel housing. A
spur gear train from the crankshaft drives the camshaft, fuel pump and accessory (air compressor / power steer-
ing pump). There are no idler gears. An internal oil rifle supply to the air compressor is provided.

Front Drive

A low mount front belt tensioner drive arrangement is used on the QSB6 and QSB4 Tier 3 similar to the Tier 2
QSB engine. The belt tensioner is located in a position between the water pump and the crank pulley. It mounts
on the water inlet connection. The Tier 2 fan drive locations and ratios are maintained. Cummins is designing and
testing the accessory mounting system as part of the base engine package. If an OEM chooses to design unique
hardware they must meet Cummins design standards for FEAD’s and engine mounted components. Fan drive
capability is 45 Horse power (same as Tier 2).

A rubber vibration damper (DA dependent option) is standard for QSB6 below 2200 rpm. A viscous damper is
standard for ratings 2200 rpm and above (rated speed). No damper is required for the QSB4. Front drive
adapters (AF options) are available for front engine power take-off.

Noise Status
The Tier 3 QSB6 and QSB4 engines will be significantly quieter due to block improvements, pilot injection and
rear gear train than current front gear train product. The noise reduction will assist OEM’s in meeting the most
stringent noise targets.

Fuel System

The fuel system is a Bosch high-pressure common rail (HPCR), with full authority electronic control. The fuel
system plays a major role in the noise level improvement attained with this product over previous offerings.

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The fuel is supplied to the engine via the pre-filter and uses a banjo connection directly into the fuel pump. The
fuel shutoff valve is incorporated into the fuel injection pump and is controlled by the ECM through the engine
wiring harness. No external shutoff valve control wiring is required. Fuel tank vents must be of such a design as
to not allow water to enter the fuel tank.

This fuel system is not light fuels capable and should be operated on Diesel 2. At operating temperatures below 0
deg C (32 deg F) blends of Diesel 1 and Diesel 2 can be used. The lubricity requirement for fuel is 460 HFRR
(minimum). Refer to the O&M manual details regarding the use of lubricity additives. Lubricity additive fuel Pre-
filters will be an available option.

Fuel Filters and Priming Pumps


A dual fuel filter system is required for the High Pressure Common Rail fuel system. A 25 micron pre-filter (FS
option) is required to be mounted by the OEM between the fuel tank and the fuel pump mounted lift pump. The
specifications for this filter are as follows: Max flow rate: 205 l/hr [54gph]; filtration rating 25 microns; filter media
area: 3760 mm2 [5.83 in2]. The pre-filter includes water separator and water in fuel (WIF) sensing features. The
WIF feature communicates with the ECM through the engine harness and will log a fault code if WIF is not
connected. The Pre-filter can be sourced from Cummins or supplied by OEM provided the specifications stated
above are met. Final filtration is provided by a 3 micron Fleetguard spin-on filter located on the pressure side of
the fuel pump mounted lift pump.

Both on-engine and remote main fuel filters will be offered (FF options). Hose lengths of 4 and 6 feet are offered
on remote filters and pre-filters. Return fuel must return to tank below fuel level.

A manual priming pump is mounted on the Cummins supplied Pre-filter. The fuel system requires manual priming
after filter changes or when the engine is run out of fuel. If the Pre-filter is customer supplied the priming pump
will also need to be supplied by the customer.

Electronic System

Hardware

The full authority electronic fuel system controls timing and fueling. The ECM (CM850) is mounted on the cylinder
block fuel pump side. The ECM has a 50 pin connector for the OEM harness, a 60 pin engine harness and a 4 pin
power supply harness. All connectors are on the outboard facing side of the ECM.

The electronic system includes the following sensors to monitor the engine system parameters:

Fuel pressure, located in the high pressure rail.


