Cumminsmanual de Partes Qsl-9 - 46561508 [PDF]

Zitiervorschau

2017-04-10

ST1030/LP RELOAD TRAINING

Engine and Fuel System

COMMITTED TO SUSTAINABLE PRODUCTIVITY We stand by our responsibilities towards our customers, towards the environment and the people around us. We make performance stand the test of time. This is what we call – Sustainable Productivity.

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OBJECTIVES

You will know the Atlas Copco Scooptram ST 1030, from the inside and the outside, including hydraulic & electrical systems, safety, and basic maintenance routines.

Content Overview Safety Engine and fuel system Transmission and axles Hydraulics introduction

Brakes Steering Dump and hoist Electrical system General maintenance

ENGINE & FUEL SYSTEM Engine

Cummins Diesel QSL9 C 250

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ENGINE & FUEL SYSTEM Engine control system

ENGINE & FUEL SYSTEM Engine control module (ECM)

CUMMINS QSL9 CM850 ECM

1 2 3

1. 2. 3.

4 Pin Power connector 60 Pin Cummins connector 50 Pin OEM (Atlas Copco)

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ENGINE & FUEL SYSTEM Connectors 50 Pin OEM

STARTER LOCKOUT SWITCH (555)

INTAKE AIR HEATER SIGNAL (302) INTAKE AIR HEATER RETURN (301)

ENGINE COOLANT LEVEL SUPPLY (916A)

ENGINE COOLANT LEVEL RETURN (952A)

ENGINE COOLANT LEVEL SIGNAL (115)

REMOTE THROTTLE +5V (916A)

REMOTE THROTTLE 0V 952B

REMOTE THROTTLE SIGNAL (510C)

REMOTE ACCELERATOR SIGNAL (531)

ENGINE OVERRIDE SIGNAL (528-B)

ALT. MIN VSG SPEED (542)

CRANKSHAFT SPEED SIGNAL

CRANKSHAFT SPEED RETURN

CAMSHAFT POSITION SIGNAL

CRANKSHAFT +5V

CAMSHAFT POSITION +5V

CAMSHAFT POSITION TERURN

RAIL FUEL PRESSURE +5V

RAIL FUEL PRESSURE SIGNAL

RAIL FUEL PRESSURE RETURN

WTR IN FUEL RET

WTR IN FUEL SIG

INTAKE MAN PRES SIGNAL

INTAKE MAN AIR TEMP SIGNAL

INTAKE MAN PRES/TEMP +5V

INTAKE MAN PRES/TEMP RETURN

ENG OIL PRESSURE RETURN

ENG OIL PRESSURE +5V

ENG OIL PRESSURE SIGNAL

BAROMETRIC PRES SIGNAL

BAROMETRIC PRES RETURN

BAROMETRIC PRESSURE +5V

ENG COOLANT TEMP SIGNAL

FUEL LIFT PUMP SUPPLY

ENG COOLANT TEMP RETURN

FUEL LIFT PUMP RETURN

FUEL PUMP ACTUATOR SIGNAL

FUEL PUMP ACTUATOR RETURN

16 48 27

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25

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47 23 37 44

13

03

ENGINE PROTECTION RED STOP LAMP (ESD-A)

SUPPLY VOLTAGE +5V (916) SIGNAL (510A) 0V (952-A)

IDLE SIGNAL (545)

OFF IDLE SIGNAL (543) (002)

BAT-

BAT+

ENGINE RUN SIGNAL +24V (439-D)

BATTERI (+) BATTERI (-)

FUEL PUMP ACTUATOR

11 01 38 33 15

32 02

WATER IN FUEL SENSOR

CAMSHAFT POSITION SENSOR

CRANKSHAFT SPEED SENSOR

RAIL FUEL PRESSURE SENSOR INTAKE MANIFOLD PRESSURE/ AIR TEMP SENSOR BAROMETRIC PRESSURE ENGINE SENSOR COOLANT TEMP SENSOR ENGINE OIL PRESSURE FUEL LIFT SENSOR PUMP

