Clase 3

MODULO 4

Sistema de
lubricación
Objetivos esperados del Modulo 4.
 El objetivo de este modulo es familiarizarnos en el sistema de lubricación, vista general de sistema, válvulas,
especificaciones y componentes asociados.

• Carter, bomba, válvulas y especificaciones

• Especificaciones de sistema
• Capacidad del Carter aplicación Minería
• Válvula relief de sistema
• Válvula reguladora
• Intercambiador de calor (enfriadores de aceite).
• Enfriadores de aceite
• Eje seccionado para desmontaje
• Eliminator
• Suministro de turboalimentadores
• Pre-lubricado
• Conexiones, alimentación, pressure Switch
• Breather (respiradero de gases de Carter, impacto variable, tubo coalescente, bomba de barrido )
• Lubricación High Pump
• DLF
• FPOP
• Pressure switch

140
 Especificaciones del sistema.
Lubricating Oil Pressure, Main Oil Rifle
(15W-40 oil at 107°C [225°F]): Especificacion
Minimum at Rated Speed 310 kPa [45 psi]
Maximum at Rated Speed 483 kPa [70 psi]
Minimum at Idle Speed 138 kPa [20 psi]
Lubricating Oil Pressure Spike on Cold Engine
Maximum 1724 kPa [250 psi]
Lubricating Oil Temperature Carter ocupado por la aplicación 930 E5
Maximum 120°C [248°F]
Eliminator™ Oil Capacity - Engine
Operation: 20 liters [5.3 gal]
QSK60 CM2350
Fleetguard™ Centrifuge - Engine
Operation:
Lubrication Oil Filter Capacity (Each 2.65 liters [0.70
Filter(Model LF9540)) gal]

141
Ventilación abierta del carter. Open (OCV)
Respiradero de impacto ciclónico
 Una unidad para motores de 23L y 30L
 Dos unidades para motores de 50L y 60L
 Montado en soportes sobre el cubrevolante
 El flujo se muestra a la derecha
 Usa 2 etapas de separación
 Efecto de impacto y ciclón
 Diseño de respiración abierta (OCV)
 Libre de mantención

Cummins Confidential - Restricted 142

Open Crankcase Breather (OCV)
2 Stage Routing
 Sistema de lubricación. Operación del
respiradero
• Respiradero impactor ciclonico–
Caracteristicas

A. Pre-separador ciclónico: remueve el aceite liquido

y las gotas de aceite a través de la fuerza
centrifuga
B. La tecnología del impactor variable patentada por
Cummins Filtration transforma las gotas del
aerosol en liquido
C. La cubierta del impactor ciclónico y le sello
aseguran que el aceite colectado sean dirigidos
al drenaje de los jets de bombeo (Patentado por
CF)
D. La bomba de jets utiliza activamente aceite
presurizado para extraer aceite de las cámaras
superior e inferior y devolverlo al motor.

• La unidad es libre de mantención

• Capacidad pata operar con flujos arriba de 29
CFM
• La válvula Check en el respiradero permite mas
flujo de aire en casos de una subida de blow by

Cummins Confidential - Restricted 144

Sistema de lubricación. Vista del hadware
del sistema respiradero del motor OCV
Sistema de lubricación. Análisis de flujo
en el respiradero Impactor ciclónico
 Block and Attachments – CCV – What is it?

• Closed crankcase ventilation or CCV

is a type of breather system which
separates oil and oil mist (in the form
of aerosol) from the crankcase gases
and directs this filtered air back into
the intake system
• How does it differ from OCV?
• Open crankcase ventilation or OCV vents
crankcase gases back into the
atmosphere therefore will count towards
total engine emissions. The technology
has improved in recent years to overcome
stricter emissions targets

Cummins Confidential - Restricted 147

Closed Crankcase Ventilation – K117
Loco Only
Outlet plumbing Coalescer Inlet
(to OEM intake) Plumbing
Pre-Separator
Coalescent Filters

Why a pre-separator was required?