Intake manifold pressure/temperature, located in the intake manifold cover.
Coolant temperature located at the front exhaust side of the cylinder head.
Crankshaft speed sensor located on front of engine.
Camshaft speed sensor located on front gear cover.
Ambient air pressure sensor - located near the top of ECM, as part of wiring harness.
Water in fuel sensor - located in bottom of spin on fuel filter.
An oil pressure switch is used.

The engine control module is standard with the engine. For Tier 3 the ECM has a 4 pin power connector, a 60 pin
engine connector, and a 50 pin OEM connector. There is no 23 pin OEM connector and the OEM interfaces to
the 4 pin power connector and the 50 pin OEM connector. The CM850 module has a separate 4 pin power supply
connection and 50 pin OEM connector. The CM850 is located on the fuel pump side near the front center of the
engine. The engine harness is bundled and covered with convolute construction and includes an on engine J1939
connection as the primary service connection. Specific electronic application engineering bulletins (AEB’s) for
OEM wiring interfaces, OEM components, OEM serial communications, and installation recommendations will be
available for detailed information.

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The dash lamp strategy is to have three lamps, one red for stop engine, one yellow for check engine and a wait
to start lamp. There will be no option for a separate maintenance lamp.

This engine is compatible with 12V and 24V electronic systems. A 42 volt system is not planned.

An M8x21mm long stud is provided on the exhaust side of engine for external starter grounding. A dedicated
electrical ground stud is provided on the fuel pump side of the engine. This stud is M8x21mm long and is used
for ECM grounding and block grounding by OEMs.

Controls/Features

QSB T3 will have all the primary features of the current Tier 2 QSB. Cummins factory supplied default parameters
will be provided for industrial applications. Multiplexing is compatible with this engine. Cummins electronic
components meet our EMC (Electro-Magnetic Compatibility) standards.

QSB6 Harness Connections and their Locations


Intake Manifold
Pressure/Temp
Fuel Rail Pressure

Coolant temp
WIF
located on
remote
Ambient Air Pre-filter
Pressure (FS)

Data Link

Speed and
Position

Oil Pressure Switch


ECM

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QSB4 Harness Connections and their Locations


Intake Manifold
Pressure/Temp
Fuel Rail Pressure
Coolant
Temp

Ambient Air
Pressure
WIF on
remote
Data Link pre-Filter
(FS)

Speed &
Position

ECM
Oil pressure Switch

Cooling System
Coolant flows have increased for the QSB6 and QSB4 product due to flow passage improvements in the block.
See GCE for the latest information on flows and pressures. Heat rejection will need to be re-calculated from Tier
2 similar ratings. The engine cooling system is compatible with long life coolants available at this printing.

Installation Requirement Exception Considerations

Cooling System Preliminary


Maximum Top Tank 225 F (107C) vs Tier 2 212F (100C) Counter-act coolant package increase
Temperature due to increased heat rejection, max.
lube oil temp., engine durability
Intake Manifold Temperature 140F (60C) for Tier 3 same as Tier 2 NOx Control, emissions certification

Minimum Pressure Cap Minimum pressure cap setting will Cap reliability , boil over, altitude,
move from 7 to 15 PSI. afterboil and cavitation protection
Fan On Temperature Coolant side - 195F (91C) Fan On time , tank mileage, AECD in
Intake air side – 110F (43C) use time, standard for all QSB

Expansion Space 6% currently required Hot shutdowns, Min Pressure Cap,


Max. TTT resolution

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Engine Water Flow Typical (With Line Inside Diameters)

Cab 13.4 19.75


35
Heater R
A
13.4 Thermostat D
W.P. I
6.35 orifice
Head 46 A
T
Engine O
13.4 Block Oil Cooler
Automatic R
Trans Cooler
3.0 orifice 12.7 12.7

22.9

Surge Tank Water cooled


air compressor
Radiator vent line 9.0

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6B CFD

Air Compressor
Coolant Supply – 6.75

Automatic Trans.
Cooler – 8.74 Air Compressor
Coolant Return – 6.75

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6B CFD Model

Cab Heater option 2– 6.35 mm

Cab Heater option 1


6.35 mm

Water Inlets
Water inlets for Tier 3 are carryover options from Tier 2.

