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09 Engine
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09/06 - Slide1
Slide1

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Course Details
Course name:

Engine B222

Content:

Cummins QSM-11 Tier 3

General objectives:

Familiarization with QSM-11 Engine

Target Group:

Big Truck technicians

Pre-requisites:

The student should have a good knowledge

of diesel technology

Learning Objectives:

Identify engine components

Perform periodic maintenance

Have a general idea of the fuel system

operation
Course Duration:

1 hour

Please note that this is not a training course to a Cummins Certification

level.

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Cummins QSM-11 Tier 3 Engine

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Engine Overview - Intake Side

1.
2.

Blow by tube
Ambient air pressure
sensor
3. 31-pin OEM connector
4. Engine data tag
5. Electronic control
module (ECM)
6. Engine serial number
7. Cooling plate
8. Starter
9. Flywheel ring gear
sensor
10. Fuel outlet from cooling
plate to injector rail

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Engine Overview - Intake Side

11. Fuel vacuum

12. Fuel outlet from pump
13. Fuel filter with integral
water-in-fuel sensor
14. Oil drain plug
15. Fuel rail pressure
sensor
16. Power steering pump
mounting location
17. Oil pressure/
temperature sensor
18. Engine position sensor
19. Freon compressor
mounting location
20. Air compressor.

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Engine Overview - Exhaust Side

1.
2.
3.

Either hookup
Turbocharger
Intake manifold temperature
sensor
4. Intake manifold pressure
sensor
5. Intake manifold
6. Coolant temperature sensor
7. Engine brake oil supply
8. Oil pan drain plug
9. Oil pan sump heater
10. Oil pressure after filter
11. Oil pressure before filter
12. Coolant heater

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Fuel system: General System

1. Fuel Inlet supply

2. Fuel Pump
3. Fuel Filter
4. Injector
5. Fuel Drain Return
6. Fuel to Injector
7. ECM Cooling Plate.

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Fuel system: Fuel Pump

Fuel pump is driven by accessory
drive gear (timing gears)
Pressure is regulated to 10.3 Bar
(150 PSI)
Provides a relatively constant
pressure needed for correct
operation of injectors

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Fuel system: WIF Sensor

WIF (water-in-fuel) sensor installed
in fuel filter
Warning light activated in case
there is too much water in fuel
Used for engine protection
Filter removes 85% of all water in
fuel
Water should be tapped often to
prevent damage on engine

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Fuel system: Fuel Pressure Regulator

- Driven by the accessory drive

- Pressure regulated at 10.3 Bar
(150 PSI )
- Filter screen installed at top
- Shutoff valve installed on
pump
- Excess flow is returned to the
inlet side of the pump

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Fuel system: Pump Injector

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Fuel system: Pump Injector Components

Injector Drive train

1.
2.
3.
4.
5.
6.

Injector
Injector link
Rocker lever
Push rod
Cam follower
Camshaft.

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Fuel system: Pump Injector Components

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Fuel system: Pump Injector Operation

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Fuel system: Pump Injector Operation

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Fuel system: Pump Injector Operation

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Fuel system: Pump Injector Operation

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Fuel system: Pump Injector Operation

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Fuel system: Pump Injector Operation

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Fuel system: Pump Injector Operation

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Fuel system: Pump Injector Operation

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Fuel system: Pump Injector Operation

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Fuel system: Pump Injector Operation

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Fuel system: Pump Injector Operation

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Fuel system: Pump Injector Operation

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Fuel system: Pump Injector Operation

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Fuel system: Pump Injector Operation

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Fuel system: Pump Injector Operation

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Fuel system: Pump Injector Operation

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Inputs & Outputs on ECM

Input
Oil pressure/
temperature sensor

Output
Shut off solenoid

Coolant temp. sensor

Injector 1

Coolant level sensor

Intake manifold temp.
sensor
Intake manifold
pressure sensor
Ambient air pressure
sensor
Engine position sensor
Water in fuel sensor

