SM-McCormick ZTX230 ZTX260 ZTX280 TRACTOR Service Repair Manual

Table of Contents
ZTX Series Tractors

Service Manual SM 8-12602
Section Pub. No.
1 GENERAL
Safety Rules, General Information and Torque Specifications ............................1001
General Specifications and Torques ...................................................................1002
2 ENGINE
Engine How it Works .................................................................................................2
Fault Codes
3 FUEL
4 ELECTRICAL
Electrical How it Works ......................................................................................... ..4
Electrical Schematics.........................................................................................4001
Instrument Cluster Programming.......................................................................4002
Battery Servicing and Testing............................................................................4004
5 STEERING
Steering How it Works ...............................................................................................5
Steering Column and Steering Hand Pump Removal ........................................5001
Rexroth Steering Hand Pump.............................................................................5002
6 TRANSMISSION
Transmission How it Works ......................................................................................6
Splitting the Tractor .............................................................................................6003
Full Powershift Transmission ..............................................................................6006
MFD Clutch..........................................................................................................6017
Rear Axle.............................................................................................................6018
Power Take Off ...................................................................................................6019
MFD Front Axle - 20.49 Axle ...............................................................................6021
Front Suspended Axle - 20.49 Axle.....................................................................6022
7 BRAKES
Brakes How it Works .................................................................................................7
Parking Brake ......................................................................................................7001
8 HYDRAULICS
Hydraulics How it Works............................................................................................8
Hydraulic Troubleshooting and Schematic ..........................................................8001
Left Hand and Right Hand Hydraulic Covers........................................................8005
Hydraulic Priority Valve Blocks ............................................................................8006
Auxiliary/Remote Spool Valves............................................................................8008
9 CHASSIS AND MOUNTED EQUIPMENT

Climate Control How it Works.....................................................................................9
Pedal, Lever And Switch Adjustments .................................................................9001
10 CONTROLLER SYSTEMS
Electrical Controllers How it Works..........................................................................10
Auxiliary/Remote Valve Controller - Error Codes,
Troubleshooting and Schematics ..................................................................10001
Hitch Controller - Error Codes,
Front Suspended Axle Controller
Calibration, Error Codes, Troubleshooting and Schematics..........................10003
Transmission and Cab (MCC) Controller - Calibration, Error Codes,
Instrument Cluster Controller - Error Codes,
Controller Programming ................................................................................10010
Automatic Temperature Control.....................................................................10012
1001
Section
1001
SAFETY, GENERAL INFORMATION

AND STANDARD TORQUE SPECIFICATIONS
© 2001 McCormick Tractors International Limited.

SM 8-10080 March 2001
2 SECTION 1001
TABLE OF CONTENTS
SAFETY ................................................................................................................................................................... 3
GENERAL INFORMATION
Cleaning ............................................................................................................................................................... 5
Inspection ............................................................................................................................................................. 5
Bearings ............................................................................................................................................................... 5
Needle Bearings .................................................................................................................................................. 5
Gears ................................................................................................................................................................... 5
Oil Seals, O-Rings And Gaskets .......................................................................................................................... 5
Shafts ................................................................................................................................................................... 5
Service Parts ........................................................................................................................................................ 5
Lubrication ........................................................................................................................................................... 5
STANDARD TORQUE DATA FOR NUTS AND BOLTS

Chart 1 (Plain Nuts/Bolts) .................................................................................................................................... 6
Chart 2 (Phosphate Coated Nuts/Bolts) ............................................................................................................... 6
Chart 3 (Zinc or Cadmium Plated Nuts/Bolts) ...................................................................................................... 7
SM 8-10080 Issued 03-2001

Hello
Thank you very much for your
download.
In the last page of this PDF
document.
There is a link.
Please click on that link and return to
our website.
Then you can get the complete
manual immediately.
No need to wait.
Thanks for continuing to read the
documentation.
Best wishes.
SECTION 1001 3
SAFETY
This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY

IS INVOLVED. The message that follows the symbol contains
! important information about safety. Carefully read the message.
Make sure you fully understand the causes of possible injury or
death.
To prevent injury always follow the Warning,

Caution and Danger notes in this section and WARNING: Before starting engine, study
throughout the manual. Operator’s Manual safety messages.
Read all safety signs on machine. Clear
Put a warning tag as shown below on the key for the the area of other persons. Learn and
key switch when carrying out servicing or repairs to practice safe use of controls before
the tractor. Warning tags (publication number 2-1000) operating.
are available from your McCormick dealer. ! It is your responsibility to understand and
follow manufacturers instructions on
machine operation, service, and to
REASON/RAISON
observe pertinent laws and regulations.
!
VERNUNFT/RAZON
Operator’s and Service Manuals may be

obtained from you McCormick dealer.
DO NOT OPERATE WARNING: If you wear clothing that is too

NE PAS UTILISER loose or do not use the correct safety
NICHT BETREIBEN equipment for your job, you can be
NO UTILIZAR
injured. Always wear clothing that will not
! catch on objects. Extra safety equipment
that can be required includes hard hat,
safety shoes, ear protection, eye or face
protection, heavy gloves and reflector
clothing.
2-1000
WARNING: When working in the area of

WARNING: Read the operators manual to the fan belt with the engine running, avoid
! familiarize yourself with the correct ! loose clothing if possible, and use
control functions. extreme caution.
WARNING: Operate the machine and WARNING: When doing checks and tests
equipment controls from the seat on the equipment hydraulics, follow the
! position only. Any other method could ! procedures as they are written. DO NOT
result in serious injury. change the procedure.
WARNING: This is one a man machine, no WARNING: When putting the hydraulic
! riders allowed . cylinders on this machine through the
! necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way.
WARNING: Use insulated gloves or

