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 Brakes
Safety Steering
Engine and fuel system Dump and hoist
Transmission and axles Electrical system
Hydraulics introduction 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. 4 Pin Power connector

2. 60 Pin Cummins connector
3. 50 Pin OEM (Atlas Copco)

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STARTER LOCKOUT SWITCH (555)
49

SPEED SENSOR
INTAKE AIR HEATER SIGNAL (302) CRANKSHAFT SPEED SIGNAL

16 48 27
CRANKSHAFT
42 40

CRANKSHAFT SPEED RETURN

INTAKE AIR HEATER RETURN (301)
CRANKSHAFT +5V
ENGINE COOLANT

CAMSHAFT
ENGINE COOLANT LEVEL SUPPLY (916A)

POSITION
CAMSHAFT POSITION SIGNAL
32 28 21

26
SENSOR
ENGINE COOLANT LEVEL SIGNAL (115) CAMSHAFT POSITION TERURN
ENGINE COOLANT LEVEL RETURN (952A) CAMSHAFT POSITION +5V
SENSOR

REMOTE THROTTLE +5V (916A)

PRESSURE
RAIL FUEL
RAIL FUEL PRESSURE RETURN
26 21

SENSOR
REMOTE THROTTLE SIGNAL (510C) RAIL FUEL PRESSURE SIGNAL

25
REMOTE THROTTLE 0V 952B RAIL FUEL PRESSURE +5V

SENSOR
IN FUEL
REMOTE ACCELERATOR SIGNAL (531) WTR IN FUEL SIG

WATER
03

14
WTR IN FUEL RET
ENGINE OVERRIDE SIGNAL (528-B)
15

INTAKE MAN PRES SIGNAL

PRESSURE/
MANIFOLD

47 23 37 44
AIR TEMP
INTAKE MAN PRES/TEMP +5V

SENSOR
INTAKE
ALT. MIN VSG SPEED (542) INTAKE MAN AIR TEMP SIGNAL
04 INTAKE MAN PRES/TEMP RETURN

ENGINE OIL
ENG OIL PRESSURE SIGNAL

PRESSURE

13
ENG OIL PRESSURE +5V

SENSOR
ENGINE PROTECTION RED STOP LAMP (ESD-A)

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ENGINE & FUEL SYSTEM

ENGINE & FUEL SYSTEM

ENG OIL PRESSURE RETURN
ACCELERATOR ASSY WILLIAMS

BAROMETRIC
SUPPLY VOLTAGE +5V (916) BAROMETRIC PRES SIGNAL

PRESSURE

03
23 09 22

SENSOR
SIGNAL (510A) BAROMETRIC PRES RETURN
0V (952-A) BAROMETRIC PRESSURE +5V

Connectors 60 Pin Cummins

TEMP SENSOR
OFF IDLE SIGNAL (543) ENG COOLANT TEMP SIGNAL

34 11 01

COOLANT

11 01 38 33 15
ENGINE
IDLE SIGNAL (545) ENG COOLANT TEMP RETURN
Connectors 50 Pin OEM

(002)

FUEL LIFT
FUEL LIFT PUMP SUPPLY
FUEL LIFT PUMP RETURN

PUMP
ENGINE RUN SIGNAL +24V (439-D)

39
9-PIN DEUTSCH CONNECTOR

BATTERI (+)
BAT+

FUEL PUMP
ACTUATOR
BATTERI (-)
BAT- FUEL PUMP ACTUATOR SIGNAL

32 02
20 10
FUEL PUMP ACTUATOR RETURN

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CYLINDER #1 DRIVER
53 45
CYLINDER #1 RETURN
CYLINDER #2 DRIVER

51 54
CYLINDER #2 RETURN
ENGINE & FUEL SYSTEM

ENGINE & FUEL SYSTEM

CYLINDER #3 DRIVER

52 55
CYLINDER #3 RETURN
CYLINDER #4 DRIVER
Connectors 60 Pin Cummins

58 56
CYLINDER #4 RETURN
CYLINDER #5 DRIVER

60 46
CYLINDER #5 RETURN
CYLINDER #6 DRIVER

59 57
CYLINDER #6 RETURN

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 Shut down
 Intake Manifold Temp High Derate to a maximum of 60% torque
 Oil Pressure Low Shut Down
 Coolant level Low 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 3. AMBIANT AIR 4. INTAKE MANIFOLD PRESSURE
TEMPERATURE SENSOR PRESSURE SENSOR & TEMPERATURE SENSOR

5. CRANKSHAFT
POSITION SENSOR

1. FUEL PUMP ACTUATOR

6. FUEL RAIL PRESSURE

SENSOR

9. CAMSHAFT 8. OIL PRESSURE 7. ECM

POSITION SENSOR SENSOR CM850
1. 4903523NX 4. 4921322
2. 4088750 5. 4921686
3. 4076493 6. 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

Barometric
TMAP Pressure
Sensor 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 The plastic tube outside the

pre separation filter cartridge will direct the
Restriction indicator Unfiltered air air to a spinning motion.
inlet

ENGINE AND FUEL SYSTEM

Cummins Tier III QSL 9

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ENGINE AND FUEL SYSTEM

Fuel system

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 Injectors

Line to Rail Fuel Rail
Pressure
Regulator

High Pressure
Connectors
Secondary
Filter Fuel
Return
Fuel
Return

Fuel
Fuel
Manifold Fuel
Return
Lift Pump Return

Fuel Out

L.P. Fuel
Gear ECM Cooling Primary Fuel Tank
H.P. Fuel Pump Pump Plate Filter

ENGINE AND FUEL SYSTEM

Fuel system Layout Front

Front View

Injector
Drain Line

High pressure fuel Pump ECM Cooling Plate ECM 5 micron secondary
Fuel Filter
High Pressure Relief Valve
Fuel Pump Drain Line
Drain Line

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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 Fuel Inlet to Fuel

to High Filter
Pressure
Pump
Fuel Outlet
From Fuel
Fuel Inlet to
Filter
Gear Pump

Fuel Inlet to ECM

Fuel Outlet From Cooling Plate
Gear Pump
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 Filter In (from LPP Out)

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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