The principle behind using a baffle box:
• to separate the liquid oil (large particles)
prior to reaching the coalescers so all
Crankcase they have to deal with is aerosol
Depression challenge.
regulator • This will minimize penetration going
(CDR) through the coalescers so potentially
maximising service life and aiding the
performance of the system.
Oil drain plumbing
(to sump)
Coalescing filtration is a steady
state process whereby aerosols
are caused to agglomerate (come
together) into even larger droplets
as they pass through the filter
element’s fiber matrix, eventually
becoming large enough to be
gravitationally drained away

• 1 year or 2000 hour Maintenance

Interval
CCV - Crankcase Depression
Regulator
• CDR Valve present on crankcase breather
• Primarily used in closed crankcase applications
• Regulates the vacuum between the breather
and the air intake
• Prevents a vacuum from being pulled on the
crankcase since filtered crankcase gases are
plumbed back into the air intake before the
turbocharger.
• In other words: Provides an artificial restriction to
prevent crankcase from being too
depressed/negative
• Still allows crankcase pressure flow to push
past the valve, but does not allow compressor
inlet vacuum to unseat the valve.

 The CDR valve characteristics/performance can be varied by changing

the valve size, spring characteristics, or diaphragm
Sistema de lubricación. Bomba de
aceite. Descripción
 Sistema de lubricación. Filtro
eliminator

Eficiencia Filtro atornillable Eficiencia Filtro Eliminator

Sistema de lubricación. Eliminator
 Eliminator montado en la misma posicion que los
tier2 (right bank)
− Tier 4 Eliminator uses finer filtration media in full flow and centrifuge
(bypass) sections
− NOT THE SAME PART NUMBER AS TIER 2!!
− Full Flow Section:
− Tier 2 A05 Mesh – 100% efficient @ 35 micron
− Tier 4 A03 Mesh – 100% efficient @ 25 micron
− Centrifuge (Bypass section)
− Tier 2 Metal disc/cone stack – 100% efficient @ 22 micron
− Tier 4 disposable w/ Spiratech media – 100% efficient at 15 micron.
− Pre and Post Oil Pressure Sensors Still Utilized Can filter
down to 2
NOTE: Centrifuge for ALL micron but
T4 Eliminators will be 100%
1000 hr service Interval… cartridge type and not efficient at
EXCEPT Locomotive will be 92 re-buildable like 15 micron.
day or 1500 hour service previous centrifuges.
interval for Eliminator option to
match fuel filter interval.
Lubricating Oil System – Filter Head CYWM - Cyclops Wide Mouth
Old CYWM

 The interface between filter and filter head is new on

the Tier 4 product – known as a ‘Cyclops Wide
Mouth’ (CYWM).

 Unique to Cummins. This prevents Non-Cummins

filters being used in the field, which can be sub-
standard.

 Helps to control the oil quality over time and ensure

a safe extended oil change interval.
Sistema de lubricación. Dedicated Lube Filter (DLF)
• Filtro separado para filtra el aceite antes que llegue a la bomba de
combustible de alta presión
• Elimina el filtro de 86 micras del mando
• Típicamente instalado en 50/60/78 T4 equipados con
eliminator
• Tiene una opción de instalación fuera del motor.

• Nuevo mando de la bomba de combustible que permite el

montaje del filtro DLF
• Filtro de 20 micras
• Filtro del motor es de 25 micrones
• Chip Detector montado debajo de la bomba de alta presion
para detectar particulado de los componentes internos de
la bomba.
• Requiere la incorporación de una extensión en el
arnés del lado L. Conectado detrás del ECM1
• Puede no ser requerido en todos los motores 60.

• El cabezal DLF incorpora:

• Fuel pump oil pressure sensor (senses post filter)
• Fuel pump oil prelube pressure switch (senses post filter)
• BOTH flywheel housing mounted pre-lube switch and
fuel pump pre-lube switch must open before
cranking is allowed. Wired in Series.
• This ensures fuel pump has adequate oil pressure
before cranking especially in cold ambient conditions.
Sistema de lubricación. Dedicated Lube Filter (DLF)

Front of engine
Lubricating Oil System – Fuel Pump Oil Pressure Improvement line

• Proposed 2020 implementation on QSK60 T2 and QSK60 T4

engines. (Not production yet but coming)
• May see some in Field Test

• Direct feed to fuel pump/DLF from LB block drilling off main Oil supply
oil rifle. from cylinder
• Different Cylinder block part number block
• Drilling is not there on early production blocks