Injector 2
ECM

Injector 3
Injector 4
Injector 5
Injector 6
Warning lights

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Inputs & Outputs on ECM: Oil Pressure/Temperature Sensor

Located on the left side of

the engine block, near the
front of the engine
Provides input for engine
protection system
Combined sensor
4 wire sensor

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Inputs & Outputs on ECM: Coolant Temperature Sensor

Located in the front side of

the thermostat housing on
the exhaust side of the
engine
Provides input for engine
protection system
2 wire sensor

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Inputs & Outputs on ECM: Coolant Level Sensor

Located in the top tank of

the radiator
Signal used to indicate a
coolant level below
normal
2 wire sensor

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Inputs & Outputs on ECM: Intake Manifold Temp Sensor

Located in the intake

manifold near the inlet
connection
Input is required for the
engine protection system
and for fuel metering and
injection timing
2 wire sensor

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Inputs & Outputs on ECM: Intake Manifold Pressure Sensor

Located on top of the intake

manifold near the front of the
engine
Input is required for electronic
control of the fuel system
3 wire sensor
Output voltage between 0.5
and 4.5 Volts

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Inputs & Outputs on ECM: Ambient Air Pressure Sensor

Located on the left side of

the engine near the rear of
the fuel pump
Provides altitude
information
3 wire sensor
Sensor output between 0.5
and 4.5 Volts

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Inputs & Outputs on ECM: Engine Position Sensor

Located in the rear face of

the gear cover
Provides information on
engine rpm and position
Dual type sensor

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Inputs & Outputs on ECM: Cam surfaces

Camshaft has 24 surfaces
One surface has a raised area
for TDC detection
If one of the sensor signals is
lost, the engine keeps running
Loss of both signals will
shutdown the engine
Magnetic pick-up type sensor

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Inputs & Outputs on ECM: Electrical Connector

Passage for connector in

cylinder head
6 pump injectors are
controlled by the ECM

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Inputs & Outputs on ECM: Shutoff Valve

Shutoff valve located on

the fuel pump
Activated by ECM
Used for engine protection
and shutdown

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Lubrication system: Overall System

1
2

Oil Pump
Pressure Regulator
Valve
3 Oil Return to Pan
4 High Pressure Relief
Valve
5 Oil Return to Pan
6 Oil Thermostat
7 Oil Cooler
8 Combination Oil Filter
9 Filter Bypass Valve
10 Accessory Drive/Air
Compressor
11 Idler Gears
12 Viscosity Sensor

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Lubrication system: Pump

Heavy duty gear

lubricating oil pump
Contains two 7 tooth
gears

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Lubrication system: Oil Pressure Regulator

The oil pressure
regulator is located in
the circuit between the
pump and the filter head

It controls the system oil

pressure

The pressure regulator

consists of a spool valve
with a balance orifice,
valve spring and
viscosity sensor

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Lubrication system: Viscosity Sensor

A viscosity sensor is used
to maintain a good oil
supply in every engine
condition.

The viscosity sensor is

located inside the pressure
regulator.

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Lubrication system: Filter Bypass Valve

Filter Bypass Valve opens at a

pressure differential of 95 PSI
Ensures oil flow to the engine
under all filter conditions
An oil thermostat is used to get
a quick warm up of the engine
oil

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Lubrication system: Oil Thermostat

An oil thermostat is used to let

the cold oil bypass the oil
cooler, enabling a quick
operating temperature

Cooling the oil, prevents oil

breakdown that could occur at
high oil temperatures

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Lubrication system: Oil Capacitors

The QSM engine uses oil
capacitors to prevent rod
dipping or windage .
Otherwise the oil would
aerate and lose its
lubricating capacity

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Lubrication system: Piston Cooling Nozzles

Piston cooling nozzles

provide significant
cooling to the piston
crown

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QUESTIONS?
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09/06 - Slide49
Slide49