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Welcome to EIM
Training Center
QSX15 CM570 Introduction
5
 Class layout

 Following training program consists of following

topics and presentations:

– Introduction
– Engine Mechanicals
– Lubrication System
– Cooling System
– Air Intake System and Exhaust System
– Fuel System
– Engine control system

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 Base Engine Specifications

 Bore x Stroke 137 mm x 169 mm

 Displacement 15 liters
 Firing Order 1-5-3-6-2-4

 Approximate Dry Engine Weight:

– Dry Weight, 1370 kg (GEN.)

 Crankshaft Rotation, (viewed from the front of the

engine) Clockwise

 Valve Clearance:
– Intake 0.36 mm [0.014 in]
– Exhaust 0.69 mm [0.027 in]
– Injector Lash Adj. Torque 8 N.M (70 IN-LB)

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 Blowby (maximum at advertised or torque peak
rpm) with 9-mm [0.354-in] orifice

New or rebuilt engines (maximum) less

305 mm H2O [12.0 in H2O]
than 100,000 miles

Used Engine (maximum) greater than

457 mm H2O [18.0 in H2O]
100,000 miles

Mile = 1.6 KM , 7000 KM = 200 Hr

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 Electronic engines are identified by the
first two letters, “QS” Off-Highway industrial
market applications
"IS" for On-Highway automotive with interact
fuel system.
Engine family.
Engine Displacement.
CID (Cubic inch displacement)
Generator Application

The control system is identified with the

letters "CM" followed by the control system
model number.
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Engine & Component
Dataplates
11
 Other ESN Location

 NOTE: If the engine

data plate (1) is not
legible, the engine
serial number (2)
can be found on the
engine block, on the
exhaust side near
the flywheel housing

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 Fuel Pump Data plate

 The data plate contains the following

information that will assist in servicing
or replacement:

– Service Part Number

– Pump Production Part Number

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 ECM Data plate

 The electronic control module

(ECM) data plate shows
information about the ECM and
how the ECM was programmed.
The data plate is located on the
ECM.

 The following information is

available on the ECM data plate:
– ECM part number (P/N)
– ECM serial number (S/N)
– Engine serial number (ESN)
– ECM code: Identifies the software
in the ECM.

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 Turbocharger Data plate

 The turbocharger data plate is

located on the turbocharger inlet
compressor housing.
 The data plate contains the
following information that will assist
in servicing or replacement:
– Cummins® assembly part number
– Serial number
– Model number.

15
Engine Mechanicals
Overview
 Features

 2-belt Drive

 Poly-Vee Auto Tensioned Belt System

 Multiple fan Centers

 Belt Driven Water Pump

 Fan Bracket and Front Engine Support

Mounts Directly to Block

 Duel vibration damper, smoother running

engine less vibration

 No Valve Cover Oil Fill

 Front Gear Cover Oil Fill

 Barring Device Located Behind Oil Fill

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 Cylinder Block – Overview#

 Grey cast iron

 Single piece
 Dual Vibration dampers -
reduced noise / improved
gear train life
 Sculpted design
– Less material
– Greater Strength

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 Cylinder Block – Overview#

 The cylinder block has many

innovative design features.
 The block casting includes
provisions for:
• Oil cooler cavity
• Coolant Passages
• Oil Passages

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 Stiffener Plate#

 To help strengthen the

cylinder block, each engine
is built with a block stiffener
plate bolted to the skirt of the
cylinder block.
 The cylinder block stiffener
plate also helps to reduce
engine noise during engine
operation

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 Cylinder Block – Overview

 The engine has replaceable

wet cylinder liners.
 The mid- stop design is used
to "locate" the liner in the
block.
 A press fit between the liner
and the block aligns the top
of the liner in the block bore
with the cylinder head gasket
providing the coolant seal.

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 Cylinder Block – Overview

 O-ring also uses to prevent oil

entering the coolant area

 The top of the liner is machined to

accommodate the fire ring and the
graphite ring .

