Engine
(Hyundai, Cummins)
Hyundai Training Center
Aug. 2019
19ECG12
1
Model & Engine Comparison
Model Engine Maker Engine Model Emission Remark
R140LC-9S Cummins B3.9-C
R180LC-9S Mitsubishi S6S-DT
HX210S Cummins(Hyundai) 6BTAA-5.9C HM5.9
R220LC-9S
HM5.9
R260CL-9S
Hyundai
R300LC-9S
HM8.3 Tier2
R330LC-9S
R380LC-9SH
HMC D6AC-C
R430LC-9SH
HX480SL QSM11-C
R480LC-9S QSM11-C
R500LC-9S Cummins QSM11-C Electronic Control
R850LC-9 QSX15 Tier3
R1200LC-9 QSK23-C Tier2
2
Model & Engine Comparison
Model Engine Maker Engine Model Emission Remark
R140W-9S Cummins B3.9-C
R180W-9S Mitsubishi S6S-DT Tier2
R210W-9S Hyundai HM5.9
Model Engine Maker Engine Model Emission Remark
HL730-9S Cummins QSB4.5 Tier3
HL740-9S Cummins 6BTA5.9T Tier1
HL757-9S Hyundai HE6.7 Tier3 QSB6.7
HL760-9S Hyundai HM8.3 Tier2
HL770-9S Hyundai HE8.9 Tier3 QSL8.9
HL775-9S Cummins QSM11 Tier3
HL780-9S Cummins QSM11 Tier3
3
Tier3
HE6.9,HE8.9
4
1. Fuel System
5
Fuel Flow
1. Fuel from fuel tank 12. High-pressure fuel pump
2. OEM fuel filter and water separator (10 micron) 13. Fuel outlet from high-pressure pump
3. OEM fuel supply connection 14. High-pressure pump drain flow connection
4. Fuel supply to ECM mounted fuel lift pump 15. Fuel rail
5. ECM cooling plate 16. High-pressure injector supply lines
6. ECM mounted fuel lift pump 17. High-pressure fuel connector
7. Fuel outlet from ECM mounted fuel lift pump 18. Injector
8. Fuel gear pump 19. High pressure relief valve
9. Fuel from gear pump to fuel filter 20. Injector drain flow line
10. Primary fuel filter (3 micron) 21. Fuel return to fuel tank
11. Fuel inlet to fuel pump actuator
6
Fuel Flow
High Pressure Common Rail
Cyl. Head
Injectors
Fuel Rail
Pressure
Relief Valve
High Pressure Fuel
Line to Rail
High Pressure
Connectors
Secondary
Filter
Fuel
Return Fuel
Return
Fuel
Return
Fuel
Hand Primer Pump Return
Fuel Out
Primary
Filter
Fuel Tank
Fuel Gear
H.P. Fuel Pump Pump
7
Fuel System Layout
3 micron
fuel filter
8
Fuel System
High Pressure Relief
Fuel Pump Drain Line Valve Drain Line
Injector Drain Line
Fuel Pump
ECM Cooling Plate ECM 2 micron Fuel Filter
9
Fuel System
8 - Fuel Inlet to
High Pressure 7 - Fuel Outlet
Pump From Fuel Filter
6 - Fuel Inlet to
Fuel Filter
1 - Fuel Inlet
4 - Fuel Inlet to Gear
Pump
5 - Fuel Outlet From
Gear Pump 3 - Fuel Outlet From 2 - Fuel Inlet to ECM
ECM Cooling Plate Cooling Plate
10
Fuel System
Fuel Drain
Connection
Fuel Lift Pump
Fuel Supply
Connection
ECM Cooling Plate Check ECM Cooling Plate
Valve
11
Fuel System
High Pressure Pump Head Fuel Pump Actuator Housing
Fuel Pump Actuator
High Pressure
Outlet Fitting Gear Pump Inlet
Cam Housing
Gear Pump Outlet
Fuel Gear Pump
Inlet Restriction Service Port
12
Fuel System Components
New Drain Line Configuration
13
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.