49 42 40 32 28 21 26 21 03 15 04 43 23 09 22 34 11 01 39 20 10 37 47 46

ENGINE COOLANT SENSOR ACCELERATOR ASSY WILLIAMS 9-PIN DEUTSCH CONNECTOR

ENGINE & FUEL SYSTEM

Connectors 60 Pin Cummins

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ENGINE & FUEL SYSTEM Connectors 60 Pin Cummins

CYLINDER #1 RETURN

CYLINDER #1 DRIVER

CYLINDER #2 RETURN

CYLINDER #2 DRIVER

CYLINDER #3 DRIVER CYLINDER #3 RETURN CYLINDER #4 DRIVER

CYLINDER #5 DRIVER

CYLINDER #4 RETURN

CYLINDER #6 DRIVER

CYLINDER #5 RETURN

CYLINDER #6 RETURN

53 45 51 54 52 55 58 56 60 46 59 57

ENGINE & FUEL SYSTEM

Engine

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ENGINE & FUEL SYSTEM Engine

Over Ride Button Caution: Only use when in emergency and when really needed.

ENGINE & FUEL SYSTEM Engine Protection The ECM (CM850) on the Cummins QSL9 will protect the engine if any of the 4 sensors below log a pressure, temperature or level fault.

Derate    

Coolant Temperature High Intake Manifold Temp High Oil Pressure Low Coolant level Low

Derate to a maximum of 60% torque Derate to a maximum of 60% torque Derate to a maximum of 60% torque and1600 RPM Derate to a maximum of 60% torque

Shut Down    

Coolant Temperature High Intake Manifold Temp High Oil Pressure Low Coolant level Low

Shut down Derate to a maximum of 60% torque Shut Down Shut Down

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ENGINE & FUEL SYSTEM Engine Protection

Derate  By push and holding the over ride button on an engine that has been de-rated because of a loss of oil pressure, low coolant level, high intake manifold or coolant temperature, will return the engine power and RPM to 100%.

Shut Down  By push and hold the over ride button on an engine that indicates that shut down will apply after 30 sec, because of a loss of oil pressure, low coolant level, intake manifold or coolant temperature, will keep the engine running at full engine power, RPM and prevent it from shut down.

ENGINE & FUEL SYSTEM Engine Protection

Engine Over Ride Button  Provides a momentary sinking signal to the ECM (CM850) at pin 15 of the OEM connector.  When held in will return derate torque and speed values to 100 % or prevent the engine to shut down (depending on ECM pre-set feature).  Will not request engine codes.

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ENGINE & FUEL SYSTEM Engine 2. COOLANT TEMPERATURE SENSOR

3. AMBIANT AIR PRESSURE SENSOR

4. INTAKE MANIFOLD PRESSURE & TEMPERATURE SENSOR 5. CRANKSHAFT POSITION SENSOR

1. FUEL PUMP ACTUATOR

6. FUEL RAIL PRESSURE SENSOR

9. CAMSHAFT POSITION SENSOR

1. 2. 3.

4903523NX 4088750 4076493

4. 5. 6.

8. OIL PRESSURE SENSOR

7. ECM CM850

4921322 4921686 3949988

ENGINE & FUEL SYSTEM Engine Protection

Coolant Temperature Sensor

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ENGINE & FUEL SYSTEM Engine Protection

Intake Manifold Temperature Sensor

ENGINE & FUEL SYSTEM Engine Protection

Oil Pressure Sensor

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ENGINE & FUEL SYSTEM Engine Protection

Coolant level Sensor

ENGINE & FUEL SYSTEM Engine Protection

 The sensors will only protect the engine if they are working properly.  If the sensor has failed, un plugged, shorted or has an open wire in the harness the ECM will log a fault code indicating an issue but it will not derate/shut down the engine.  If the check or stop engine light is on because an electrical fault and then there is a true fault (pressure, temp or level). The ECM will not protect or derate/shut down the engine.

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ENGINE & FUEL SYSTEM Engine Protection

Conclusion All sensors must be kept in proper working condition or there will not be any engine protection.