! mittens when working with hot parts.
SM 8-10080 Issued 03-2001

4 SECTION 1001
CAUTION: Lower all attachments to the CAUTION: When servicing or repairing

ground or use stands to safely support the machine. Keep the shop floor and
! the attachments before you do any operator’s compartment and steps free of
maintenance or service. ! oil, water, grease, tools, etc. Use oil
absorbing material and or shop cloths as
required. Use safe practices at all times.
CAUTION: Pin sized and smaller streams
of hydraulic oil under pressure can
penetrate the skin and result in serious CAUTION: Some components of this
infection. If hydraulic oil under pressure machine are very heavy. Use suitable
does penetrate the skin, seek medical ! lifting equipment or additional help as
treatment immediately. Maintain all hoses instructed in this Service Manual.
! and tubes in good condition. Make sure
all connections are tight. Make a
replacement of any tube or hose that is DANGER: Engine exhaust fumes can
damaged or thought to be damaged. DO cause death. If it is necessary to start the
NOT use your hand to check for leaks, engine in a closed place, remove the
use a piece of cardboard or wood.
! exhaust fumes from the area with an
exhaust pipe extension. Open the doors
and get outside air into the area.
CAUTION: When removing hardened pins
such as a pivot pin, or a hardened shaft,
use a soft head (brass or bronze) hammer DANGER: When the battery electrolyte is
! or use a driver made from brass or bronze frozen, the battery can explode if (1), you
and a steel head hammer. try to charge the battery, or (2), you try to
jump start and run the engine. To prevent
! that battery electrolyte from freezing, try
CAUTION: When using a hammer to to keep the battery at full charge. If you do
remove and install pivot pins or separate not follow these instructions, you or
parts using compressed air or using a others in the area can be injured.
! grinder, wear eye protection that
completely encloses the eyes (approved
goggles or other approved eye DANGER: Batteries contain acid and
protectors). explosive gas. Explosions can result from
sparks, flames or wrong cable
connections. To connect the jumper
CAUTION: Use suitable floor (service) ! cables correctly to the battery of this
jacks or chain hoist to raise wheels or machine see the Operator’s Manual.
! tracks off the floor. Always block machine Failure to follow these instructions can
in place with suitable safety stands. cause serious injury or death.
SM 8-10080 Issued 03-2001

SECTION 1001 5
GENERAL INFORMATION
Cleaning Gears
Clean all metal parts except bearings, in mineral Check all gears for wear and damage. Replace
spirits or by steam cleaning. Do not use caustic gears that have wear or damage.
soda for steam cleaning. After cleaning dry and put
oil on all parts. Clean oil passages with compressed Oil Seals, O-Rings And Gaskets
air. Clean bearings in kerosene, dry the bearings
completely and put oil on the bearings. Always install new oil seals, o-rings and gaskets.
Put petroleum jelly on seals and o-rings.
Inspection
Shafts
Check all parts when the parts are disassembled.
Replace all parts that have wear or damage. Small Check all shafts that have wear or damage. Check
scoring or grooves can be removed with a hone or the bearing and oil seal surfaces of the shafts for
crocus cloth. Complete visual inspection for damage.
indications of wear, pitting and the replacement of
parts necessary will prevent early failures. Service Parts
Always install genuine McCormick service parts,
Bearings when ordering refer to the Parts Catalog for the
Check bearings for easy action. If bearings have a correct part number of the genuine McCormick
loose fit or rough action replace the bearing. Wash replacement items. Failures due to the use of other
bearings with a good solvent or kerosene and than genuine McCormick replacement parts are not
permit to air dry. DO NOT DRY BEARINGS WITH covered by warranty.
COMPRESSED AIR.
Lubrication
Needle Bearings Only use the oils and lubricants specified in the
Before you press needle bearings in a bore always Operators or Service Manual. Failures due to the
remove any metal protrusions in the bore or edge of use of non specified oils and lubricants are not
the bore. Before you press bearings into position covered by warranty.
put petroleum jelly on the inside and outside
diameter of the bearings.
SM 8-10080 Issued 03-2001

6 SECTION 1001
STANDARD TORQUE DATA FOR NUTS AND BOLTS

NOTE: A “click type” torque wrench is recommended for the bolt torques listed below.
Chart 1 (Plain Nuts/Bolts)
BOLT TYPE 8.8 TYPE 10.9

SIZE MIN MAX MIN MAX
(mm) lb ft Nm lb ft Nm lb ft Nm lb ft Nm
M4 3.0 4.0 3.4 4.5 4.3 5.8 4.8 6.5
M5 4.8 6.5 5.5 7.5 7.0 9.5 7.8 10.5
M6 8.2 11.0 9.2 12.5 11.8 16.0 13.3 18.0
M8 20.0 27.0 22.5 31.0 28.7 39.0 32.3 44.0
M10 40.0 54.0 45.0 61.0 56.0 77.0 64.0 87.0
M12 69.0 94.0 78.0 106.0 100.0 134.0 110.0 151.0
M14 110.0 150.0 125.0 170.0 160.0 215.0 180.0 240.0
M16 175.0 235.0 190.0 260.0 245.0 335.0 275.0 375.0
M20 345.0 470.0 390.0 530.0 480.0 650.0 540.0 730.0
M22 475.0 640.0 530.0 720.0 655.0 890.0 735.0 1000.0
M24 600.0 810.0 675.0 915.0 830.0 1125.0 930.0 1265.0
M30 1190.0 1615.0 1340.0 1815.0 1645.0 2235.0 1855.0 2515.0
M36 2080.0 2825.0 2340.0 3175.0 2875.0 3900.0 3235.0 4390.0
Chart 2 (Phosphate Coated Nuts/Bolts)

M4 2.3 3.0 2.6 3.4 3.2 4.4 3.6 4.9
M5 3.6 4.9 4.1 5.6 5.2 7.1 5.9 8.0
M6 6.2 8.3 6.9 9.4 8.9 12.0 10.0 13.5
M8 15.0 20.3 16.9 23.3 21.5 29.2 24.2 32.8
M10 30.0 41.0 34.0 46.0 42.0 58.0 48.0 65.0
M12 52.0 71.0 59.0 80.0 75.0 101.0 83.0 113.0
M14 83.0 113.0 94.0 126.0 120.0 161.0 135.0 180.0
M16 131.0 176.0 143.0 195.0 185.0 251.0 205.0 280.0
M20 259.0 353.0 293.0 400.0 360.0 490.0 405.0 550.0
M22 355.0 480.0 400.0 540.0 490.0 665.0 550.0 750.0
M24 450.0 608.0 506.0 686.0 625.0 845.0 700.0 950.0
M30 893.0 1211.0 1005.0 1361.0 1235.0 1675.0 1390.0 1885.0
M36 1560.0 2119.0 1755.0 2381.0 2156.0 2925.0 2425.0 3295.0
SM 8-10080 Issued 03-2001

SECTION 1001 7
Chart 3 (Zinc or Cadmium Plated Nuts/Bolts)

M4 2.6 3.5 2.9 3.9 3.7 5.0 4.1 5.6
M5 4.1 5.6 4.6 6.3 5.9 8.0 6.6 9.0
M6 7.0 9.5 7.8 10.6 10.0 13.6 11.3 15.3
M8 17.0 23.1 19.1 25.9 24.4 33.1 27.4 37.2
M10 34.0 46.0 38.3 52.0 48.0 65.0 54.0 74.0
M12 59.0 80.0 66.0 90.0 85.0 114.0 94.0 128.0
M14 94.0 128.0 106.0 145.0 136.0 183.0 153.0 205.0
M16 149.0 200.0 161.0 220.0 208.0 285.0 235.0 320.0
M20 293.0 400.0 330.0 450.0 408.0 555.0 460.0 620.0
M22 400.0 545.0 450.0 615.0 555.0 755.0 625.0 850.0
M24 510.0 690.0 575.0 780.0 705.0 955.0 790.0 1075.0
M30 1010.0 1375.0 1140.0 1545.0 1400.0 1900.0 1580.0 2140.0
M36 1770.0 2400.0 1990.0 2700.0 2445.0 3315.0 2750.0 3730.0
SM 8-10080 Issued 03-2001

