Operation and maintenance manual Control instruments

Engine control panel Cummins QSB

1 2 3 4 6

5 7

1. Idle speed adjust switch

Push up the switch in order to increase (+) the idle speed,
push down the in order to decrease (-) the idle speed.
2. Maximum engine rpm limit switch
Selecting this switch the maximum engine rpm will be limited at
2000.

Note: it is recommended to use this control in the yard to

improve hydraulic system efficiency and to decrease machine
noise level

3. Diagnostic switch
To be used to check for active engine electronic fuel system and
engine protection system fault codes.
4. Stop light
The STOP lamp is red and indicates the need to stop the engine as
soon as it can be safely done. The engine should remain shut down
until the fault can be repaired.
5. Warning light
The WARNING lamp is yellow and indicates the need to repair the
fault at the first available opportunity.
6. Water-in-fuel separator light.
The WATER-IN-FUEL (WIF) lamp is green and indicates that the
engine’s water-in-fuel separator needs to have the water drained out
of it. This task should be performed as soon as possible whenever
this lamp is illuminated.
7. Wait-to-start light
The WAIT-TO-START (WTS) lamp is yellow and is illuminated
during the preheat time that takes place when the keyswitch is in the
ON position during cold weather starting. To minimize cranking time
during cold weather starting, the engine should not be cranked until
the WAIT-TO-START lamp has been extinguished.

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Control instruments Operation and maintenance manual

Engine generaI Information

The QSB engine control system is an electronically operated fuel control

system that also provides many operator and vehicle or equipment
features.

The base functions of the control system include fueling and timing
control, limiting the engine speed operating range between the low and
high idle set points and reducing exhaust emissions while optimizing
engine performance.

The control system uses inputs from the operator and its sensors to
determine the fueling and timing required to operate at the desired
engine speed.
The electronic control module (ECM) is the control center of the
system. It processes all of the inputs and sends commands to the fuel
system and engine control devices.

The ECM performs diagnostic tests on most of its circuits and will
activate a fault code if a problem is detected in one of these circuits.
Along with the fault code identifying the problem, a snapshot of engine
operating parameters at the time of fault activation is also stored in
memory.
Some fault codes will cause a diagnostic lamp to activate to signal the
driver.

The control system utilizes a number of sensors to provide information

on engine operating parameters. These sensors include:
1. Coolant Temperature Sensor
2. Intake Air Temperature Sensor
3. Intake Manifold Pressure Sensor
4. Oil Pressure Sensor
5. Engine Speed/Position Sensor
6. Water-in-Fuel Sensor.

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Operation and maintenance manual Control instruments
Engine Protection System
The QSB engines are equipped with an engine protection system. The
system monitors critical engine temperatures and pressures, and will
log diagnostic faults when an over or under normal operation condition
occurs. If an out-of range condition exists, and engine derate action is
to be initiated, the operator will be alerted by an in-cab WARNING
lamp. The WARNING lamp will blink or flash when out-of-range
conditions continue to get worse. When the red STOP lamp is
illuminated, the driver must pull to the side of the road, when it is safe
to do so, to reduce the possibility of engine damage.
The engine protection system monitors the following data:
• Coolant temperature
• Coolant level (opt)
• Oil pressure
• Intake manifold temperature
• Engine overspeed
• OEM pressure (opt)

NOTE: Engine power and speed will be gradually reduced,

depending on the level of severity of the observed condition.

Diagnostic Fault Codes

The QSB control system can show and record operation anomalies that
present themselves as fault codes. These codes will make
troubleshootjng easier. The fault codes are recorded in the ECM. They
can be read using the fault lamps in the cab panel .

NOTE: Not all engine or QSB control system anomalies are shown as
fault codes.

There are two types of fault codes:

• Engine electronic control system fault codes
• Engine protection system fault codes
All fault codes recorded will either be active (fault code is
active at the moment) or inactive (fault code that was active at some
time but is not presently active).

Some, but not all, of the electronic fault codes will light a lamp when
they are active.

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Control instruments Operation and maintenance manual

To check for active engine electronic fuel system and engine protection
system fault codes, turn the keyswitch to the OFF position and move the
diagnostic switch to the ON position.
Turn the vehicle keyswitch to the ON position.
If no active fault codes are recorded, both warning and stop lamps will
come on and stay on.
If active fault codes are recorded, both warning and stop lamps will
come on momentarily, then begin to flash one code of the recorded
faults.

The fault code will flash in the following sequence:

First, a WARNING (yellow) lamp will flash. There will be a short 1 or 2
second pause after which the number of the recorded fault code will
flash in the STOP (red) lamp. There will be a 1 or 2 second pause
between each number. When the number has finished flashing in red,
a yellow lamp will appear again. The fault code will repeat in the same
sequence.

The lamps flash each fault code 3 times before advancing to the next
code. To skip to the next fault code, move the idle speed adjust switch
momentarily to the positive (+) position. You can go back to the
previous fault code by momentarily moving the idle speed adjust switch
to the negative (-) position. If only one active fault is recorded, the QSB
control system will continuously display the same fault code when
either + or -switch is depressed.

Fault Code Snapshot Data

Additional fault code information can be obtained by using the INSITE

service tool. The snapshot data records the value or state of the control
system sensors and switches at the time a fault occurred. These data
are stored for the first occurrence of the fault, since it was last cleared,
and the most recent occurrence. These data can be very valuable
when trying to recreate or determine engine operating conditions at the
time of a fault.
The ECM communicates with INSITE service tool through on SAE
J1939 datalink. The datalink connector is placed inside the electric
connection box near the batteries housing.

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