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 Cylinder Block – Overview
Two Cylinder liner types :

- Two different designs of cylinder Old style New style

liner are used on QSX engines Grooved – top liner Flat – top liner
dependent on engine production
vintage & ESN

CAUTION

Liners of different design can not

be mixed within an engine. All six
liners must be of the same
design.

Why: differences in cylinder head

gasket

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 Cylinder Block – Overview

 Cylinder Liner Protrusion

 For each cylinder take a total of
six measurements
 Three on the exhaust side and
three on the intake side.

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 Connecting Rod Bearings #

 The upper and lower

connecting rod bearing are
made from different materials
 Upper and lower bearings
have different part numbers.
 Upper bearing material
changed for more durability
under heavy load of
combustion.
 Inverting upper and lower
bearings will cause
misalignment between
bearing and saddle

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 Main Bearings

 The upper main bearings for each

journal are the same, except for
the number four main bearing
journal
 The number four main bearing
journal is fitted with a thrust
bearing.
 The flanges on this main bearing
control the end thrust of the
crankshaft
 The upper bearings have hole to
receives lubricating oil from the
main oil rifle.

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 Main Bearings

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 Piston Cooling Nozzles

 These engines use J-jet piston

cooling nozzles
 Located in between the main
bearing saddles on the fuel pump
side of the engine.
 Lubricating oil is supplied from an
oil gallery in the cylinder block on
the intake side of the engine.
 The nozzles supply lubricating oil
to the underside of the pistons.
 The pistons have an oil passage
into the top of the piston for cooling
purposes.
 Lubrication for the piston pin and
journal is supplied by residual
spray from the nozzles.
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 Piston & Assembly

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 Piston & Assembly

 A full floating, hollow piston pin is used to

attach the piston to the connecting rod
 When assembling and installing the
piston and connecting rod assembly, it is
critical that the orientation of the
components is correct.
 The notch in the piston skirt provides
clearance for the J-jet piston cooling
nozzle when the piston is at bottom dead
center
 The piston ring type and location can be
identified by the piston ring profile.
– Top piston ring
– Intermediate piston ring
– Oil control ring.

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 Piston & Assembly

 Two Piston Style types

 Articulated Piston forged steel crown
with Aluminum skirt
 The single piece piston is a one-piece
piston that does NOT have a pushing
and is forged from a high-strength alloy
steel.

 Both articulated pistons and single-

piece pistons have an arrow on the top
of the piston crown which will point to
the front of the engine when the piston
is installed properly

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 Connecting Rod#

 Heavy duty CUMMINS design.

 The match between the rod and rod cap

uses dowel rings for alignment .

 Four cap screws used to connect the cap

with the rod.

 Both the connecting rod tang and the

piston notch (notch of nozzle) are
oriented in the same side.

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 Piston And Connecting Rod Orientation

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 Piston And Connecting Rod Orientation

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 Crankshaft & Gear

 The crankshaft is a balanced,

cast steel component.

 No counterweights in number 2
or number 5 crank thoughts .

 The crankshaft gear, tone wheel,

and adapter are permanently
installed in the crankshaft and if
any of these components
becomes damaged the
crankshaft assembly must be
replaced.
 One of the counterweights is
slotted to hold the timing pin.

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 Front Gear housing

 Aluminum, Mounted to the front

of the engine block using edge
molded steel shim type gasket

 The front housing contains,

– Crankshaft gear
– lower idler concept gear
1 – adjustable idler gear
2 – Injector camshaft concept gear
– valves camshaft gear
3

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 Front Gear housing

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 Front Gear Covers

 Two stamped
steel covers
used (upper
lower)

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 Front Crankshaft Seal

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 Front Crankshaft Seal

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 Front Crankshaft Seal

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 Front Crankshaft Seal

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 Front Crankshaft Seal

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 Front Crankshaft Seal

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 Front Crankshaft Seal

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 Cylinder Head

 One-piece.
 Replaceable valve seats and valve guides.
 Cross flow design.
 Integral intake manifold.
 Four valves per cylinder, the exhaust valves
have longer stem than intake valve.
 The cylinder head houses tow overhead cam
shafts
- the injectors cam shafts and mounted in
fuel pump side of the engine.
- the valves cam shaft and mounted in the
exhaust side of the engine.