14
ECM Cooling Plate Assembly
Fuel Lift Pump Check Valve
Lift Pump Inlet
Lift Pump Outlet
15
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
16
Fuel Pump Head Details
17
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
18
Injector Details
Multiple injection events per cylinder firing
Pilot / Main / Post
Fuel at high pressure is
conveyed to each injector by
its high pressure fuel connector.
Injector Solenoid Leakage
Leakage fuel from the match
fits in the injector and injector
HPC to Injector Leakage
solenoid travels through a
drilling in the cylinder head and
exits at the rear of the cylinder
head.
A damaged high pressure fuel
Match Fit Leakage connector-to-injector interface
will result in excessive drain
flow from the back of the
cylinder head.
19
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)
20
Field Replaceable Components
• Fuel Pump Head Capscrews
• “Racetrack” o-ring
• Fuel Pump Head o-ring
• Fuel Pump Mounting Seal
• Oil supply o-ring (at gear housing)
• Fuel Pump Actuator Housing
• Fuel Pump Actuator Housing Capscrews
• Fuel Pump Actuator Housing Gasket
• Fuel Pump Actuator
• Fuel Pump Actuator Capscrews
• Fuel Pump Actuator o-rings
• Fuel Pump (Gear Pump)
• Gear Pump Gasket
• Gear Pump Capscrews
• Gear Pump Drive Coupling
• Outlet Fitting (Male Union)
• Outlet Fitting Seal Washer
• High Pressure Pump Tappet Assemblies
21
2. Electronic
Components
22
CM850 Engine Harness
23
CM850 Engine Harness
Engine harness connector
24
CM850 Injector Circuits
Engine harness connector
CM850 Injector Circuits
Injector
25
CM850 Internal Injector Wiring
• Three sets of internal 2 Plastic clamps hold
yellow & orange wires and red & brown wires
injector wiring provides
power to the injectors.
• Polarity does not matter
when connecting the
wiring to the injector.
Wire tie holds yellow
& orange wires to
Plastic tube protects reduce extra length
wires from casting
26
QSM11
27
QSM11
28
QSM11
29
Intake Manifold Temperature Sensor
30
Intake Manifold Temperature Sensor
31
Intake Manifold Pressure Sensor
32
Barometric Air Pressure Sensor
33
Coolant Temperature Sensor
34
Common Rail Pressure Sensor
35
Oil Pressure Sensor
36
Engine Position Sensor
37
Intake Air Heater
38
Fuel Pump Actuator
39
39
Electronic Control Module
40
40
Injector
41
OEM Water in Fuel Sensor
42
3. Insite
43
Select Inline 2, Autodetect.com1 in case of users for Inline 2 Adapter
Click
44
Select Inline 5 com1(Autodetect) connection in case of Inline 5Adapter
선택
45
Connection Insite
Click
46
Creation of Workorder
Click
47
Creation of Workorder
Click
48
Creation of Workorder
It will take 30 seconds to connect ECM
49
To save the created workorder after change eif to csv
Click mark “+” to export
or save “eif” file
50
To save the created workorder by excel file(csv) or eif(export image)
Right click of the mouse
51
To save the created workorder after change eif to csv
Click
52
To save the created workorder after change eif to csv
You can select either the default
file name(yy-mm-dd) or certain
file name that you want.
To be saved as “eif” file
53
Convert the workorder to an excel and export file and save it
Click
54
To save the created workorder after change eif to csv
You can select either the default
file name(yy-mm-dd) or certain
file name that you want.
To be save as “csv” file
55
To locate the saved files in the Export folder
Double click
56
To locate the saved files in the Export folder
Click
Intelect/Insite
/Export
57
To locate the saved files in the Export folder
Click
58
To open the saved file by “Excel”
59
To check fault codes
Click “ Fault Code”
60
Fault Code
Yellow means
current active
fault codes
61
Fault Code Troubleshooting
현재상태 확인
To locate fault tree
overview you need to
right-click of the
mouse.
필요항목을 더블 클릭하면
우측으로 이동하여 현재상태 표시
62
Tier 2
HM5.9,HM8.3
63
Engine Identification & Dataplate Information
- The engine serial number and Control Parts
List provide information for ordering parts
and for service.
- The engine dataplate must not be changed
unless approved by Cummins Inc.
- The information on the dataplate is
mandatory when sourcing service parts.
