MOVING YOU FURTHER

Cummins Engine(Tier3)
QSB/QSL CM850

Service Engineering Team

Training Center
By H . J . Kim ( Master Kim )

2018. 09.
Hyundai Construction Equipment
1
1. Wheel loader Main Component
1) Maker & Engine Model

Descriptions HL730-9S HL740-9S HL757-9S HL760-9S HL770-9S HL780-9S

CUMMINS ← ← ← ← ←
Engine
( QSB4.5 ) ( 6BTA5.9 ) (QSB6.7) (6CTAA8.3) ( QSL ) ( QSM11 )

ZF ← ← ← ← ←
Transmission
( 4WG130 ) ( 4WG160 ) (4WG190) ( 4WG210 ) ( 4WG260 ) ( 4WG310 )

ZF ← ← ←
DANA ←
Axle ( MT- ( MT- ( MT- ( MT-
( 123/123 ) ( 113/123 )
L3085/3075 ) L3095/3085 ) L3105/3095 ) L3125/3115 )

JINSUNG
DAVID BROWN PARKER ←
Main Pump PRECISION ← ←
(X1A50) ( T67DC ) (T7DBS)
(G300 )

JEIL
MCV HUSCO ← ← DAVID BROWN ←
HYDRAULICS

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 2) Eco friendly Electronic Engine (HL730/757/770/780-9S)

Characteristic

■ Tier-3 Emission Certified : Eco friendly E/G

■ Electronic Control & Self-diagnostic
■ HPCR (High Pressure Common Rail) Fuel System
■ Enhanced function of Fuel Pre-Filter
■ Enhanced Reliability of Main Parts

HPCR (High Pressure Common Rail) Fuel System

■ Advanced Fuel Injection System

- Multi fuel Injection
- Optimal Control for Fuel Injection by ECM
■ Structure Simplification of Fuel System
- Verified durability for Fuel System
■ Emission Reduction & Easy starting at Low
Temperature by High pressure Fuel
Injection (Max. 1600bar)

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3) Robust Mechanical Engine (HL740/760-9S)

Characteristic

■ Tier 1 Emission Certified : HL740-9S

■ Tier 2 Emission Certified : HL760-9S
■ Mechanical In-Line Type Fuel Injection Pump

Endurance in Poor Fuel Quality Condition

■ Mechanical Bosch In-Line Fuel Pump

▪ The Most Common Fuel System
in Poor Fuel Quality Area
▪ Endurance in Poor Fuel Quality Condition
by applying OIL Lubrication Type
■ Easy maintenance & Serviceability
▪ Easy part supply & Economic part price
▪ Easy service by applying mechanical type

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2. QSB CM850 Cummins Engine (HL757-9S)
Intake Manifold Intake Air Heater
Pressure/Temperature
Sensor Fuel Rail Pressure Sensor

Fuel Pump Actuator

Coolant Temperature
Sensor

Data Link Connector

Oil Pressure Switch

Ambient Air Pressure

Engine Speed & Position
Sensor
Sensors

ECM

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2-1. Cummins Engine - QSB CM850 ECM (HL757-9S)

ƒCM850 ECM
– 4 pin power connector
– OEM connector has 50 pins
– Engine harness connector
has 60 pins
– Air cooled on QSB Tier III
engines

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2-2. QSB CM850 Sensors & Switch (HL757-9S)

ƒ Oil Pressure Switch

ƒ Camshaft Position Sensor
ƒ Crankshaft Speed Sensor
ƒ Coolant Temperature
ƒ Barometric Pressure Sensor
ƒ Fuel Rail Pressure Sensor
ƒ Intake Manifold Temperature & Pressure
ƒ Water-In-Fuel Sensor

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2-2. QSB CM850 Sensors & Switch (HL757-9S)

Oil Pressure Switch

ƒ Normally Closed Device

ƒ Single wire takes a 5
VDC reference voltage to
ground.
ƒ Sensor contacts open at
7-10 psi (ECM sees full 5
VDC when contacts are
opened).
ƒ A fault will be set if the
ECM sees 5 VDC at
startup on this circuit for
ten consecutive engine
starts.
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2-2. QSB CM850 Sensors & Switch (HL757-9S)

Camshaft Position Sensor

ƒ Primarily used to
determine engine position
for fuel timing.
ƒ Hall-effect type sensor
ƒ Looks at drillings on a
ring bolted to the end of
the camshaft.
ƒ Acts as a backup for the
crankshaft speed sensor.