Section
1002
1002
GENERAL SPECIFICATIONS AND TORQUES
ZTX Series Tractors

SM 8-12501 March 2004 (Revised June 2004)
2 SECTION 1002
TABLE OF CONTENTS
GENERAL SPECIFICATIONS
Lubricants and Capacities ....................................................................................................................................3
Engine ..................................................................................................................................................................3
Fuel ......................................................................................................................................................................3
Electrical ...............................................................................................................................................................3
Transmission ........................................................................................................................................................4
Hydraulics .............................................................................................................................................................4
Air Conditioning ....................................................................................................................................................5
SPECIAL TORQUES
Engine ..................................................................................................................................................................6
Transmission ........................................................................................................................................................6
Cab and Chassis ..................................................................................................................................................6
SM 8-12501 Issued 06-2004

SECTION 1002 3
GENERAL SPECIFICATIONS
Lubricants and Capacities

ENGINE
Oil Type....................................................................................................... McCormick Engine Oil, SAE 15W - 40
Capacity (With Filter Change).........................................................................................20 Litres (5.3 US gallons)
ENGINE COOLANT
Coolant Mix......................................................................................................... McCormick Universal Anti-freeze
Solution of 33% to 50% Ethylene Glycol
(depending on market requirements)
Capacity........................................................................................................................40 Litres (10.6 US gallons)
AIR CONDITIONER SYSTEM

Compressor Oil................................................................................................................. Sanden SP - 20 Pag Oil
Capacities ...................................................................................................................................... Refer to Page 5
TRANSMISSION
Oil Type...................................................................................................................................... McCormick UTTO
Capacity......................................................................................................................158 Litres (41.7 US gallons)
MFD AXLE
Oil Type........................................................................................................... McCormick Multi-Purpose Gear Oil
SAE 85W - 140 EP Gear Oil to API GL-5
or MIL-L-2105 Specification
Differential Oil .................................................................................................................10 Litres (2.6 US gallons)
Axle Planetaries (Each) .................................................................................................1.9 Litres (0.5 US gallons)
FUEL TANK
Fuel Capacity...............................................................................................................570 Litres (150 US gallons)
Engine
NOTE: For the Engine Specifications, refer to the your Engine Service Manual.
Fuel
NOTE: For the Fuel Specifications, refer to the your Engine Service Manual.
Electrical
System Type .................................................................................................................... 12 Volt Negative Ground
Batteries....................................................................................... Two 12 Volt, Low Maintenance Hybrid Batteries
Connected in Parallel, DIN Type 60527, Top Stud Terminals
BATTERY SAE (COLD CRANKING AMPERE RESERVE

IEC DIN
TYPE CAPACITY) HOURS CAPACITY
644 660 Amps 440 Amps 400 Amps 95 180 mins
Alternator ..................................................................................................................................... 12 Volt, 150 Amp

Starter Motor................................................................................................................................... 12 Volt, 4.2 kW
SM 8-12501 Issued 06-2004

4 SECTION 1002
Transmission
Pinion Shaft Bearing Preload ........................................................................................................0.05 to 0.15 mm
MFD Output Shaft End Play .................................................................................................................0 to 0.1 mm
MFD CLUTCH
Number of Clutch Plates
Friction Plates ...............................................................................................................................................8
Separator Plates ...........................................................................................................................................7
DIFFERENTIAL AND DIFFERENTIAL LOCK

Ring Gear and Pinion Backlash.....................................................................................................0.15 to 0.45 mm
Differential Lock Clutch
Number of Plates
Friction Plate ................................................................................................................................................ 8
Separator Plate............................................................................................................................................ 7
Hydraulics
HYDRAULIC PUMPS
Charge Pump
110 l/min ........................................................................................................................... 60 cm3 per revolution
150 l/min ........................................................................................................................... 80 cm3 per revolution
Variable Displacement Pump
110 l/min .................................................................................................................... 0 to 45 cm3 per revolution
150 l/min .................................................................................................................... 0 to 60 cm3 per revolution
SM 8-12501 Issued 06-2004

SECTION 1002 5
Air Conditioning
REFRIGERANT
Type ....................................................................................................................................................... HFC-134A
System Capacity............................................................................................................................................1.9 kg
Boiling Point at Atmospheric Pressure.......................................................................................................... -26° C
COMPRESSOR
Manufacturer............................................................................................................................................ SANDEN
Model .......................................................................................................................................... SD 7H15MD4609
Number of Cylinders ............................................................................................................................................. 7
Displacement Per Revolution........................................................................................................................155 cc
Clutch Voltage ............................................................................................................................................12 Volts
Clutch Ampage Draw at 12 Volts .............................................................................................. 3.6 to 4.2 Amperes
Front Clutch Plate Air Gap ................................................................................................................ 0.4 to 0.8 mm
COMPRESSOR AND SYSTEM LUBRICATION

Lubrication Type............................................................................................................... Sanden SP - 20 PAG Oil
HIGH PRESSURE SWITCH

Operation ................................................................................................... Closed by Excessive System Pressure
LOW PRESSURE SWITCH

Operation ............................................................................................................ Closed by Low System Pressure
SM 8-12501 Issued 06-2004

6 SECTION 1002
SPECIAL TORQUES
Engine
Engine to Transmission Retaining Bolts
Adapter Plate to Engine...........................................................114 to 128 Nm (84 to 94 lb ft)
Adapter Plate to Transmission .................................................555 to 620 Nm (409 to 457 lb ft)
Torque Dampener Retaining Bolts...............................................74 to 84 Nm (54 to 62 lb ft)
Front Bolster to Transmission Retaining Bolts .........................555 to 620 Nm (409 to 457 lb ft)
Flywheel ..................................................................................108 to 132 Nm (80 to 97 lb ft)
Transmission
DIFFERENTIAL AND DIFFERENTIAL LOCK
Ring Gear Retaining Bolts .......................................................240 to 340 Nm (177 to 251 lb ft)
Differential Lock Clutch Cage Retaining Bolts .........................110 to 130 Nm (81 to 96 lb ft)
Differential Bearing Carrier Retaining Bolts .............................100 to 130 Nm (74 to 96 lb ft)
REAR AXLES
Rear Axle Mounting Nuts.........................................................247 to 253 Nm (182 to 187 lb ft)
MFD DRIVE SHAFT