ENGINE & FUEL SYSTEM Engine

TMAP Sensor

Barometric Pressure Sensor Ambient

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ENGINE & FUEL SYSTEM Engine

The Camshaft Position Sensor (EPS)

ENGINE & FUEL SYSTEM Engine

The Crankshaft Speed Sensor (Engine Speed Sensor)

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ENGINE & FUEL SYSTEM Engine

Inlet Metering Valve (IMV)

ENGINE & FUEL SYSTEM Engine

Fuel Rail Pressure Sensor

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ENGINE & FUEL SYSTEM Engine

Barometric Ambient Pressure Sensor

ENGINE & FUEL SYSTEM Engine

Turbo Waste gate

OPEN

CLOSED

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ENGINE & FUEL SYSTEM Engine

Grid heater

ENGINE & FUEL SYSTEM Engine

AC/P/N 5590 0028 08

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ENGINE & FUEL SYSTEM Engine Fault Codes

Cummins Diagnostic Fault Codes will be in the Display

Cummins engine fault codes

ENGINE & FUEL SYSTEM Fuel System Components Diesel tank

High Pressure pump

Primary fuel filter and water separator

Secondary fuel filter Low Pressure pump

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ENGINE & FUEL SYSTEM Fuel System

ENGINE AND FUEL SYSTEM Air filtration Unfiltered air intake. Engine starting The plastic tube outside the filter cartridge will direct the air to a spinning motion.

Filtered clean air

Pre separated particles.

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ENGINE AND FUEL SYSTEM Air filtration

Evacuator valve for pre separation Restriction indicator

Unfiltered air inlet

The plastic tube outside the filter cartridge will direct the air to a spinning motion.

ENGINE AND FUEL SYSTEM Cummins Tier III QSL 9

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ENGINE AND FUEL SYSTEM Fuel system

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ENGINE AND FUEL SYSTEM Fuel system

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ENGINE AND FUEL SYSTEM Fuel system

CYL Head High Pressure Common Rail

High Pressure Fuel Line to Rail

Injectors Fuel Rail Pressure Regulator High Pressure Connectors

Secondary Filter

Fuel Return Fuel Return

Fuel Return

Fuel Manifold Lift Pump

Fuel Return Fuel Out

H.P. Fuel Pump

L.P. Fuel Gear Pump

ECM Cooling Plate

Primary Filter

Fuel Tank

ENGINE AND FUEL SYSTEM Fuel system Layout Front

Front View Injector Drain Line

High pressure fuel Pump

5 micron secondary Fuel Filter High Pressure Relief Valve Drain Line

ECM Cooling Plate

Fuel Pump Drain Line

ECM

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ENGINE AND FUEL SYSTEM Fuel system Layout Back

Fuel Drain Connection Fuel Supply Connection

ECM Cooling Plate Electric Fuel Lift Pump Check Valve ECM Cooling Plate

ENGINE AND FUEL SYSTEM Fuel system Layout

Fuel Inlet to Fuel Filter

Fuel Inlet to High Pressure Pump

Fuel Outlet From Fuel Filter

Fuel Inlet to Gear Pump

Fuel Outlet From Gear Pump

Fuel Inlet to ECM Cooling Plate Fuel Outlet From ECM Cooling Plate

Fuel Inlet

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ENGINE AND FUEL SYSTEM Fuel system Layout Low Pressure Layout

Filter Out (to IMV)

IMV In

LPP In LPP Out

Filter In (from LPP Out) ECM Cooler out with internal check valve (to LPP in Out)

ENGINE AND FUEL SYSTEM Electronic Injector

Electronic injector designed by Bosch Essentially an off-the-shelf injector Many common components with QSB with CM850 Leads to a reliable product. Advanced design allow for up to 4 injection events for emissions control Pilot injection, also for lower noise & improved cold starting Split main injection – into two events Post injection for emissions control

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ENGINE AND FUEL SYSTEM Electronic Injector

ENGINE AND FUEL SYSTEM High Pressure Fuel Connector

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ENGINE AND FUEL SYSTEM Electronic Injector and high-pressure Fuel Connector

ENGINE AND FUEL SYSTEM Electronic Injector

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ENGINE AND FUEL SYSTEM Electronic Injector

ENGINE AND FUEL SYSTEM Electronic Injector

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ENGINE AND FUEL SYSTEM Electronic Injector

COMMITTED TO SUSTAINABLE PRODUCTIVITY.

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