Water Outlets
QSB Tier 2 water outlet options will be carried across to the QSB T3 configuration. The hose connection location
changes when existing QSB water outlet connections are used. This is due to a different thermostat housing
mounting location on QSB T3.

Thermostat Housing and Vents


RP options (vent arrangements) are carry over from the Tier 2 QSB products. See the Option eBook on the Web
for the latest options. The thermostat itself is structured in a dependent EC option.

The provision to route bypass coolant to a remote transmission cooler is specified as a “TK” option. Selecting a
TK option will drive a new Water outlet since the position of the outlet connection will be different when the TK is
specified. The TK option sits on top of the head with its own housing. This TK option has been released to
provide clearance to the QSB T3 block and head, and to provide increased water flow to the transmission cooler.

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Cooling Fan
Locate the fan at least 20mm (.75inches) away from the engine components to minimize noise, reduce fan blade
vibration and improve air flow past the engine. For optimum air flow the fan should be located as far form the
core as practical. Sucker fans should be located at least 50 mm (2 inches) away from the core and blower fans
should be located at least 100 mm (4 inches) away from the core.

For the QSB6.7 the bending moment imposed on the front of the fan hub should not exceed 6.8 Nm (60 in-lbs)
(total weight of the fan and spacers multiplied by the total length of spacing). Total length of the spacing should
not exceed 76.2 mm (3.0 inches).

Fan mountings on unbalanced QSB4.5 engines require special attention. In general, fans on these engines
should be as light as practical and mounted as close to the engine as sound installation practices allow. As
guideline, the overhung moment imposed on the front of the fan hub on these engines should not exceed 2.35
Nm (20 in-lbs).

As a guideline, fan tip speeds should be limited to a maximum of 91 m/sec (18,000 ft/min).

Charge Air Cooler


Charge air cooling (CAC) is required on the QSB6/4 Tier 3 to achieve lower intake temperature that in turn helps
reduce NOx emission. Heat from intake air is removed with the use of CAC. The CAC system must be designed
for the requirements of the air flow needed per the rating and must also be able to maintain a specific intake
manifold temperature differential (IMTD, 63F for Industrial applications) in order to meet the emission certification
designation. Reference Curves and Data sheets on the Web for specific CAC requirements. Also refer to AEB
24.06 and AdvisorTM for the correct method of calculating heat rejection and sizing the charge air cooler. Heat
rejection to the charge air cooler is calculated rather than supplied on the data sheet due to customer specific
variables. Some examples of customer specific variables are limiting ambient temperature and the intake air
temperature rise the machine will be designed for.

Lubrication System

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 filter is a full flow, spin-on element. Both engine and remote mounted filters are offered.

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Remote Lube Filter Guidelines:
Minimum Hose Size: #12 wire braid reinforced
Maximum hose length: 1016mm (40 inches) per hose

Filter mounting locations:


The filter inlet and outlet ports should not be more than 6 inches above or below the engine supply and return
ports. The filter should be mounted in the vertical position.

Oil fill is through the top of the valve cover or at the side of the engine via OB options.

Standard length Dipsticks Lengths and locations will be offered. Accessibility to some of the locations is restricted.
Oil filters will not change between Tier2 and Tier 3.

Marketing Actual Length


StyleLength (mm)
Steel 100 153
Steel 200 219
Nylon 400 418
Nylon 600 621
Nylon 800 840
Nylon 1000 1033
Nylon 1200 1210
.
Be sure to factor in all engine equipment (air compressors, remote filters) when determining lube system
capacity available for OEM accessory use.

Oil change interval change interval is 500 hours with all oil pans (see O&M manual for approved lubricants, some
lubricants will have reduced oil change intervals). Deep sump pans are offered for both QSB6 and QSB4 that will
allow 500 hour oil change interval with no top off. QSB4 engines have balancer specific oil pan options.