MFD Drive Shaft Centre Mounting Bolts.............................................570 Nm (420 lb ft)
PTO
PTO Housing Retaining Bolts ......................................................480 to 640 Nm (354 to 472 lb ft)
PTO Clutch Pack Retaining Bolt ..................................................25 to 34 Nm (18 to 25 lb ft)
PTO Clutch Assembly Retaining Bolt ..........................................50 to 70 Nm (37 to 52 lb ft)
Bearing Carrier Retaining Bolt.....................................................72 to 96 Nm (53 to 71 lb ft)
Cab and Chassis

CAB
Cab Mounting Bracket to Rear Axle Bolts ...............................190 to 244 Nm (140 to 180 lb ft)
Cab Mounting Bracket to Transmission Bolts Bolts .................205 to 260 Nm (151 to 192 lb ft)
Cab Mounting Bolt to Threaded Plate ........................................47 to 61 Nm (33 to 45 lb ft)
Cab Mounting Nut....................................................................190 to 244 Nm (140 to 180 lb ft)
WHEELS
Front Wheel to MFD Axle Nuts ................................................530 to 570 Nm (391 to 420 lb ft)
Wheel Hub to Tapered Bushing ...............................................500 to 600 Nm (369 to 443 lb ft)
Wheel to Wheel Hub................................................................640 to 680 Nm (472 to 502 lb ft)
SM 8-12501 Issued 06-2004

Section
2
2
ENGINE
How it Works
ZTX Series Tractors

DT50-50260 March 2004
SECTION!2
This!page!is!intentionally!blank
Page!2 !!!DT50-50260 McCormick!Service!Training

SECTION!2
Contents!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !Page
Engine!Description! ................................................................................................4
Engine!electronic!Control!System! .........................................................................5
Engine!Control!Circuit! ...........................................................................................8
Fuel!Pump!Schematic! ...........................................................................................10
Fuel!Pump!Operation! ............................................................................................11
Caps!Fuel!System! .................................................................................................13
Troubleshooting! ....................................................................................................18
Distributor!Valve!Check!.........................................................................................19
Bleeding!the!Fuel!System! .....................................................................................20
!McCormick!Service!Training! DT50-50260 Page!3

SECTION!2
Engine!Description
The!ZTX,!models!ZTX230,!ZTX!260!and!ZTX!280,!are!fitted!with!the!Cummins!QSC
24!valve!8.3!Litre!Engine.!These!engines!have!full!authority!electronic!control.!A!vast
number! of! changes! have! been! implemented! when! compared! to! the! previous! C
series!8.3-liter!Cummins!engines.
These! engines! have! 24! valves,! 4! valves! per! cylinder,! to! ensure! optimum! airflow,
improved!fuel!economy!and!fully!emissions!compliant.!The!fuel!injector!is!located!in
the! center! of! the! cylinder! to! provide! a! more! centralized! injection! and! improved!fuel
burn!over!conventional!layouts.
The!fuel!system!itself!is!totally!electronically!controlled!and!uses!an!engine!mounted
ECM! (Engine! Control! Module)! to! process! all! relevant! information,! and! make
necessary!adjustments.

SECTION!2
Engine!Electronic!Control!System
Fuel!Pump
Engine!Control!Module
(View!left-hand!side!of!engine)

SECTION!2
Engine!Electronic!Control!System!(Cont'd)
The! electronic! control! system! for! the! QSC! Engine! uses! input! information! from! a
number!of!sensors!installed!on!the!engine!and!related!equipment.!This!information
is!used!to!monitor!the!current!engine!operating!conditions,!and! therefore! allow! the
ECM!to!determine!the!quantity!and!timing!of!the!fuel!delivery!to!the!engine.
The! engine! control! module! (ECM)! is! mounted! on! the! left-hand! side! of! the! engine,
just!to!the!rear!of!the!fuel!pump.!All!the!information!received,!and!all!corresponding
outputs!will!enter!and!exit!the!ECM!via!two!50-pin!connectors!located!on!the!body!of
the! controller.! All! inputs! and! outputs! use! the! rearmost! 50-pin! connector,! the! foot
throttle!is!the!only!circuit!that!makes!a!connection!through!the!front!50-pin!connector.
Should! there! be! a! requirement! to! download! software! into! the! ECM,! or! to! monitor
data! for! the! aid! of! diagnostics,! this! can! be! achieved! using! the! Cummins! EST
(Electronic!Service!Tool)!by!an!authorized!Cummins!agent.!Although!a!connection!is
provided!for!at!the!controller,!it!is!not!used!by!McCormick!Tractors!as!all!fault!code
retrieval;! data! monitoring! functions! can! be! carried! out! through! the! diagnostics
connector!found!in!the!operators!cab.

SECTION!2
Engine!Control!Circuits
Accumulator
Temperature!Sensor
Oil!Pressure!Sensor
Accumulator!Pressure
Sensor
Engine!Position
Sensor
Coolant!Temperature
Sensor
Engine!Speed
Sensor
Intake!Manifold
Temperature!Sensor
Intake!Manifold
Pressure!Sensor
Engine!Control!Module
Foot!Throttle
Injection
Lift!Pump Control!Valve
Data!Bus Rear!Pumping
Connection Control!Valve
Power!Supply Front!Pumping
Control!Valve

SECTION!2
Engine!Control!Circuits
The!components!that!send!information!to!the!ECM!are:!-
•! The! accumulator! fuel! pressure! and! temperature! sensors! are! located! at! the! top
rear!of!the!injection!pump!and!indicate!the!pressure!available!to!inject!fuel!to!the
engine! and! the! temperature! of! the! fuel! to! be! injected! respectively.! The
accumulator! pressure! sensor! has! a! working! range! between! 0! bar! (0! psi)! and
1655!bar!(24000!psi).
•! The!engine!speed!sensor!is!located!at!the!left!rear!of!the!timing!gear!housing!and
indicates!the!speed!of!the!engine.!There!is!a!71-position!signal!indicator!ring!on
the!rear!of!the!cam!gear,!which!triggers!this!sensor.!At!top!dead!center,!the!signal
indent!is!removed!leaving!a!wide!blank.
•! The!engine!position!sensor!is!located!at!the!left!rear!of!the!timing!gear!housing,
next! to! the! engine! speed! sensor,! and! indicates! the! position! of! the! crankshaft
camshaft!to!allow!for!precise!timing!of!fuel!injection.!There!is!a!71-position!signal
indicator!ring!on!the!rear!of!the!cam!gear!that!triggers!this!sensor.
•! The! intake! manifold! air! temperature! sensor! is! located! on! the! left! side! of! the
cylinder!head!and!indicates!the!temperature!of!the!intake!air.
•! The! intake! manifold! pressure! sensor! is! located! on! the! left! side! of! the! cylinder
head!and!indicates!the!manifold!boost!pressure.
•! The! coolant! temperature! sensor! is! located! on! the! right! side! of! the! engine,! just
behind!the!alternator,!and!indicates!the!operating!temperature!of!the!engine.
•! The! engine! oil! pressure! sensor! is! located! on! the! left! side! of! the! engine! block
behind! the! fuel! filter.! This! sensor! indicates! the! actual! engine! oil! pressure! and,
This!information!is!transmitted!to!the!to!the!instrument!cluster!via!the!data!bus.
•! The!foot!throttle!(accelerator!pedal)!is!located!in!the!cab!and!is!connected!to!the
engine!control!module!via!dedicated!wiring!through!the!front!50-pin!connector!on
the!ECM.