• Increases oil pressure supply to high pressure fuel pump

DLF
• Eliminates oil pressure feed from gear cover/housing
• New fuel pump drive
Sistema de lubricacion. Fuel Pump Chip Detector
• Proposed implementation on QSK50, QSK60 T2 and QSK60 T4
engines. (Not production yet for T4 but coming)
• May see some in Field Test
• Watch for a TSB

• Mounting location may vary depending on engine platform but

intended to be mounted in drain oil path from high pressure fuel
pump.
• Picture shows it mounted at bottom of high pressure fuel pump (QSK50)
but location may vary per engine model
• Can be mounted at bottom of fuel pump drive assembly (QSK60 T2 and
T4)
• Can be mounted at bottom of gear housing (QSK78 T4)

• Normally open until enough debris collects on magnet to close

circuit.

• Will set a fault code typically tied in with ambient air fault.

• Required to upfit:
• New main harness
• New extension harness
• New ECM calibration
Sistema de lubricacion– Intervalos de servicio

Incremento en el intervalos de cambio de

aceite para motore Tier 4
Recommended Oil
• CJ-4 Valvoline Premium Blue
• Oil and filter service intervals can be extended when • 15w-40
compared to Tier 2 engines.
• Spin on Filters = 500 hrs
• Eliminator = potentially 1500 hrs (see oil
analysis techniques for HHP engines bulletin.

• Improved combustion for Tier 4 (less soot) enables

service interval improvement.

• Oil analysis recommended every 250 hours

• Varies based on utilized power output/duty cycle.

Múltiple de aceite y galería principal
Analisis de las galerías del motor
 Bonus Track (parameters & FC CM2350).

P° FPOP / Presion de rifle / RPM

800 80
700 P°Rifle 18,5 psi / 23,5 psi 70
P°FPOP 8,5 psi / 20,6 psi
600 60
RPM 0 rpm / 101 rpm
500 50
400 40
300 30
200 20
100 10
0 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Velocidad del Motor (RPM)- Identificador0
Fuel Pump Oil Pressure (psi)- Identificador0
Presión de Aceite del Motor (psi)- Identificador0