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2-2. QSB CM850 Sensors & Switch (HL757-9S)

Crankshaft Position Sensor

ƒ Primarily used to
determine engine speed.
ƒ Hall-effect type sensor
ƒ Looks at drillings on a
ring bolted to the end of
the camshaft.
ƒ Acts as a backup for the
camshaft position sensor.

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2-2. QSB CM850 Sensors & Switch (HL757-9S)

Coolant Temperature Sensor

ƒ Two wire sensor

ƒ Found on the cylinder
head between the engine
water outlet and rocker
cover.

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2-2. QSB CM850 Sensors & Switch (HL757-9S)

Barometric Pressure Sensor

ƒ Used for engine

(turbocharger) protection at
high altitudes.
ƒ Mounted on the fuel
pump side of the engine
near the ECM on the main
engine harness.

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2-2. QSB CM850 Sensors & Switch (HL757-9S)

Fuel Rail Pressure Sensor

ƒ Used by the ECM to

determine the pressure of
fuel stored in the high
pressure fuel rail.

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2-2. QSB CM850 Sensors & Switch (HL757-9S)
Intake Manifold Temperature & Pressure Sensor
ƒ Combination Sensor
- Temperature
- Pressure
ƒ Used by the ECM for
air/fuel tuning/control.
ƒ Four wire sensor.
ƒ Mounted on the intake
manifold cover.

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2-2. QSB CM850 Sensors & Switch (HL757-9S)

Water-In-Fuel Sensor

ƒPositioned in the OEM

installed 25 micron Suction
Side filter.
ƒ Senses water
accumulation in the water-
stripping fuel filter.
ƒ ECM notifies operator
with a amber or water-in-
fuel lamp.

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3. QSL CM850 Cummins Engine (HL770-9S)

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3-1. QSL CM850 Cummins Engine (HL770-9S)

Intake Side Engine View (CM850 Control Module)

1. Air intake connection 9. Crankcase breather oil drain tube

2. Crankcase breather 10. Starter
3. Intake air heater 11. Engine oil drain plug
4. Turbocharger control valve-적용않됨 12. Fuel lift pump
5. Fuel rail 13. Electronic control module (ECM)
6. Fuel drain manifold 14. Air compressor
7. Fuel filter 15. Engine data plate
8. Crankcase breather draft tube 16. High-pressure pump
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3-1. QSL CM850 Cummins Engine (HL770-9S)

Exhaust Side Engine View (CM850 Control Module)

1. Exhaust manifold 8. Coolant outlet connection

2. Turbocharger (VGT shown)-적용않됨 9. Coolant heater port
3. Variable geometry turbocharger actuator-적용않됨 10. Coolant inlet connection
4. Crankcase breather 11. Lubricating oil cooler
5. Rocker lever cover 12. Lubricating oil filter
6. Engine oil fill 13. Dipstick location
7. Rocker lever housing 14. Flywheel housing
2006-04-14 18
3-2. QSL CM850 ECM (HL770-9S)

Electronic
Control Module

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3-3. QSL CM850 Sensors & Switch (HL770-9S)

Intake Manifold
Temperature
Sensor

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3-3. QSL CM850 Sensors & Switch (HL770-9S)

Intake Manifold
Pressure
Sensor

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3-3. QSL CM850 Sensors & Switch (HL770-9S)

Barometric Air
Pressure
Sensor

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3-3. QSL CM850 Sensors & Switch (HL770-9S)

Coolant
Temperature
Sensor

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3-3. QSL CM850 Sensors & Switch (HL770-9S)

Common Rail
Pressure
Sensor

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3-3. QSL CM850 Sensors & Switch (HL770-9S)

Oil Pressure
Swtich

2006-04-14 25
3-3. QSL CM850 Sensors & Switch (HL770-9S)

Engine Position
Sensor

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3-3. QSL CM850 Sensors & Switch (HL770-9S)

