Cummins B Series engine

Cummins B Series
Overview
Manufacturer	Cummins
Also called	ISB
Production	1984–present
Layout
Configuration	I4 and I6 diesel engines
Combustion
Fuel type	Diesel
Oil system	Wet sump
Cooling system	Water cooled

The Cummins B Series is a family of straight-four and straight-6 diesel truck and industrial piston engines manufactured by Cummins. The B Series is known for displacing "one liter per cylinder" because of the popular 3.9 litres (238.0 cu in) straight-four and 5.9 litres (360.0 cu in) straight-six. A 3.3 litres (201.4 cu in) straight-four is also available. The B Series is widely used in many segments, including pickup trucks (the Dodge Ram), buses, military vehicles, construction equipment, and marine. Some of the construction and marine applications have actually featured two B series Cummins engines.

The engine was originally designed by Cummins and Case Corporation for commercial truck applications, and appeared in a light-duty truck, the Dodge Ram, in 1989. This was not the first engine to appear in Dodges as a Diesel option. Mid-1970s D models offered the rare, underpowered, Mitsubishi non-turbo diesel. Every Cummins powered Dodge Pickup (since initial production in 1989) has come equipped with a turbocharger. It uses a gear-drive camshaft for extra reliability. Also specified is a deep-skirt engine block and extremely strong connecting rods. A Holset turbocharger is used.

The original B Series was updated with 24 valves and an electronic engine management system to become the ISB in 1998.

6BT

The 5.9 litres (360.0 cu in) 6BT, aka the Cummins "12-valve" was the first member of the "B" engine family to be used in a light truck vehicle. The 6BT used Robert Bosch GmbH fuel systems, injectors and VE rotary pump and P7100 inline injection pumps. This engine started life in 1984 as an agricultural engine, for use in Case agricultural equipment. It was produced in a joint venture between Cummins Engine Corp. and Case - called Consolidated Diesel Corp. After 1989, this engine was also used in the Dennis Dart midibus, as well as in light to medium sized commercial trucks and buses.

Dodge Ram 6BT

Appearing in the 1989-1998 Dodge Ram pickup truck, it quickly became a popular alternative to the large V8 gasoline engines normally used in full-size pickup trucks, while producing nearly double the torque at low engine speeds. The 6BT was also made popular for its fuel mileage over gasoline engine counterparts, roughly doubling fuel mileage in some applications. Further adding to the 6BT popularity in the Dodge Ram was the fact that it was the only diesel pickup, during the time, that featured Direct Injection and didn't rely on glow plugs for cold weather start up.

The 1989-1993 Dodge Ram pickup engines were rated at 160 horsepower (119 kW; 162 PS) and 400 pound-feet (542 N⋅m). The fuel systems for these Dodge Rams featured Bosch injectors and Bosch VE mechanically controlled fuel injection pumps. Intercoolers were added 1991. In 1994 when Dodge introduced the completely restyled Ram, changes were made to the 6BT as well. The fuel systems for these Dodge Rams featured different Bosch injectors and a de-tuned Bosch P7100 mechanically controlled fuel injection pump. The 1994-1995 6BT was rated at 160 horsepower (119 kW; 162 PS) and 400 pound-feet (542 N⋅m) when equipped with the 47RH automatic transmission, and 175 horsepower (130 kW; 177 PS) and 420 pound-feet (569 N⋅m) when equipped with the NV4500 manual transmission. The 1996-1998 6BT was rated at 180 horsepower (134 kW; 182 PS) and 420 pound-feet (569 N⋅m) when equipped with the 47RE automatic transmission, and 215 hp (160 kW; 218 PS) and 440 pound-feet (597 N⋅m) when equipped with the NV4500 manual transmission. The 6BT for 1996-1998 California Dodge Rams had the same ratings were 180 horsepower (134 kW; 182 PS) and 420 pound-feet (569 N⋅m) regardless of transmission. These engines also featured EGR Valves to meet the California Nitric Oxide emissions. All the Dodge Ram 6BT engines had a compression ratio of 17.5:1.

ISB

The 5.9 litres (360.0 cu in) ISB (Interact System B) is one of the largest straight-six engines ever produced for light truck vehicles, and the improved high output 600 version was on the Ward's 10 Best Engines list for 2004.

One unusual feature of the ISB is that it is a multi-valve pushrod engine design. The engine displaces 5,883 cubic centimetres (359.0 cu in), with a 102.1 millimetres (4.02 in) cylinder bore and 119.9 millimetres (4.72 in) piston stroke. A turbocharger output in the high-compression (17.2:1 in recent versions) diesel. It is an all-iron engine with forged steel connecting rods, an assembled camshaft, and a cast aluminum intake manifold. The engine is produced in Columbus, Indiana. The 24 valve design has various advantages over the older 12 valve head.