Lube cooler/filter options (“LC”, “LF”) are specified as a filter (“LF”) option only. The oil filled engine option
changed is “LO”.

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Exhaust System
Several exhaust manifold configurations will be offered to support turbo locations. The exhaust valve springs and
train have capability for exhaust brake operation to 60 psi (4.3 bar). No factory exhaust brake option is planned.

Minimum recommended exhaust pipe sizes (I.D.):


QSB6, QSB4 – 3 in. (75 mm).

Maximum allowable exhaust restriction level at maximum engine rated speed and load is 76mm (3.0 in) Hg.
.
The maximum allowable bending moment is 13.5 N m (10 ft-lb) at the turbocharger exhaust outlet.

Wastegated Turbocharger
The QSB6 Tier 3 engines incorporate a wastegated HX-35 Holset turbocharger similar to the one used on QSB
Tier 2 product. This arrangement limits the adjustability of the turbo compressor housing in chassis to +/- 5
degrees. QSB4 engine incorporates an HX27 Holset turbo with similar limitations on orientation. Multiple turbo
options are available to accommodate various turbo locations and compressor outlet angles to meet installation
requirements. Ratings at the lower end of the Horsepower range may be non-wastegated.

Intake System
Recommended intake pipe sizes (I.D.):
QSB4 – 75 mm (3 in.)
QSB6 – 100 mm (4 in)

The system restriction must not exceed 635 mm (25 in) H2O (dirty filter), 381 mm (15 in) H2O clean filter. A heavy-
duty air cleaner with 25g/cfm minimum dirt holding capacity should be used in most construction/industrial
applications or other operations exposed to high dirt environment.

Turbo air transfer connections (“IT”) and air intake connections (“IC”) are available for the charge air cooling
system.

Application specific major hardware


Engine Mounting
Front mounted engine supports are carry over options from QSB Tier 2. The front of the block has similar side
and front mounting pad hole patterns to B5.9/QSB. Some existing side of block engine mountings will be suitable;
however checks are required on all mounting arrangements for Water inlet and ECM compatibility. Some options
may not be compatible with side of block engine mounting. See AEB 21.36 for additional engine mounting
details.

A 3-cylinder idle feature is used for extended cold-weather idling (QSB6). This feature activates after 4 minutes,
under low coolant and Intake manifold temperature conditions. Different frequency vibration will be experienced
when this feature is activated.

Special consideration is required when mounting four cylinder engines. There is unbalanced vertical second order
forces proportional to RPM squared. Mount systems designed for six cylinder engines typically will not provide
adequate isolation when applied to four cylinder engines.

For engine mount consideration in vehicles, the following mass moment of inertia data is applicable.

No. of Cylinders 1xx (pitch) kg.M2 1yy (yaw) kg.M2 1zz (roll) kg.M2
4 25.0 19.1 14.7

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Balancer (BA) options are available for the QSB4.

Power train (Flywheels & Flywheel Housings)


SAE No. 1, 2 and No. 3 aluminum flywheel housings (new for the rear gear train engine) will be available with 490
mm spacing across the mounting pads. These will be compatible with current Tier 2 B5.9/QSB flywheels.
Flywheels are “carry over” options. Flywheel housings can be selected with exhaust side starter locations only.

Accessory drives
The gear driven accessory location is on the left hand side rear above the fuel pump. The drive runs at 1:1 and is
clockwise rotation (viewed from the front of the engine). This is opposite to Front Gear train QSB rotation. The
maximum torque capability of the drive is 180 lb-ft.

Air Compressors
Cummins branded Wabco single cylinder 15.2 cfm air compressors will be offered on QSB6 and QSB4 products.

Alternators

Delco 11Si and 24Si Cummins branded alternators will be offered, 35SI brushless alternators are planned. All are
available in 12 and 24 volt configurations.

Starting System
Starters are “carry over” options. Both Denso and Delco 38MT-HD Cummins branded starters will be offered.