OEM Water in
Fuel Sensor

2006-04-14 27
3-4. QSL CM850 Actuators

Injector

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3-4. QSL CM850 Actuators

Fuel Pump
Actuator

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3-4. QSL CM850 Actuators

Fuel Pump Actuator

– PWM (Pulse Width
Modulated) device driven by
the ECM
– “Normally Open”
– The fuel pump actuator is a
serviceable part.
– Troubleshooting procedures
have been updated to reflect
when the fuel pump actuator
should be replaced vs the
entire fuel pump assembly

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3-4. QSL CM850 Actuators

Intake Air
Heater

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3-4. QSL CM850 Actuators

Fuel Heater (Optional)

– The fuel heater is not controlled by

the electronic control module (ECM).
A bimetallic strip acts as a thermostat.

– Mounted at the priming pump filter

head. The fuel heater will turn on
below approximately 2°C [35.6°F] and
turn off above approximately 24°C
[75°F].

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 4. Fuel System Clean Care
Upon completion of this course you will be capable of :

ƒ Demonstrating knowledge of fuel system sensitivity

to contamination.
ƒ Demonstrating knowledge of fuel system filtration
specifications.
ƒ Identifying possible sources of fuel system
contamination and demonstrating knowledge
of Clean Care techniques.

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Introduction

Clean Fuel Systems =

ƒ Performance
ƒ Reliability
ƒ Life Cycle
ƒ Emissions

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Why are some fuel systems so sensitive?

ƒ Emissions
ƒ Performance
ƒ Higher Pressures

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Clean from the start

ƒ Parts manufactured
in clean
environments.
ƒ Parts packaged and
shipped clean.

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Think Ahead
ƒ Easier to keep it
clean than to try and
clean it up later.
ƒ Some systems and
parts cannot be
cleaned once
contaminated.

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Microns ??????

ƒ What's a Micron?
ƒ Micrometer
ƒ Smallest particles a filter
can capture.

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Human Hair

Human Hair (0.003 Inch Diameter)

Dust mite

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 Pollen

Remember that dust mite from the last slide?

ƒ 15 microns
ƒ Equal to 0.0006 Inches
ƒ Roughly the size of a single pollen particle.

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A Red Blood Cell

ƒ 10 Microns
ƒ Equal to 0.0004 Inches
ƒ Roughly the size of a single red blood cell.

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A Yeast Spore

ƒ 5 Microns
ƒ Equal to 0.0002 Inches
ƒ Slightly smaller than a single spore of yeast.

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Bacteria

ƒ 2 Microns
ƒ Equal to 0.00008 Inches
ƒ The size of bacteria

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Filter Ratings
ƒ Micron Ratings?
ƒ Filter Efficiency?

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Clean Care
Thinking about possible
consequences for your
actions.

Think about sources of

contamination:
ƒ Cleaning process
ƒ Disassembly process
ƒ Repair environment
ƒ You

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Cleaning
Watch for:
ƒ Rust
ƒ Dirt
ƒ Paint
Sometimes it’s best to:
ƒ Clean
ƒ Loosen
ƒ Clean again

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Cleaning continued …..

ƒ What will your

wrench loosen
besides the
fitting/line?
ƒ Be aware of the
repair environments
potential to
contaminate the
system.
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Caps & Plugs
ƒ Save specialty fuel
system caps and plugs
from new parts.
ƒ Keep them clean, dry,
and organized.
ƒ Don’t use dirty caps and
plugs.

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Cap/Plug Kits

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Cap & Plug ASAP
ƒ Cap & Plug ASAP
ƒ Whenever the system is
opened.
ƒ Fuel systems often
contaminated when
other systems are the
focus of the repair.

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Parts Handling
ƒ Keep new fuel system parts
plugged or in the package
until you really need them.
ƒ Don’t always assume that a
new part is clean.
ƒ Read the service literature
before beginning your work
many engines specify to
NOT pre-fill fuel filters.

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Cleaning Methods

ƒ Choose and use lint free

shop towels.
ƒ Cloth towels can leave lint.
ƒ Paper towels can leave lint.
ƒ The best cleaning job is
often chemicals only.

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