SECTION!2
Engine!Control!Circuits!(Cont'd)
The!outputs!from!the!ECM!that!are!used!to!control!the!operating!state!of!the!engine
are:!-
•! The!electrically!operated!lift!pump!is!located!at!the!left!rear!of!the!engine!and!is
controlled!by!the!engine!control!module.!The!lift!pump!only!runs!for!the!first!30!ñ
60! seconds! after! the! key! switch! is! turned! on.! It! draws! fuel! from! the! tank! and
supplies!pressurized!fuel!to!prime!the!filter!and!gear!pump.!If!additional!priming!is
required,!the!key!switch!can!be!cycled!to!the!off!position!and!then!returned!to!the
on! position.! The! gear! pump! provides! the! continuous! fuel! pressure! required! for
the!injection!pump.
•! The!Cummins!CAPS!fuel!system!has!two!high-pressure!pumps!to!pressurize!fuel
to!the!very!high!pressure!required!for!injection.!An!electrically!actuated!pumping
control! valve! individually! controls! each! pumping! element.! The! engine! control
module!controls!when!the!pumping!control!valve!closes!during!the!rotation!of!the
injection!pump!crankshaft.!At!light!load!and!idle,!the!pumping!control!valve!closes
later! during! the! pumping! cycle! so! that! less! fuel! is! delivered! to! the! accumulator.
When! the! engine! is! operating! under! heavy! load! and! additional! fuel! is! required,
the! pumping! control! valve! closes! earlier! to! deliver! more! pressurized! fuel! to! the
accumulator.
•! The! injection! control! valve! is! an! electrically! operated! valve! controlled! by! the
engine! control! module,! which! controls! the! delivery! of! fuel! to! each! cylinder.! The
opening!of!the!injection!control!valve!controls!the!timing!of!injection.!The!length!of
time! that! the! valve! as! well! as! the! fuel! pressure! stored! within! the! accumulator
controls!the!total!amount!of!fuel!delivered!which!in!turn!controls!the!power!output.
The! single! injection! control! valve! ports! fuel! to! each! injector! through! a! rotary
distributor!valve.! As! the! injection! pump! rotates,! the! rotary! distributor! valve! ports
fuel!to!the!correct!injector!based!on!crankshaft!rotation.

SECTION!2
Fuel!Pump!Schematic

SECTION!2
Fuel!Pump!Operation
When!the!key!switch!is!initially!actuated,!the!lift!pump!runs!for!30!-!60!seconds!and
draws!fuel!from!the!tank!to!prime!the!system.!The!lift!pump!pressurizes!the!system
to!approximately!6.5!bar!(95!psi).!The!lift!pump!also!incorporates!a!check!valve!to
allow!fuel!flow!when!it!is!not!running.!The!fuel!filter!is!located!between!the!lift!pump
and!gear!pump!on!the!left!side!of!the!engine.
The! gear! pump! is! part! of! the! injection! pump! assembly! and! is! driven! by! the! input
shaft.!Its!purpose!is!to!provide!fuel!flow!to!the!system!during!engine!operation.!This
fuel!flow!is!delivered!to!both!the!front!and!rear!pumping!control!valves!(PCV),!which
are!mounted!on!the!top!of!the!accumulator!housing.!A!pressure!regulator!valve!that
is! integral! to! the! gear! pump! housing! controls! the! output! pressure! from! the! gear
pump.! This! regulator! valve! is! set! to! a! pressure! of! 11.5! bar! (165! psi)! and! is
considered!non!adjustable.
The! two! pumping! control! valves! are! normally! open! solenoid! valves! and! will! close
when!commanded!to!do!so!by!the!ECM.!Closing!these!solenoid!valves!will!result!in
the!high!pressure!pumping!units!to!increasing!the!fuel!pressure!from!approximately
11.5! bar! (165! psi)! to! between! 345! 1035! bar! (5000! to! 15000! psi)! required! for
injection.! The! output! pressure! from! these! pumping! elements! is! determined! by! the
fuel!requirement!of!the!engine.
The!input!shaft!in!the!injection!pump!body!has!two!tri-lobe!cams!on!the!shaft,!which
actuate!the!high!pressure!pumping!units.!Each!high!pressure-pumping!unit!actuates
three!times!each!revolution!of!the!injection!pump!shaft.!The!duration!of!the!revolution
that! the! pumping! control! valve! is! closed! controls! the! quantity! of! high-pressure! fuel
that!is!delivered.!During!the!time!that!the!pumping!control!valve!is!open,!the!output!of
the! high! pressure-pumping! unit! returns! to! the! fuel! tank! via! the! pressure! regulator
valve.! When! the! pumping! control! valves! are! closed! the! high! pressure! pumping
elements! will! deliver! the! fuel! flow,! through! one! way! check! valves,! into! the
accumulator!housing.

SECTION!2
Fuel!Pump!Operation!!(Cont'd)
The!point!at!which!the!pumping!control!valves!are!commanded!on!can!be!monitored
using! the! Cummins! Electronic! Service! Tool! (EST).! The! parameter! that! should! be
viewed! is! the! Valve! Crank! Angle! (VCA)! and! relates! to! the! angle,! in! degrees! of
rotation,!before!top!dead!center!when!the!control!valves!are!energized.
The!accumulator!stores!pressurized!fuel,!typically!at!pressures!between!345!to!1035
bar!(5000!to!15000!psi),!ready!for!injection!event.!The!accumulator!is!also!connected
to!the,!normally!closed,!injection!control!valve!(ICV)!via!the!ìRate!Shape!Tubeî.!The
injection! control! valve! opens! at! the! required! time! to! control! the! injection! timing! to
each!cylinder.!The!length!of!time!that!the!injection!control!valve!is!open!controls!the
amount!of!fuel!delivery,!which!in!turn!controls!the!power!output.
The!output!of!the!injection!control!valve!is!connected!to!the!rotary!distributor!valve!at
the! lower! rear! of! the! injection! pump.! This! rotary! distributor! valve! is! driven! by! the
pump!drive!shaft!and!is!used!to!direct!the!fuel!to!the!required!injector.