1. Control Parts List (CPL)
2. Model
3. Engine Serial Number
4. Emissions certification
5. Horsepower and rpm rating.
1 2 3
64
Engine Model Number
- Automotive applications provides the data shown below For example:
- B5.9-190
– B = Engine series
– 5.9 = Displacement in liters
– 190 = Advertised horsepower.
- Industrial applications provides the data shown below For example:
- 4BTAA-3.9
– 4 = Number of cylinders
– B = Engine series
– T = Turbocharged
– AA = Charge air cooled
– 3.9 = Displacement in liters.
• NOTE: The suffix RGT refers to “Rear Gear Train” engines.
• Ex. : HM5.9 ; Hyundai Mechanical 5.9L
65
Bosch in-line Fuel Injection Pump
The injection pump dataplate for the Bosch® in-line pump is located on the side
of the injection pump. The data plate provides information for fuel pump
calibration.
66
B Series Fuel system
67
Fuel Flow
The fuel injection pump performs the three basic functions of:
1. Metering the exact amount of fuel for each injection cycle
2. Producing the high fuel pressure required for injection
3. Delivering the high-pressure metered fuel to each cylinder at the precise time.
68
Individual plunger & delivery valve
Individual plungers are used in the pumps to develop and distribute the high pressure required for
injection.
A worn or damaged plunger in the pump will affect only one cylinder.
69
C Series Fuel system
70
B & C Series Inline Fuel System
Max Inlet Restriction Minimum Pressure
6 inches Hg 25 psi @ Rated Speed
Vent
Pre-Filter Transfer Vent Fitting
Pump Injection Pump Opens @
20 -22 PSI
Filter
Max 5 PSI Drop
Fuel Tank
Maximum Drain Line Restriction
20 in Hg / 10 psi
71
B & C Bosch Injection Pump
72
Remove & Install
Remove
Install
73
Remove & Install
74
Remove & Install
75
Remove & Install
76
Remove & Install
After installing the injection pump,
77
B5.9 Scheduled Maintenance Procedures
250 Hours or 500 Hours or 1000 Hours or 2000 Hours or
Daily Interval
3 Months 6 Months 1 Year 2 Years
Check Check Check Check Check
• Cooling Fan • Air Cleaner Restriction • Engine Coolant • Cooling Fan Belt • Air Compressor
• Engine Coolant Level • Air Compressor Mounting Tensioner Discharge Line
• Drive Belts Hardware • Fan Hub, Belt-Driven • Vibration Damper
• Engine Lubricating Oil • Charge Air Cooler - Rubber
Level • Charge Air Piping - Viscous
• Fuel Injection Pump Moun
Inspect ting Hardware
• Air Intake Piping • Radiator Hoses
• Crankcase Breather • Radiator Pressure Cap
Tube
Drain Change Change Adjust Flush
• Air Tank and Reservoirs • Lubricating Oil and Filters • Lubricating Oil • Overhead Set • Cooling System
• Fuel-Water Separator and Filters
• Fuel Filter
• Canister Type
• Spin-On Type
78
C8.3 Scheduled Maintenance Procedures
250 HOURS OR 3 500 HOURS OR 1000 HOURS OR 2000 HOURS OR
DAILY INTERVAL
MONTHS 6 MONTHS 1 YEAR 2 YEARS
Check Check Check Check Check
• Crankcase Breather • Charge Air Cooler • Supplemental Coolant • Cooling Fan Belt • Air Compressor
Tube • Charge Air Piping Additive (SCA) and Tensioner Discharge Lines
• Lubricating Oil Level • Air Cleaner Restriction Antifreeze • Fan Hub, Belt-Driven • Vibration Damper
• Cooling Fan • Air Compressor Concentration - Rubber
• Air Intake Piping • Radiator Pressure • Air Compressor - Viscous
• Drive Belts Cap Discharge Lines
Drain Change Change Change Flush
• Air Tank and • Lubricating Oil and • Coolant Filter • Air Cleaner Assembly • Cooling System
Reservoirs Filters (Engine-Mounted)
• Fuel-Water Separator • Fuel Filter (Spin-On
Type)
Adjust
• Overhead Set
79
AFC & Fuel Heater
80