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 Cylinder Head

 Contains special opening to

mesh the fuel pump to its
special drive gear in injectors
cam shaft.
 Cast coolant cavities to
control coolant flow.
 Mounted location for
thermostat housing.
 Mounted location for
camshaft position sensor.

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 Cylinder Head

Two long cylinder head capscrews

placed toward each end of the cylinder
head serve as convenient guides when
lowering the cylinder head into place.

Tighten capscrews in sequence.

Torque Value:
203 n.m [150 ft-lb]
407 n.m [300 ft-lb]
Rotate 90 degrees.

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 Cylinder Head Gasket

 Two Cylinder head gasket types

 New one piece Head Gasket…Requires new flat
top Cyl. liner

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 Rocker Levers

 Shaft mounted and

include cam
followers.
 Spacers included
between rocker
levers

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 Rocker lever cover

-Available in cast
aluminum and plastic.
- reusable gasket
between the cover and
the head.
- mounted in the head
using torque limited
isolators cap screws.

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 Flywheel Housing

 Edge molded steel

shim gasket.
 Fitted with dowel pins
and that help in
adjusting flywheel
housing position
without using dial
gauge

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 Rear camshafts cover plates

 Provide thrust service

to limit camshafts
movement to the rear.
 oil sealing for the
cylinder head at the
end of camshafts

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 Vibration damper

 Doweled to the front

end of the crankshaft.
 Its necessary to adjust
the position of
vibration damper
because it holds the
timing marks for valve
lash adjust.
 Timing pointer in lower
front gear cover aligns
with timing marks on
damper
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 Concept Gears

 Exists in both injector camshaft

gear and lower idler gear.
 Reducing engine noise by
providing balanced gear lash on
both meshes of concept gears
 Every gear consists of wide
section of gear teeth and narrow
section of gear teeth.
 The two sections aligned under
pressure of series of springs
located near the center of the
gear, and these springs can be
adjusted through bolts exists on
each spring.

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 Over head set

Intake Exhaust Injector

Torque
0.36 mm 0.69 mm 8 N.M
[0.014 in] [0.027 in] (70 IN-LB)

Do not use a click-type torque wrench.

Use a dial-type torque wrench with a
range of 0 to 150 in-lb to tighten the
injector rocker lever adjusting screw

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 Base engine timing

 One of the crankshaft counter

weight is slotted
 This slot is aligned with a
timing port in the side of the
block.
 A timing pin is used by
entering the pin into the slot
to hold the crankshaft in
position during base engine
timing

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 Base engine timing

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Lubrication System
Overview
 Lubrication System Specifications

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 Use of a high quality SAE 15W-40
heavy-duty engine oil, which
meets the American Petroleum
Institute (API) performance
classification CH-4 / CI-4

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 Lubricating Oil Pump

 Mounted inside oil pump.

 Driven directly from
crankshaft through the
pump idler gear.
 Pump includes,
- pressure relief (dump to
sump over 130 psi)
- pressure regulator
(regulates the oil pressure
to the desire value, dump
to inlet side of oil pump)

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 Lubricating Oil Pump

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 Lubricating Oil Filter

 Strata Pore Filter combine full flow

and by bass filtration in one
package.
 Located on the exhaust side of the
engine.
 Pre-filling is recommended to
prevent lubrication oil pressure delay
at start-up
 When pre-filling:
– Be careful that debris is not
allowed into the filter
– If using an oil filter supplied with a
metallic or plastic seal under the
cap, be careful to peel the seal
back.

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 Lubricating Oil Filter

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 Lubricating Oil Cooler

 The lubricating oil cooler is

located on the exhaust side of
the engine beside the oil filter
 Lubricating oil flows through the
plates of the oil cooler, where it
is cooled by engine coolant
flowing past the plates

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 Lubricating Oil Cooler thermostat

Used to prevent oil to go throw oil cooler until

reaches desired value

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 Lubricating Oil suction tube

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 Lubricating Oil Pan

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 Lubricating Oil Pressure Temperature sensor

 Mounted on main oil rifle.