162
Bonus Track (parameters & FC CM2350).

163
Bonus Track (parameters & FC CM2350).
7313 Engine Fuel Pump Oil Pressure - Data Valid But Below Normal Operating Range - Most Severe Level RED
556 Crankcase Pressure - Data Valid But Above Normal Operating Range - Most Severe Level RED
214 Engine Oil Temperature - Data Valid But Above Normal Operating Range - Most Severe Level RED
415 Engine Oil Rifle Pressure - Data Valid But Below Normal Operating Range - Most Severe Level RED
3491 Engine Oil Filter Differential Pressure - Data Valid But Above Normal Operating Range - Most Severe Level RED
5119
• RED : Engine Protection
Fuel Pump Oil Pressure Sensor Circuit - Voltage Above Normal, or Shorted to High Source AMBER
5121 Fuel Pump Oil Pressure Sensor Circuit - Voltage Below Normal, or Shorted to Low Source AMBER
5122 Fuel Pump Oil Pressure Sensor Circuit - Data erratic, intermittent or incorrect AMBER
7314
555
Engine Fuel Pump Oil Pressure - Data Valid But Below Normal Operating Range - Moderately Severe Level
Crankcase Pressure - Data Valid But Above Normal Operating Range - Moderately Severe Level
AMBER
AMBER • YELLOW : Precaution
1843 Crankcase Pressure Circuit - Voltage Above Normal or Shorted to High Source AMBER
1844
4696
Crankcase Pressure Circuit - Voltage Below Normal or Shorted to Low Source
Crankcase Pressure 2 Sensor Circuit – Voltage above normal, or shorted to high source
AMBER
AMBER
• MAINTENANCE
4697 Crankcase Pressure 2 Sensor Circuit – Voltage below normal, or shorted to low source AMBER
4699 Crankcase Pressure 2 – Data Valid but Above Normal Operating Range –Moderately Severe Level AMBER
5178
135
Crankcase Pressure 2 – Data Erratic, Intermittent, or Incorrect
Engine Oil Rifle Pressure 1 Sensor Circuit - Voltage Above Normal or Shorted to High Source
AMBER
AMBER
• Posibles códigos de fallas
141
143
Engine Oil Rifle Pressure 1 Sensor Circuit - Voltage Below Normal or Shorted to Low Source
Engine Oil Rifle Pressure - Data Valid But Below Normal Operating Range - Moderately Severe Level
AMBER
AMBER
Recuerda siempre confirmar
212
213
Engine Oil Temperature Sensor 1 Circuit - Voltage Above Normal or Shorted to High Source
Engine Oil Temperature Sensor 1 Circuit - Voltage Below Normal or Shorted to Low Source
AMBER
AMBER
la información con los datos
421
521
Engine Oil Temperature - Data Valid But Above Normal Operating Range - Moderately Severe Level
Transmission Oil Temperature Sensor Circuit - Voltage Above Normal or Shorted to High Source
AMBER
AMBER
en QSOL.
522
1357
Transmission Oil Temperature Sensor Circuit - Voltage Below Normal or Shorted to Low Source
Engine Oil Level Remote Reservoir - Data Valid But Below Normal Operating Range - Moderately Severe Level
AMBER
AMBER
• Diference
1362
1428
Engine Oil Filter Differential Pressure - Data Valid But Above Normal Operating Range - Moderately Severe Level
Low Oil Pressure (LOP) Shutdown Relay Driver Diagnostic has detected an error - Condition Exists
AMBER
AMBER
Moderately / Most
1431 Pre-Low Oil Pressure Warning Relay Driver Diagnostic has detected an error - Condition Exists AMBER
1891 Engine Oil Change Interval - Condition Exists AMBER
2196 Engine Oil Temperature - Data Valid But Below Normal Operating Range - Moderately Severe Level AMBER
5947 Engine Oil Level Remote Reservoir - Data Valid But Above Normal Operating Range - Moderately Severe Level AMBER
6592 Engine Waste Oil Reservoir Level Sensor Circuit - Voltage Above Normal or Shorted to High Source AMBER
6593 Engine Waste Oil Reservoir Level Sensor Circuit - Voltage Below Normal or Shorted to Low Source AMBER
8129 Engine Oil Filter Differential Pressure - Voltage Above Normal or Shorted to High Source Warning
8131 Engine Oil Filter Differential Pressure - Voltage Below Normal or Shorted to Low Source Warning
164
Agenda y resumen de Modulo 4.
• Diagnostic Test :
 Preguntas en el test (Dudas, consultas)
• Revisemos lo aprendido, modulo 4 :

 Carter, bomba, válvulas y especificaciones

 Capacidad del Carter aplicación Minería
 Válvula relief de sistema
 Válvula reguladora
 Intercambiador de calor (enfriadores de aceite).
 Enfriadores de aceite
 Eje seccionado para desmontaje
 Eliminator (filtro centrifugo)
 Suministro de turboalimentadores
 Pre-lubricado
 Conexiones, alimentación, pressure Switch
 Breather (respiradero de gases de Carter, impacto variable, tubo coalescente, bomba de barrido )
 Lubricación High Pump
 DLF
 FPOP
 Pressure switch

165
MODULO 5

Sistema de
Refrigeración
Objetivos esperados del Modulo 5.
 El objetivo de este modulo es familiarizarnos con el sistema de refrigeración y establecer las diferencias
que existen entre el sistema HTC y LCT, al igual que las temperaturas de funcionamiento de los
circuitos.

• Vista general del sistema

• Diámetros de piping
• Lineas de venteo
• Sistema presurizado
• Sistema HTC (High temperature Coolant)
• Filtros de refrigerante
• Refrigeración de los turboalimentadores
• Refrigeración de las Wastegate
• Caja de termostatos rango de trabajo
• Sistema LTC (High temperature Coolant)
• Caja de termostatos rango de trabajo
• Refrigeración de los ECM´s

