3. Cummins Bridgeway Training Center
• Programa
– Apresentação ISCe
– Sensores & Localizações
– Desmontagem Parcial ISCe & Ferramentas
– VCO & INSITE
4. Cummins Bridgeway Training Center
• Emissions Reduction
– New 2.5 g/hp-hr NOx and Hydrocarbons emissions standard set by
the EPA for October 2002.
– This required Cummins to reduce the NOx and Hydrocarbon output of
all automotive engines.
– The ‘03 ISC and ISL are the last automotive engines to be updated to
meet the new EPA emissions standard.
– The ISB, ISM, and ISX engines were launched in 2002 to meet the
new emissions regulations.
• Reducing emissions requires an increase in cylinder pressure.
• The higher cylinder pressure requirements drove many base
engine changes.
Why New ISC and ISL Engines?
5. Cummins Bridgeway Training Center
• Improve Engine Reliability
– New Cummins Common Rail fuel system is easier to troubleshoot
than the CAPS fuel system.
– Make base engine reliability improvements.
• New roller tappets and directed piston cooling nozzles for the ISC
• Increased size of the roller tappet to improve camshaft durability
• New crankcase breather to reduce oil carryover.
• Increased capacity lubrication pump and modified filter head for
increased oil flow.
• Complete the Cummins Product Line
– Without the ISC and ISL, Cummins would lose many customers who
want to buy different horsepower engines from the same
manufacturer.
Why New Q/ISC and Q/ISL Engines?
8. Cummins Bridgeway Training Center
19 %
increase in
torque avail
to turn roller
Large Tappet Design
10% larger
OD.
Increase
resistance to
OD wear
Center stress
277ksi with
brake push
tube loads and
0.090” lash
Improved
roller/poc
ket
clearance
At lease
50%
reduction
in
assembly
stress
Decrease
in
sensitivity
to
pin/roller
friction
Current Product Tappet
28mm Diameter
Large Tappet
31mm Diameter
9. Cummins Bridgeway Training Center
Valve Train
• Many valve train components are changing slightly due to
the increased cylinder pressure.
• Most changes are very minor geometry changes that cannot
be distinguished by sight.
10. Cummins Bridgeway Training Center
Pistons and Piston Pins
• Piston configurations are the same as current product
– ISC pistons are 1 piece aluminum pistons
• Piston bowl geometry has changed as part of the
emissions reduction.
11. Cummins Bridgeway Training Center
Piston Pins
ISC and ISL CM850
• Piston pin geometry’s have changed internally due to the
increased cylinder pressure. Outside dimensions are the
same.
12. Cummins Bridgeway Training Center
Connecting Rod Bearings
• The ISC has one connecting rod bearing for both the upper an
lower bearing shells.
• The ISL engine uses two different materials for the upper and
lower bearing shells.
• 3950661 = ISC upper and lower. Similar construction to current
product bearings except narrower to accommodate crank fillet
change.
• 3966244 = ISL upper. Looks similar to the above bearing. Marked
"UPR" on back. Stronger than ISC bearings and narrower to
accommodate crank fillet change.
• 3950661 = ISL lower. This bearing is just to hold the upper bearing
in place. It does not have the strength to live in upper position of
the ISL engine.
14. Cummins Bridgeway Training Center
Connecting Rod Bearings
• ISL connecting rod bearings are labeled for correct
orientation.
– ‘UPR’ = Upper Bearing Shell
15. Cummins Bridgeway Training Center
Piston Cooling Nozzle
• Piston cooling nozzle geometry has changed slightly to
provide better cooling.
• Piston cooling nozzle is no longer a banjo style bolt.
• A capscrew now holds the piston cooling nozzle for added
strength.
Current ISL ISC CM850
16. Cummins Bridgeway Training Center
Crankshaft Speed Indicator Ring
• Primary engine speed sensor has been moved to the
crankshaft.
• Provides increased speed resolution for the fuel system.
• Increases reliability from current product because the
primary and secondary speed sensors are reading from two
different targets.
17. Cummins Bridgeway Training Center
Main Bearing Capscrew & Torque
• New 14 mm capscrew requires higher torque
• Capscrews are longer
• Using incorrect torque will result in engine damage
18. Cummins Bridgeway Training Center
Valve Covers and Rocker Housing
• All 2003 engines will require a rocker lever housing spacer to
accommodate the injector pass-through wiring.
• This rocker lever housing is very similar to the current engine
brake spacer used on ISL engines.
• Two valve covers will be used.
– Short valve cover for all Q/ISC’s, and Q/ISL’s without engine brakes.
– Tall valve cover for Q/ISL engine with engine brakes.