 Found in intake side of the engine.

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 Lubrication Flow Descriptions

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 Lubrication Flow Descriptions

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 Lubrication Flow Descriptions

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 Lubrication Flow Descriptions

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Fuel System
Overview
 HD-HPI-TP Fuel System

 HD = Heavy duty.
 HPI = High pressure injection.
 TP = Time pressure (variable time
and fixed pressure fuel comes to
actuator rail).
 Fuel System Cleanliness During
Repairs Is Very Important.
 Clean all fuel system fittings, lines,
and components before
disassembly.
 Make sure that no dirt or debris
enters the fuel system components
to prevent the passing of
contaminants to fuel lines.
 Small amounts of dirt and debris
can cause a malfunction of these
components.

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 Clean Care Review

Questions:
1. What is a micron?
2. What are potential sources of fuel
system contamination?
3. What can you as the technician
do to prevent fuel system
contamination?
4. Can you always pre-fill fuel filters?

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 Integrated fuel system module IFSM

 IFSM contains many of fuel

component and connections,
- Timing actuators
- Metering actuators
- Fuel shutoff valve
- Fuel pump
- Fuel regulators
- fuel pressure sensor
- fuel filter
- fuel inlet line
- fuel return line

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 Fuel inlet screen

 In the inlet of IFSM.

 140 micron mesh screen.
 Prevent contamination from
entering the IFSM.

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 Fuel Filter

 Combination filter, fuel

filter water separator.
 10 micron filtering
media.
 Water drain.
 W/F Sensor.

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 Why is pre-filling pressure-side fuel
filters not recommended?
 Normal System
operation
 Fuel from the
suction side filter
has been filtered, Dirty Side of
but not at the Filter
micron level the Clean Side
fuel system of Filter
requires
Fuel entering filter head and filter

Fuel passing through the filter media

Fuel cleaned to the final micron level

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 Contamination happens that
quickly
Continued … Both sides of the filter media are
exposed to unfiltered fuel
 What really happens Critical system parts are now at
during pre-filling? risk
 During pre-filling the
“clean side” of the
filter is exposed to
any contamination in
the fuel supply
source

Fuel from pre-fill source

Fuel passing through the filter media

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 Fuel Actuators

 Controls the fuel flow to

the injectors by the on time
of actuators when open.

 Every pair of actuators

controls the fuel flow to 3
cylinders.

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 Fuel Pump

 Pulls the fuel from fuel

tank.
 Driven by integrated gear
in injectors camshaft.
 Mounted in the intake side
of the engine.

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 IFSM Fuel dampers

 Three dampers exist on

IFSM.
 First damper exists on fuel
pump to reduce pulsation
resulting from fuel pump
gears movement and that
helps in stable supply of fuel
to the system.
 The other two dampers
exists on fuel actuators to
reduce pulsation resulting
from rapid opining and
closing of actuators and that
helps the ECM in more
accurate control fuel flow to
timing and metering
champers

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 Fuel shutoff valve & Fuel pressure sensor

 Shut off the fuel flow to

the actuators rail when it
deactivated.
 Normally close valve and
opens when the key
switch is on.

 Fuel pressure sensor

installed in the bottom of
IFSM beside the fuel
filter, used by ECM to
monitor the fuel pressure

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 Fuel Maintenance ports & Rifles

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 Injectors

 One piece open nozzle.

 Operates at 28000 psi and
can withstand to 35000 psi.

 Four O-rings used to

separate timing, metering
and drain ports.

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 Injectors

 The injector contains,

- upper plunger
- timing check valve
- timing plunger
- timing plunger spring
- rail metering check valve
- lower plunger
- trapped volume spill (TVS) port
- lower plunger spring
- spill regulator
- inlet screen
- leakage vent

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 Fuel flow description

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Cooling System
Overview
92
 Cooling System Specifications

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 Coolant Pump

 The water pump is a

belt-driven, with the
bypass integral parts of
the cylinder block and
the inlet as external part.
 Water inlet made of
Aluminum
 It is not practical to
replace the components
of the water pump; the
water pump is serviced
as an assembly.