167
Diagrama simplificado HTC/LTC
 Especificaciones del sistema. 1P/2L
Sistema de refrigeracion Especificacion
Ver manual del
Coolant Capacity:
equipo
Standard Modulating 82 to 94°C [180
Thermostat Range to 202°F]
Standard LTA Thermostat 46 to 57°C [115
Range to 135°F]
Maximum Allowable Top
100°C [212°F]
Tank
Minimum Recommended
71°C [160°F]
Top Tank Temperature
Maximum Allowable
25 minutes
Deaeration Time
Minimum Allowable
Drawdown or 20 Percent of
28 liters [7.4 gal]
System Capacity (whichever
is greater)

169
Sistema de refrigeration. HTC y LTA LTA Outlet (To Rad)

HTC Outlets (To Rad)

LTA Bypass
LTA Pump Outlet (To LTA’s)
HTC Bypass

HTC Pump Outlet (To

Block)

LTA Pump Inlet

HTC Pump Inlet
Sistema de refrigeración. Wastegate

Motor simple etapa

• La válvula Wastegate debe ser

refrigerada para proteger el actuador
electrónico asi que un conjunto de
tuberías fue agregadas

• El circuito utilizado corresponde al LTA

Sistema de refrigeración. Motor doble etapa

• El suministro de refrigerante
proviene del sistema HTC
• Frente
• Desde la cavidad del enfriador
N°1
• Trasero
• Desde la cavidad del enfriador
N°4

• Retorno de refrigerante
• Trasero:
• Fluye a través de la tapa N°4 a
través de tubería se conecta
con la tapa 1 y a través de
tubería llega la cabezal de
termostatos.
• Frente:
• Fluye directamente hacia el
cabezal de termostatos
Partes del sistema del intercooler
Refrigeración de los intercooler
Diferencia arreglo para motor simple y
doble etapa
Vistas del sistema de refrigeración
Lineas de purga de aire
Sistema de refrigeracion- CCV Heating.
Aplicacion ferrocarril
• At sub-zero temperatures ice could form in the coalescing filters and block
the filters.
• Coolant heating package included with CCV breather option which allows
HTC coolant from #1 oil cooler cover to heat the filter housings and return
back to left side of HTC thermostat housing.
Bonus Track (parameters & FC CM2350).
Cummins
SPN FMI Description Lamp
Fault Code

151 110 0 Engine Coolant Temperature - Data Valid But Above Normal Operating Range - Most Severe Level RED

228 109 1 Coolant Pressure - Data Valid But Below Normal Operating Range - Most Severe Level RED

235 111 1 Coolant Level - Data Valid But Below Normal Operating Range - Most Severe Level RED
Cummins
SPN FMI Description Lamp
Fault Code
144 110 3 Engine Coolant Temperature 1 Sensor Circuit - Voltage Above Normal or Shorted to High Source AMBER
145 110 4 Engine Coolant Temperature 1 Sensor Circuit - Voltage Below Normal or Shorted to Low Source AMBER
146 110 16 Engine Coolant Temperature - Data Valid But Above Normal Operating Range - Moderately Severe Level AMBER
195 111 3 Coolant Level Sensor 1 Circuit - Voltage Above Normal or Shorted to High Source AMBER
196 111 4 Coolant Level Sensor 1 Circuit - Voltage Below Normal or Shorted to Low Source AMBER
197 111 18 Coolant Level - Data Valid But Below Normal Operating Range - Moderately Severe Level AMBER
231 109 3 Coolant Pressure Sensor Circuit - Voltage Above Normal or Shorted to High Source AMBER
232 109 4 Coolant Pressure Sensor Circuit - Voltage Below Normal or Shorted to Low Source AMBER
3613 111 9 Coolant Level Sensor - Abnormal Update Rate AMBER

181
Agenda y resumen de Modulo 5.
• Diagnostic Test :
 Preguntas en el test (Dudas, consultas)
• Revisemos lo aprendido, modulo 5 :

 Vista general del sistema

 Diámetros de piping
 Lineas de venteo
 Sistema presurizado
 Sistema HTC (High temperature Coolant)
 Filtros de refrigerante
 Refrigeración de los turboalimentadores
 Refrigeración de las Wastegate
 Caja de termostatos rango de trabajo
 Sistema LTC (High temperature Coolant)
 Caja de termostatos rango de trabajo
 Refrigeración de los ECM´s

183