19. Cummins Bridgeway Training Center
Valve Cover Breather
• New valve cover mounted crankcase breather for Q/ISC and Q/ISL
engines will reduce oil carryover complaints.
• Breather has two tubes attached to it
– Crankcase gas draft tube (larger tube)
– Oil drain tube to the cylinder block (smaller tube)
• No maintenance required on breather parts
• Not backwards compatible to current product ISC and ISL
Draft Tube
Oil Drain Tube
20. Cummins Bridgeway Training Center
Air Intake Connection
• New 3 piece air intake connection.
• Grid heaters are now above the intake cover and are the like
the ISB CM850.
21. Cummins Bridgeway Training Center
New Electronics
• New Electronic Control Module (ECM) - Model CM850
• Same ECM architecture as the ISB CM850 and ISX CM870
engines
• Three connectors on the ECM
– 50-pin OEM connector
– 60-pin engine harness connector
– 4-pin ECM power supply (main power and ground for the ECM)
Power
Engine
Harness
OEM Harness ECM is behind low
pressure fuel lines
22. Cummins Bridgeway Training Center
Lubricating Oil Filter Requirements
• Q/ISC and Q/ISL CM 850 engines must use the LF9009 oil filter
with an internal venturi that provides filter bypass oil flow through a
‘stacked disk’ section of the filter.
• The current product oil filter head contained an internal drilling that
allowed the LF3000 (same media as LF9009) to function. This
drilling has been removed in the 2003 Q/ISC and Q/ISL oil filter
head.
• Premature engine wear will occur due to the lack of proper oil
filtering if the LF3000 is used on the Q/ISC and Q/ISL CM850.
23. Cummins Bridgeway Training Center
Gaskets
• Head Gasket
– Changed to balance coolant flow through the cylinder head.
• Oil Pan Gasket
– Corner braces added to spread the load.
• Rocker Lever Housing Gasket
– Press-in formed gasket to seal against the cylinder head.
(like valve cover gasket)
24. Cummins Bridgeway Training Center
Oil into oil cooler
Oil out of oil cooler
Oil supply from oil pump
Oil dump to pan if
regulator is open
Oil out of filter to oil rifle
Lube Cooler Oil Flow
25. Cummins Bridgeway Training Center
Oil in from oil pump
Oil out to oil cooler
Oil in from oil cooler
Oil into filter
Oil out of filter to oil rifle
Oil pressure regulator
Oil dump to pan if
regulator is open
Oil cooler bypass valve
Lube Cooler Oil Flow
27. Cummins Bridgeway Training Center
Fuel System Layout
Fuel Pump
Fuel Pump Drain Line
2 micron Fuel Filter
Injector Drain Line
ECM Cooling Plate
High Pressure Relief
Valve Drain Line
ECM
28. Cummins Bridgeway Training Center
ECM Cooling Plate
Fuel Lift Pump
Fuel Supply
Connection
Fuel Drain
Connection
ECM Cooling Plate
Check Valve
Fuel System Layout
30. Cummins Bridgeway Training Center
Fuel System Flow
8 - Fuel Inlet to
High Pressure
Pump
2 - Fuel Inlet to ECM
Cooling Plate
1 - Fuel Inlet
4 - Fuel Inlet to
Gear Pump
6 - Fuel Inlet to
Fuel Filter
3 - Fuel Outlet From
ECM Cooling Plate
5 - Fuel Outlet
From Gear Pump
7 - Fuel Outlet
From Fuel Filter
31. Cummins Bridgeway Training Center
Fuel System Layout
Fuel Pump Actuator
Fuel Gear Pump
Cam Housing
High Pressure
Outlet Fitting
Fuel Pump Actuator Housing
Inlet Restriction Service Port
Gear Pump Inlet
Gear Pump Outlet
High Pressure Pump Head
32. Cummins Bridgeway Training Center
Engine Priming
• The primary purpose of the priming circuit is to provide pressure to
the gear pump for quick engine starts.
• The fuel lift pump only runs for 30 seconds at key-on. It is only used
for priming the fuel system at start-up.
• The priming pump will fill the pressure side filter when installed dry.
5 or 6 key cycles is required to fill the pressure side filter.
• The lift pump does not do a good job of priming a dry system. It is
recommended that the suction filter be pre-filled with clean fuel
when replaced.
33. Cummins Bridgeway Training Center
Fuel Lift Pump Check
Valve
Lift Pump
Inlet
Lift Pump Outlet
ECM Cooling Plate Assembly
34. Cummins Bridgeway Training Center
ECM Cooling Plate Check Valve
• Without the ECM cooling plate check valve, fuel would
continuously circulate through the ECM cooling plate when
the lift pump is not running.
• The check valve can become damaged upon installation.
Inspect the check valve for damage or debris when
troubleshooting low power and performance problems.