SECTION!2
CAPS!Fuel!System
The!Cummins!Accumulator!Pump!System!(CAPS)!consists!of!six!basic!components,
components!are!separate!assemblies!and!will!be!discussed!individually.
The!fuel!pump!body!is!directly!connected!to!the!engine!timing!cover!and!includes!the
input!shaft!and!camshaft!lobes!that!actuate!the!high!pressure!pumping!units.
The! gear! pump! is! mounted! to! the! rear! of! the! fuel! pump! body! and! is! driven! by! the
input!shaft;!a!small!internal!coupling!connects!the!two!components.!The!gear!pump
will!take!fuel!from!the!fuel!tank!and!pass!it!through!the!fuel!filter.!It!will!then!make!it
available!to!the!inlet!of!the!high!pressure!pumping!units.!The!outlet!pressure!of!this
pump!is!regulated!to!approximately!11.5!bar!(165!psi).
The! accumulator! assembly! mounts! directly! to! the! top! of! the! fuel! pump! body! and
consists!of!the!following!components:!-
•! The! camshaft! in! the! fuel! pump! body! actuates! the! high-pressure! pumping! units.
These! units! take! fuel! delivered! by! the! gear! pump! and! increase! the! pressure! to
that! required! for! injection! into! the! combustion! chamber.! The! outlet! pressure! of
these! units! is! typically! regulated! between! 345! to! 1035! bar! (5000! to! 15000! psi).
Individual!pump!control!valves!control!the!outlet!flow!of!these!pumping!units.
•! Electrically! operated! pump! control! valves! are! located! on! the! top! of! the
accumulator! assembly.! The! timing! of! the! actuation! of! these! valves! controls! the
quantity! of! fuel! delivered! by! the! high! pressure! pumping! units! and! therefore! the
injection!pressure.!The!engine!control!module!controls!these!valves.!These!pump
control! valves! are! installed! and! calibrated! on! initial! assembly! and! cannot! be
adjusted.! Replacement! of! a! faulty! pumping! control! valve! would! require! a! new
accumulator!assembly
•! The! accumulator! portion! of! the! accumulator! assembly! consists! of! drilled
passages!within!the!accumulator!body.!The!accumulator!function!is!based!on!the
fact! that! diesel! fuel! is! approximately! 8%! compressible! at! 1035! bar! (15000! psi).
These! drilled! passages! are! sealed! with! plugs! that! have! seal! discs! under! them.
These!seal!discs!are!currently!not!available!as!separate!service!parts.

SECTION!2
CAPS!Fuel!System!(cont'd)
•! The! accumulator!fuel!pressure!and! temperature! sensor! is! located! at! the! rear! of
the!accumulator!assembly.!This!sensor!monitors!the!pressure!and!temperature!of
the!high-pressure!fuel!stored!in!the!accumulator.!This!sensor!sends!information!to
the!engine!control!module.
•! The!rate!shape!tube!is!located!at!the!top!rear!of!the!injection!pump!assembly!and
ports! the! high-pressure! fuel! from! the! accumulator! to! the! injection! control! valve.
The!length!of!this!tube!controls!the!shape!of!the!injection!line!pressure!rise!curve.
The! length! of! this! tube! affects! NOX! emissions.! Do! not! bend! this! tube! during! or
after!installation.

SECTION!2
CAPS!Fuel!Pump!Components
Rate!Shape!Tube
Accumulator
Distributor!Housing
Gear!Pump
Assembly
Fuel!Pump
Body

SECTION!2
CAPS!Fuel!Pump
Pumping!Control
Valves
Accumulator
Housing
Injection
Control!Valve
Rate
Shape
High!Pressure
Pumping
Elements
Fuel!Pump Distributor
Body Valve
Drive
Gear Coupling
Tri-lobe Pump
Cams
Drive
Coupling

SECTION!2
CAPS!Fuel!System!(cont'd)
The! injection! control! valve! (ICV)! is! located! at! the! rear! of! the! injection! pump.! This
control! valve! is! an! electrically! operated! valve! commanded! by! the! engine! control
module! (ECM),! which! controls!the! delivery! of!fuel! to! each! cylinder.! The! opening! of
the!injection!control!valve!controls!the!timing!of!injection.!The!length!of!time!that!the
valve!is!open,!as!well!as!the!fuel!pressure!stored!within!the!accumulator!controls!the
total! amount! of! fuel! delivered,! which! in! turn! controls! the! power! output.! The! single
injection! control! valve! ports! fuel! to! individual! injectors! through! a! rotary! distributor
valve.
The!rotary!distributor!control!valve!is!located!at!the!lower!rear!of!the!injection!pump
and! is!driven! from!the! gear! pump! shaft;!a! small! internal! coupling! connects! the! two
components.!As!the!injection!pump!rotates,!the!distributor!will!control!which!injector
is!supplied!with!fuel,!based!on!the!rotation!of!the!crankshaft.
The! injectors! are! located! at! the! top!of! the! cylinder! head! centered! over! the! pistons.
The! injectors! inject! atomized! fuel! into! the! combustion! chamber! during! the! power
stroke!of!the!combustion!cycle.

SECTION!2
Engine!Troubleshooting
Retrieval! of! fault! code! information! from! the! Engine! Control! Module! can! be! done
through!the!instrument!cluster,!or!with!the!Cummins!Electronic!Service!Tool!and!the
McCormick!Diagnostic!Tool
Engine! troubleshooting! information! is! available! in!the! QSC! Engine! Troubleshooting

Manual!(available!from!Cummins).
If!QSC!engine!running!problems!are!encountered:!-
•! Inspect!the!fuel!level!in!the!tanks;
•! Check!for!air!leaks!and!restrictions!in!the!fuel!inlet!system;
•! Inspect!for!air!intake!problems;
•! Inspect!for!mechanical!problems;
•! Inspect!for!rotary!distributor!valve!problems;
•! Inspect!for!injector!problems;
•! Check!for!fault!codes!using!the!tractor!instrumentation!or!the!electronic
service!tool.