Starting Aids

Air Intake Grid Heater

Engine Starting Aids

An electric Pre-heat grid type air intake heater is optional on the Tier 3 QSB engines. Installation requirements
for the grid heater will be covered in the Electronic Subsystem Technical Package AEB 15.41, OEM Components
(reference is to ISB02).

Intake Air Heater (or Grid Heaters) aid starting during cold ambient conditions. There are two phases of intake air
heater operation:
Pre-heat (after key-on and before cranking)
Post-heat (just after a successful engine start)

There is no heat during cranking.

The amount of time the grid heaters stay on in the pre-heat phase is a function of the intake manifold temperature
at key-on. The post heat cycle is also a function of the intake manifold temperature at key-on and can operate for
several minutes on very cold days as the grid heaters energize through a series of calibrated duty cycles.

The intake air heaters are energized or de-energized from a relay controlled by the ECM.

A “Wait to Start” lamp is also controlled by the ECM and is illuminated to indicate that it is not the optimal time to
crank the engine. This will not prohibit the engine from starting.

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Option Strategy and Product Specification Language Summary
The QSB6 and QSB4 Tier 3 engines have been released with in Cummins MR-03 product specification language.
This is common with the ISB02 and Tier 2B engines launched in 2003 and 2004. That means “carry over options”
will share the same option numbers with these platforms.

The GCE Option eBook gives the definition of the QSB tier 3 options that are released for use. The Option
information is available only on the Web (hardcopy can be printed out). An “Option Status and Conversion Matrix”
is available to assist in cross referencing a Tier 2 specification into a Tier 3 equivalent specification.

Changes from -02 Language to MR-03 Language used for QSB6 and QSB4 Tier 3 product

1. The accessory drive pulley that mounts on the front of the fan hub changes from (AD) to (PA)
2. The vibration damper (DA) changes to front drive adapter (AF) and becomes a general category
3. The customer software (DO) category is available (common for electronic engines) to specify the
electronic parameter default settings.
4. The cam follower cover (CM) changes to crankcase breather (BR).
5. Oil pressure sensor and coolant temperature sensors changed from (EO) to (SD) options
6. Lift pump (FS) changed to fuel inlet fitting (FI, general option)
7. New turbo air transfer connection (IT) and air intake connection (IC) option categories are added for
the charge air cooling system.
8. The lube cooler/filter options (LC, LF) are now specified as a filter (LF) option only.
9. The oil filled engine option changes from (SS) to (LO).
10. The front gear train accessory (DF) option changes to an auxiliary pump (HD) option. The DF
location option changes to a DR option.
11. The shipping skid has changed from (SS) to (SK).
12. The thermostat housing (TH) option changes to water outlet connection (WO).
13. The radiator plumbing options change from (WH) to (RP).
14. The heater plumbing options change from (WH) to (HC)
15. The provision to route the bypass coolant to a remote transmission cooler is specified as a (TK)
option rather than a (TH) option.
16. WR wiring harness options are dependent options
17. Current option categories no longer required on MR-03 specifications:
• Base Parts (BP) are now dependant options
• FV options are not required
• Performance parts (PP) are now dependant options
• Thermostats (EC) now specified as part of the engine coolant vent (RP) options. The EC
thermostat is a dependent option.

Product Specifications
Customer Specific Language (CSL) will be used for all QSB6 and QSB4 engine specifications. Product Identifier
and Standard Pricing Configuration numbers required for CSL are being established and updates will be provided
on the Cummins Web (GCE site).