• High fuel inlet restriction will be measured at the gear pump
inlet if the check valve is damaged.
Check Valve
36. Cummins Bridgeway Training Center
High Pressure Relief Valve
• High pressure relief valve acts like a ‘fuse’ in the fuel system.
• If fuel pressure exceeds the relief valve pop-off pressure, fuel rail
pressure will be regulated to 900 bar and the excess fuel will be
returned to drain.
• If the high pressure relief valve opens, fault code 449 or 2311 will
activate indicating a pressure overshoot occurred.
• If the control system still has pressure control, the valve will reseat
through a momentary pressure interruption (3x max) and normal
operation will continue.
High Pressure Relief Valve
37. Cummins Bridgeway Training Center
Low Pressure Fuel Lines
• All low pressure fuel supply lines have ‘quick connect’ fittings.
• The ‘tabs’ must be pushed in to release the connector from the fitting.
• Flexible lines must be routed properly to allow engines to run and to
prevent damage.
• Removal of supply lines from high pressure pump is easier if all 3 lines
are disconnected.
• NOTHING may be permitted to rub against lines!
Release Tabs
38. Cummins Bridgeway Training Center
Fuel at high pressure is
conveyed to each injector
by its high pressure fuel
connector.
Leakage fuel from the
match fits in the injector
and injector solenoid
travels through a drilling in
the cylinder head and exits
at the rear of the cylinder
head.
A damaged high pressure
fuel connector-to-injector
interface will result in
excessive drain flow from
the back of the cylinder
head.
Match Fit Leakage
Injector Solenoid Leakage
HPC to Injector Leakage
Injector Details
39. Cummins Bridgeway Training Center
CM850 Injector Circuits
Avoid Failures:
Orient inlet feature toward HPC
Follow T&R Manual (seat injector
completely, use holding clamp to index
injector, do not “side load” injector clamp
but finger tight both bolts first so that the
clamp is centered on the injector)
“Feel” the HPC engage the injector
Always use proper torque on the HPC jam
nut
ALWAYS replace the HPC when installing
a new injector.
Be cautious of generated debris (shipping
plugs, plant cleanliness, part cleanliness).
41. Cummins Bridgeway Training Center
Gear Pump Pressure
• Procedure
– Install CUC fitting and
diagnostic T-Adapter at the
pressure filter outlet
– Install the pressure gauge and
the 0.043” orificed diagnostic
fuel line at the T-Adapter
– Operate the engine at idle
• When to Perform Test
– FC2215
– Low power complaints
– Engine will not start (without
wasteline)
Fuel Filter Inlet Fuel Filter Outlet
42. Cummins Bridgeway Training Center
Air-in-Fuel
• Procedure
– Install Compuchek fitting and the 0.043” orificed diagnostic fuel line at
pressure filter outlet (P/N 3164621)
– Route the output of the 0.043” orificed diagnostic fuel line into a bucket
– Operate the engine at idle.
– Allow fuel to fill the collection bucket until the outlet of the fuel line is
submerged
– Check for excessive amounts of air bubbles exiting the fuel line
• When to Perform Test
– Surge (continuous surging)
– Engine difficult to start / loss of prime
43. Cummins Bridgeway Training Center
Leakage Test
• Procedure
– Install drain flow adapters for the high pressure
relief valve, high pressure pump, and injectors.
(P/N3164618)
– Route fuel lines from the flow adapter to a
bucket
– Operate the engine at idle and begin the
INSITE ‘High Pressure Leakage Test” t
– Measure the drain flow from each device into a
graduated cylinder
– Use “blocker” tool to isolate injector/HPC
leakage if necessary (P/N3164325)
44. Cummins Bridgeway Training Center
Leakage Test
• When to perform test
– FC2215
– No start and can not build rail pressure (perform test while cranking)
• HPP Failures:
– HP Seal Leaks to Drain, Pump Head Cracks, Severe B/P Leakage
• Injector Failures:
– Injector body cracked
– P.V. severe erosion
• HPC Failures:
– Poor seal with injector
• High Pressure Relief Valve Failures:
– Valve seat leaks
– Broken Spring
• High Pressure Lines:
– Observe fuel seepage at high pressure
46. Cummins Bridgeway Training Center
Internal Injector Wiring
2 Plastic clamps hold
yellow & orange wires and red & brown wires
Wire tie holds yellow
& orange wires to
reduce extra length
Plastic tube protects
wires from casting
• Three sets of
internal injector
wiring provides
power to the
injectors.
• Polarity does not
matter when
connecting the
wiring to the
injector.
47. Cummins Bridgeway Training Center
Hold leads so that they can not “flare out”
where they may short against a rocker
lever or brake housing.
Injector Leads