SECTION!2
Fuel!Pump!Distributor!Valve!Inspection
Remove!the!key!from!the!ignition!switch
to! prevent! any! attempt! at! starting! the
engine.
!Thoroughly! clean! the! area! around! the

fuel! pump.! Pay! particular! attention! to
the!rear!connections!area.
After! removing! the! front! access! cap,

rotate!the!engine!using!the!turn!over!tool
until! the! Timing! mark! on! the! pump! drive
gear! aligns! with! the! TDC! mark! on! the
timing!cover.
Remove!the!distributor!plug!(1).
Do! not! attempt! to! start! the! engine! with

the! distributor! plug! removed.! To! do! so
could! result! in! the! rotor! being! ejected
from! the! distributor,! causing! damage! to
the!rotor.
Check! the! position! of! the! notch! on! the

rotor.! It! should! line-up! with! the! alignment
mark!(A)!on!the!outside!of!the!distributor.!If
the! alignment! is! correct! the! rotor! is
properly!timed!to!the!engine.
If! the! alignment! is! incorrect! inspect! the

internal!drive!couplings.
Replace! distributor! plug! oíring! as

necessary.

SECTION!2
Recommendations!For!Bleeding!CAPS!Fuel!System
Crank!the!engine,!checking!for!exhaust!smoke!or!no!exhaust!smoke!and!follow!the
appropriate!troubleshooting!tree!of!the!lnsite!diagnostic!information.
If! the! engine! cranks! but! does! not! start! after! running! out! of! fuel,! and! there! is! no
smoke!from!the!exhaust,!carry!out!the!following!procedure:!-
•! Confirm!that!the!fuel!level!is!low!and!fill.
•! Check!instrumentation!for!engine!faults.
•! Confirm!the!electric!lift!pump!run!after!the!key!switch!is!activated.
•! Refer!to!the!relevant!sections!service!manual!as!required.
1.! Loosen!the!fitting!(1/18"!pipe!plug)!at!the!outlet!of!the!fuel!filter.
2.! Cycle!the!electric!lift!pump!with!the!key!switch!until!air!is!purged.
3.! If!air!cannot!be!purged!after!several!cycles!of!the!lift!pump,!an!air!leak
may!be!present.!Check!the!fuel!supply!system!from!the!fuel!tank!to!the
fuel!filter.
•! If!engine!does!not!start!after!purging!air,!check!for!battery!voltage.
•! Check!Engine!Control!Module!for!6.5!VDC!minimum!during!engine!cranking.
•! Recheck!for!exhaust!smoke!during!cranking!and!go!back!to!appropriate!fault
trouble!shooting!tree.

Cummins QSC 8.3 Litre Tier III
Extract from Cummins Product Announcement July 2006.

Not to be reproduced in hard copy or electronic form or used for any purpose without
the consent of Cummins Ltd.
McCormick Product Support January 2007

Introduction to the QSC 8.3 litre Tier III engine.
QSC Tier III Engine View.
The QSC8.3 with CM850 engine is designed to meet the Environmental

Protection Agency (EPA) Tier III levels.
Engine Configuration Numbers
The configuration numbers for the QSC engine is as follows.
Engine type Configuration Number

QSC D413055CX03

Design Features
Cylinder Block – Overview

The QSC8.3 with CM850 utilizes the same connecting rod bearing shell for
the upper and lower location. The construction is similar to previous product
bearings with the exception of a narrower base to accommodate the
crankshaft fillet radii changes. The QSC8.3 with CM850 engine is equipped
with J-jet directed piston cooling nozzles. The nozzle geometry is similar to
the ISL with CM554 with slight changes to the oil spray targeting for improved
cooling of the piston. A standard cap screw secures the piston cooling nozzle,
replacing a banjo style bolt for added strength and oil flow.
The primary speed indicator ring has been moved internally and mounted to
the crankshaft. The new indicator ring provides increased speed resolution for
the Cummins Common Rail Fuel System. To calculate the engine speed and
position, a sensor is mounted at the rear of the block on the intake side of the
engine.
The secondary (backup) indicator pick-ups are cast into the camshaft gear.
The secondary sensor is located in the backside of the gear housing.
Due to geometrical differences, the primary and secondary speed sensors are
not interchangeable and have different part numbers.

Rocker Levers – Overview
The crankcase breather system utilizes a baffle system that is mounted on the
valve cover. The breather contains two tubes. The larger tube is the
crankcase gas draft tube. The smaller tube is for draining oil that is
accumulated in the valve cover baffle. The oil is drained back to the oil pan
through a port on the lower intake-side of the cylinder block. There is no
maintenance required for any breather system components.
A rocker housing spacer is required on the QSC8.3 engine to accommodate a

pass-through location for the injector wiring harness. The rocker housing
utilizes a press-in-place gasket to form a seal with the cylinder head. The
valve cover is mounted to the rocker housing by cap screws, isolators, and a
press-in-place gasket.

Camshaft Followers/Tappets - Overview
The QSC8.3, with CM850 engine is equipped with new roller tappets. The
new design incorporates larger diameter rollers to reduce the load on the
camshaft and improve durability.
Fuel System – Overview

General Fuel System Notices
WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment,
and switches out of the work area and areas sharing ventilation to reduce the
possibility of severe personal injury or death when working on the fuel system.
CAUTION
To reduce the possibility of engine damage, always use the proper torque on
the high-pressure line nuts.
The Cummins Common Rail Fuel System is a high-pressure common rail

injection system. A fuel rail is used to store pressurized fuel for fuel injection.
There are four components that provide or receive input to the electronic
control module (ECM). The ECM powers the electric fuel lift pump (located
behind the ECM) for approximately 30 seconds at key-on to make sure the
fuel system is primed. The normally open fuel pump actuator receives a pulse
width modulated (PWM) signal from the ECM to open or close in response to
the signal from the fuel rail pressure sensor. The injectors have individual
solenoids. The ECM powers each injector individually to provide fueling to
each cylinder.

The high-pressure fuel pump can be divided into four distinct assemblies.
They are the fuel gear pump, fuel pump actuator housing, cam housing,
and high-pressure fuel pump head. Fuel flows through the gear pump to a
2-micron pressure-side filter.
After the pressure-side filter, fuel enters the fuel pump actuator housing. The
fuel pump actuator housing includes an air-bleed fitting and the fuel pump
actuator. Some fuel continuously returns to drain through the air-bleed orifice
fitting. Fuel that is metered through the fuel pump actuator enters the high-
pressure fuel pump head where it is pumped to fuel rail pressure and exits at
the high-pressure outlet fitting.
A lift pump is used for priming the gear pump at start-up. The lift pump runs
for approximately 30 seconds after key-on. Once the engine is started, the
gear pump is able to maintain prime without any assistance from the lift pump.
The ECM and ECM cooling plate must be removed to access the lift pump
and lift pump fuel lines. This is accomplished by disconnecting the engine
harnesses and the quick disconnect style fuel lines first. Removal of the ECM
cooling plate cap screws allows the ECM, cooling plate, lift pump and lift pump
plumbing to be removed as one assembly.