The ISB uses electronically controlled Robert Bosch GmbH fuel systems, unlike the 6BT which were mechanical. Early ISB engines utilize Bosch injectors and a Bosch VP44 high pressure pump. Later ISB designs have common rail fuel injection, and once again utilized Bosch injectors and a Bosch CP3 high pressure pump.

QSB

The 5.9 litres (360.0 cu in) QSB (Quantum System B) is the offroad, heavy duty, version of the ISB. Typically used in Marine, Agricultural, and Construction applications, these engines share many of the same parts as the ISB.

Dodge Ram ISB

Midway through model year 1998, the Dodge Ram switched from the 6BT to the ISB to meet updated emissions requirements. Like other ISB's, these engines started out using the Bosch VP44 rotary injection pump. The VP44 setup meant that timing and fuel could be precisely controlled, which led to cleaner emissions. However, VP44 failure rates were very high versus the older P7100 injection pump. The compression ratio in these engines was 16.3:1. The 1998-2000 ISB was rated at 215 horsepower (160 kW; 218 PS) and 420 pound-feet (569 N⋅m) when equipped with the 47RE automatic transmission. The 1998 ISB was rated at 235 horsepower (175 kW; 238 PS) and 420 pound-feet (569 N⋅m) when equipped with the manual transmission. The 1999-2000 ISB was rated at 235 horsepower (175 kW; 238 PS) and 460 pound-feet (624 N⋅m) when equipped with a manual transmission. For the 2001-2002 model years, a standard output and high output ISB Cummins engine was offered. The standard output, which was the same as the previous engines was rated to 235 horsepower (175 kW; 238 PS) and 460 pound-feet (624 N⋅m) when equipped with either a manual transmission or automatic. The high output ISB was rated at 245 horsepower (183 kW; 248 PS) and 505 pound-feet (685 N⋅m), and only a NV5600 six-speed manual transmission was offered behind it. The high output engine was different in a few ways from the standard output engine. The high output ISB had higher compression (17.1:1), powdered metal valve seat inserts and a larger flywheel. The Bosch fuel system was reworked as well to allow increase fuel delivery and a slight increase in timing.

Dodge Ram ISB CR

For the 2003 model year, the Cummins was introduced with Bosch high pressure common rail fuel injection, again increasing power output. On automatic equipped vehicles, the 47RE was upgraded internally to increase durability and torque capacity, now known as the 48RE. The 2003 rating for the Dodge truck was released at 305 horsepower (224 kW; 308 PS) and 555 foot-pounds (752 N·m). This rating and it's performance was based on the combustion system developed during a joint venture Cummins had with Iveco and New Holland called the European Engine Alliance, or EEA. Pat Shea led the development of this performance hardware and rating for Cummins, Inc. The engine development started as the "Hot 6" program internally to Cummins. Pat, along with the help of Dave Murray, Daryl Walker and Aaron Quinton, worked on this engine development at the Mid Range Technical Center. The work, along with Pat, Daryl and Dave, was moved to a facility south of Columbus, known as Oly internally to Cummins. The name Oly came from the prior owner of the facility who was named Olympic Truck, or Oly for short. Pat Shea is considered one of the best, if not the best, combustion, performance and emissions engineer within the Cummins family. The engine and rating is arguably the most desirable of all engines released for the Dodge Truck.

Midway through the 2004 model year, the Cummins 600 was introduced, producing 325 horsepower (242 kW; 330 PS) at 2,900 rpm and 600 pound-feet (813 N⋅m) at 1,600 rpm. This high torque output gives the engine its name, and also offers a high specific output of 102 pound-feet (138 N⋅m) per litre of displacement (1.67 ft·lbf/CID)

A 610 version, new for the 2005 model year, pushes torque to 610 pound-feet (827 N⋅m).

3.9L/4BT

The 3.9L/4BT Cummins is an engine in the same family as the 5.9 litres (360.0 cu in) Cummins turbodiesels. The 3.9L/4B is an inline four cylinder turbodiesel that was popular for many step van applications, including bread vans and other commercial vehicles. This engine is also used in various industrial, construction and agricultural applications. With a cylinder bore of 4.02 inches (102.1 mm) and a piston stroke of 4.72 inches (119.9 mm), the engine had a wet weight of 745 pounds (338 kg). In recent years it produced 130 horsepower (97 kW; 132 PS) and 355 pound-feet (481 N⋅m) of torque. The 4BT today is also popular as a conversion engine among many light-duty pickup trucks that were originally equipped with gasoline engines. This is due to its high fuel efficiency while producing power comparable to the original light-duty gasoline engine. The 4BT engines have the same pistons, connecting rods, valvetrain components, and injectors as their 6BT counterparts.