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 Coolant Filter

 Mounted on coolant
pump inlet.
 Shut off valve included
for easier service

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 Thermostat & Housing

 Thermostat modulating range

82 to 93°C [180 to 198°F].
 Seals bypass during
normal operation.
 Aluminum Housing and cover
 Mounting location for coolant
temp sensor.
 Mounted location for optional
coolant temp sensor

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 Thermostat & Housing

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 Thermostat & Housing

 The thermostat controls the engine

coolant temperature. When the
coolant temperature is below the
operating range, engine coolant is
bypassed back to the inlet of the
water pump. When the engine
coolant temperature reaches the
operating range, the thermostat
opens, seals off the bypass, and
forces engine coolant to flow to the
radiator or the heat exchanger.
 Never operate the engine without a
thermostat. Without a thermostat,
the path of least resistance for the
coolant is through the bypass to the
water pump inlet. This can cause the
engine to overheat.

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 Fan belt

 To make sure the

cooling fan drive belt is
routed correctly upon
installation, make a
diagram of the cooling
fan belt routing prior to
removing the belt as
shown in the illustration.

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 Cooling System Flow

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 Cooling System Flow …

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 Cooling system content & mixing

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Intake Air System
Overview
 Intake Air System

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 Intake Manifold

 The air intake manifold

is integrated in the
cylinder head gasket.
 The same side of IFSM

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 Turbocharger

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 Charge Air Cooling

 Charge Air Cooling is

required on all ratings
 The air-to-air heat exchange
process reduces the
temperature of air caused by
turbo charging.
 Lower intake air temperature.
 Increase engine power.
 Reduce engine emission

116
 Air Intake Flow

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Exhaust System
Overview
 Exhaust flow

119
Electronic control
system
 Electronic control system Function

121
 CM570 ECM & Cooling plate

 50 pin sensor connector.

 50 pin OEM connector.

 50 pin actuator connector.

 ECM cooled by air using

ECM cooling plate.
 Cooling plate have fins
mounted inside intake
manifold.

122
 Engine wiring harness

 Engine wiring
harness
connects the
individual
sensors and the
electronic
component to
the ECM

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 Fuel pressure sensor

 Installed in bottom of IFSM

 Fuel rail pressure sensor
used to monitor the fuel
out from metering actuator

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 Intake manifold pressure temperature

 Located in air inlet

connection.
 Combined sensor used to
measure intake manifold
pressure produced by
turbocharger, and intake
manifold temperature for
fueling control.

125
 Barometric air pressures sensor & Ambient air temperature sensor

 Barometric air pressure

sensor used for turbocharger
over speed protection in high
altitude conditions.
 Ambient air temperature
sensor used by the ECM to
calculate the turbocharger
compressor outlet
temperature.

126
 Engine camshaft speed/position sensor

 Hall effect sensor.

 Take feeding from special
loop in injector camshaft.
 Located in the side of
cylinder head in the same
side of fuel pump.
 Primary used to determine
engine position for timing.
 Secondary used to
determine engine speed if
speed sensor malfunction.

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 Engine crankshaft speed/position sensor

 Hall effect sensor.

 Take feeding from crankshaft
tone wheel.
 Mounted beside front gear
housing in the fuel pump side.
 Primary used to determine
engine speed.
 Secondary used to determine
engine position if the position
sensor malfunction.

128
 Coolant temperature sensor

 Located in the
thermostat housing.
 used to determine
coolant temperature
in the engine.
 Provide engine
protection.

129
 Lubricating Oil Pressure Temperature sensor

 Mounted on main oil rifle.

 Found in intake side of the engine.
 Provides engine protection

130
 Fuel Actuators

 Controls the fuel flow to

the injectors by the on time
of actuators when open.

 Every pair of actuators

controls the fuel flow to 3
cylinders.

131
 Water in fuel sensor

Ulminate warning lamp

when water found.

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Questions?
Thank You