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Technical Configuration: D313001CX03


Model Agri Prod Agri Pric Cons Prod CONS
Name Power Range (Hp) ID's Spec ID's Pric Spec
QSB6.7 Above 260 AGRI 208 PRIC 3247 CONS 497 PRIC3241
QSB6.7 241 to 260 AGRI 207 tbd CONS 514 tbd
QSB6.7 221-240 AGRI 206 tbd CONS 512 tbd
QSB6.7 206-220 AGRI 205 tbd CONS 513 tbd
QSB6.7 191-205 AGRI 204 PRIC 3246 CONS 511 PRIC 3249
QSB6.7 180-190 AGRI 221 PRIC 3318 CONS 527 PRIC 3317
QSB6.7 166-179 AGRI 222 PRIC 3322 CONS 528 PRIC 3321
QSB6.7 151-165 AGRI 203 tbd CONS 510 tbd
QSB6.7 150 & Below AGRI 202 PRIC 3245 CONS 509 PRIC 3248

Technical Configuration: D323001CX03


Model Agri Prod Agri Pric Cons Prod CONS
Name Power Range (Hp) ID's Spec ID's Pric Spec
QSB4.5 161 - 170 AGRI 223 PRIC 3325 CONS 529 PRIC 3324
QSB4.5 131-160 AGRI 212. PRIC 3259 CONS 498 PRIC 3188
QSB4.5 126-130 AGRI 209 PRIC 3258 CONS 516 PRIC 3257
QSB4.5 111-125 AGRI 210 tbd CONS 517 tbd
QSB4.5 100-110 AGRI 224 PRIC 3329 CONS 530 PRIC 3328
QSB4.5 99 & Below AGRI 211 tbd CONS 518 tbd

Installation Recommendations Summary


It is a requirement that the Industrial Installation Quality Assurance (IQA) Procedure (AEB 20.12) is followed for
each new QSB6 or QSB4 machine application to insure that this application meets or exceeds Cummins’ and the
OEM’s installation requirements. This process is in concurrence with the Installation Quality Assurance (IQA)
Standard Work.

Cummins Advisor is a CD-ROM product designed to assist the user in selecting the best engine and rating for the
machine application, and assists with the design and installation reviews. For more information, refer to: AEB
20.12 Installation Quality Assurance

Other technical references that will be available via Cummins AdvisorTM (Industrial Reference disc) and the GCE
website (http://www.gce.cummins.com/ice/ice_btier3/index_4b6bt3s3.htm) include:
·
Performance Curves and Data Sheets
· Industrial Installation Drawings
· Option eBook
· Installation Recommendations (Automotive and CMLA) and Installation Requirements Bulletins (IRB)
· Component(s) Manufacturer Information
· Application Engineering Bulletins (AEB)
AEB 24.17 Application Guidelines for Industrial Engine Selection
AEB 24.06 (CAC), AEB 24.08 (Air compressors) and AEB 53.05 (Grid Heaters) specifically referenced in
this document
AEB 15.58 Virtual Engineer
AEB 21.36 Installation Requirements Engine mounting AEB
AEB 46.02 Angularity Requirements
AEB24.10 Fuel Systems Requirements
AEB24.18 Cooling system Requirements
AEB111.15 Cummins Branded Electrics (Alternators, Starters and Fuel Shutoffs) – Installation
Recommendations
AEB174.04 Cold Weather Requirements
· B & C Series Engines Installation Recommendations bulletin 3382769

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Installation Drawings
QSB6 Drawing 3170561
QSB4 Drawing 3170613
These drawings are currently available on the GCE Web site, along with 3D models available for download.

Prototype and Production Availability


Information regarding the availability of QSB6 and QSB4 prototypes and production engines can be obtained from
your Cummins OEM Account Sales Manager or DOEM Regional Sales Manager. Prior to Production launch
details around prototype availability and procedures are maintained on the GCE website.

Appendix – Tier 2 vs Tier 3 Overlays

Top View 6 Cylinder

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Front View 6 Cylinder

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Right Side 6 Cylinder

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Top View 4 Cylinder

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Front View 4 Cylinder

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Right Side 4 Cylinder

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Change Log

Date Change Page


Jun04 Updates to document in blue (Coolant connections, Fan Several
recommendations, remote lube filter recommendations, Fuel Filter
section), added appendix with Overlays
Mar04 Document origination All

Cummins Confidential

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