B6.7

The B6.7 is the latest version of the B Series. It is currently the largest straight-six engine produced for a light duty truck. It produces 350 horsepower (261 kW; 355 PS) and 650 pound-feet (881 N⋅m) in the 2007.5 and newer Dodge 2500/3500 pickup trucks with the Chrysler-built six-speed 68RFE automatic transmission built at the Kokomo Transmission plant in Kokomo, Indiana. Engine torque is slightly reduced with the Mercedes G56 6-speed manual transmission at 350 horsepower (261 kW; 355 PS) and 610 pound-feet (827 N⋅m). The 2007 and newer 3500 Cab & Chassis trucks only get the 305 horsepower (227 kW; 309 PS) and 610 pound-feet (827 N⋅m) version of the B6.7, whether it has the Aisin AS68RC or the Mercedes G56 6-speed manual transmission. As for the 2008 4500/5500 medium duty Chassis Cabs or the Sterling Bullet Trucks, they will also receive the 305 horsepower (227 kW; 309 PS) and 610 pound-feet (827 N⋅m) version of the B6.7, whether it has the Aisin AS68RC or the Mercedes G56 6-speed manual transmission.

There are many changes over the previous B5.9 for the Dodge truck, the most obvious being the larger displacement. The B6.7 had an increase of cylinder bore and piston stroke to 4.21 inches (106.9 mm) and 4.88 inches (124.0 mm) stroke, respectively, thereby giving a displacement of 408 cubic inches (6,686 cc). It includes a cooled EGR system, variable geometry turbocharger, a new higher-pressure version of the Bosch direct-injection fuel system, and a particulate filter designed to reduce diesel particulate matter by more than 90%. Template:PDFlink. Still, it retains 45% of the original 5.9 components.

The 6.7L base engine design proposal was lead by Jerl Purcell and his team out of the Darlington, England Cummins facility. Jerl was instrumental in the development of the rear gear train ISB engine that resulted from the European Engine Alliance and is considered the Father of this engine layout. The 6.7L ISB engine was launched in the European EURO4 application and the Tier III off high-way application before being released in the Dodge Truck and US EPA medium duty automotive applications in January 2007.

The Dodge trucks' B6.7 competes head to head with V8 engines offered by General Motors and Ford Motor Company, the DMAX manufactured Duramax and Navistar manufactured 6.4  Power Stroke, respectively.

Both the B4.5 and B6.7 are used in DAF Trucks' LF45, and LF55 and CF65 range respectively.

B6.7 Emission Control Issues

On January 27, 2010, the Houston, Texas-based law firm Craft Hughes Law filed a class action lawsuit in the United States District Court for the District of South Carolina (Greenville Division) alleging defects in the emission control system used in conjunction with the B6.7 engine in 2007-2010 Dodge trucks.

Popular power ratings (B 6.7)

School bus

• 520 pound-feet (705 N⋅m) @ 1,600 rpm, 200 horsepower (149 kW; 203 PS) electronically governed at 2,600 rpm
• 520 pound-feet (705 N⋅m) @ 1,600 rpm, 220 horsepower (164 kW; 223 PS) electronically governed at 2,600 rpm
• 550 pound-feet (746 N⋅m) @ 1,600 rpm, 240 horsepower (179 kW; 243 PS) electronically governed at 2,600 rpm
• 560 pound-feet (759 N⋅m) @ 1,600 rpm, 240 horsepower (179 kW; 243 PS) electronically governed at 2,600 rpm
• 620 pound-feet (841 N⋅m) @ 1,600 rpm, 260 horsepower (194 kW; 264 PS) electronically governed at 2,600 rpm
• 660 pound-feet (895 N⋅m) @ 1,600 rpm, 280 horsepower (209 kW; 284 PS) electronically governed at 2,600 rpm

Urban bus

• 520 pound-feet (705 N⋅m) @ 1,300 rpm, 200 horsepower (149 kW; 203 PS) electronically governed at 2,600 rpm
• 520 pound-feet (705 N⋅m) @ 1,600 rpm, 220 horsepower (164 kW; 223 PS) electronically governed at 2,600 rpm
• 560 pound-feet (759 N⋅m) @ 1,600 rpm, 240 horsepower (179 kW; 243 PS) electronically governed at 2,600 rpm
• 660 pound-feet (895 N⋅m) @ 1,600 rpm, 280 horsepower (209 kW; 284 PS) electronically governed at 2,600 rpm

See also

• List of Cummins engines
• List of Chrysler engines