The gear pump output is routed to a 2-micron fuel filter. The filtered fuel
returns to the fuel pump actuator housing. The high-pressure pump is driven
by the engine camshaft. The gear pump is driven by the pump camshaft
through an internal coupling.
Each of the two pumping plungers is driven by a three lobed camshaft. The
camshaft is located in the cam housing module by tapered roller bearings.
The bearings that support the camshaft, as well as the tappets, rollers and
camshaft itself are lubricated with engine oil. These are the only components
in the pump lubricated with engine oil.
Engine oil to the high-pressure pump is supplied through a drilling in the
engine gear housing. The oil passes from the engine gear housing to the high-
pressure pump cam housing. A small o-ring in a recess on the back of the
engine gear housing seals this passage.

Pressurized fuel from the gear pump is supplied to the fuel pump actuator.
The fuel pump actuator is opened or closed by the ECM to maintain the
appropriate fuel rail pressure.
An air-bleed orifice fitting in the fuel pump actuator housing aids in purging air
from the fuel supply. Because of the air-bleed orifice fitting, some fuel that is
supplied by the gear pump will return to drain at all times.
Fuel that is metered past the fuel pump actuator enters the high-pressure fuel
pump inlet drilling, past the inlet check valve and fills the pumping chamber by
pressing the pumping plunger downward. When the camshaft pushes the
pumping plunger upward, fuel reaches rail pressure and causes the outlet
check valve to lift. Fuel then enters the outlet drilling of the fuel pump and
exits the high pressure fuel line to the fuel rail.

Injectors and Fuel Lines - Overview
WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing
equipment, and switches out of the work area and areas sharing
ventilation to reduce the possibility of severe personal injury or death
when working on the fuel system.
High-pressure common rail fuel systems use solenoid-actuated injectors.
High-pressure fuel flows into the side of the injector. When the solenoid is
activated, an internal needle lifts and fuel is injected. The clearances in the
nozzle bore are extremely small and any dirt or contaminants will cause the
injector to stick. This is why it is important to clean around all fuel connections
before servicing the fuel system. Also, cap or cover any open fuel connections
before a fuel system repair is performed.
High-pressure fuel is supplied to the injector from the fuel rail by an injector
supply line and a fuel connector. The fuel connector pushes against the
injector body when the fuel connector nut is tightened. The injector supply line
is then connected to the fuel connector.
CAUTION
To reduce the possibility of engine damage, always use the proper
torque on the high-pressure line nuts.
The torque and sequence for this joint is critical. If the nut or line is under-
tightened, the surfaces will not seal and a high-pressure fuel leak will result. If
the nut is over-tightened, the connector and injector will deform and cause a
high-pressure fuel leak. This leak will be inside the head and will not be
visible. The result will be a fault code, low power, or no-start.
If the injector is not fully seated prior to the installation of the high-pressure
connector, the joint will not seal.

The fuel connector contains an edge filter that breaks up small contaminants
that enter the fuel system.
The edge filters are not a substitute for cleaning and covering all fuel system
connections during repair.
Be sure to cap or cover all fuel fittings and ports.
All injectors feed into a common return drilling contained within the cylinder
head. Any excess fuel is returned to the tank via this drilling and return line
attached to the rear of the cylinder head. A back-pressure valve is located on
the back of the cylinder head where the drain line attaches.
The electronic control module (ECM) controls the fueling and timing of the
engine by actuating the injector solenoids. An electronic pulse is sent to the
solenoids to lift the needle and start the injection event. By electronically
controlling the injectors, there is a more precise and accurate control of fueling
quantity and timing. Also, multiple injection events can be achieved by
electronically controlling the injectors.
Fuel Filters
The QSC8.3 with CM850 engine, requires original equipment manufacturers
(OEM's) to mount a 10-micron suction filter prior to the OEM fuel supply
connection at the rear of the engine block. The 10-micron filter performs water
stripping and includes a water-in-fuel sensor. The water-in-fuel sensor must
be installed. If not, a fault code warning lamp will be active.
The QSC8.3, with CM850 engine includes a 2-micron pressure-side fuel
filter. The pressure-side filter will be located downstream of the gear pump

before the high-pressure fuel pump inlet. If a water-in-fuel fault is
experienced, drain the water stripping filter and replace the pressure side
fuel filter.
Air Intake System - Overview
The QSC8.3 engines utilize a Holset® waste gated turbocharger. The waste
gate is pneumatically controlled by intake manifold pressure and factory
calibrated. The waste gates are not adjustable in the field.
Engine Data plate

The engine data plate provides important facts about the engine. The engine
serial number (ESN) and control parts list (CPL) provide information for
service and ordering parts. The engine data plate must not be changed
unless approved by Cummins Inc.
The data plate is located on the top side of the gear housing.
If the engine data plate (1) is not readable, the ESN (2) can be found on the
engine block on top of the lubricating oil cooler housing. Additional engine
information is on the electronic control module (ECM) data plate.

Fuel Injection Pump Data plate
The Cummins Common Rail Fuel System data plate is located on the side of
the high-pressure pump. The data plate contains the following information:
A. Cummins part number
B. Pump serial number

C. Factory code.
The ECM dataplate is located on the front of the ECM. The following
information is found on the ECM dataplate:
• ECM part number (PN)
• ECM serial number (SN)
• ECM date code (DC)
• Engine serial number (ESN)
• ECM Code (identifies the software in the ECM).
Flow Diagram, Fuel System

1. Fuel from supply tank
2. Fuel filter and water separator
3. OEM fuel supply connection
4. Fuel supply to ECM mounted fuel lift pump
5. ECM cooling plate
6. ECM mounted fuel lift pump
7. Fuel outlet from ECM mounted fuel lift pump
8. Fuel gear pump
9. Fuel from gear pump to fuel filter
10. Primary fuel filter
11. Fuel inlet to fuel pump actuator
12. High-pressure fuel pump
13. Fuel outlet from high-pressure pump
14. High-pressure pump drain flow connection
15. Fuel rail
16. High-pressure injector supply lines
17. High-pressure fuel connector
18. Fuel injector
19. Fuel pressure relief valve
20. Fuel injector drain flow line
21. Fuel return to supply tanks
Electronic Engine Controls – Overview

The electronic control module (ECM) controls all engine operations and is
fuel-cooled by a cooling plate. The CM850 module on the QSC8.3, engine
processes all sensor inputs and sends commands to, performs calculations
for, and monitors the following:
• Fueling and timing
• Turbocharger boost pressure
• Operator interface data communications
• Auxiliary systems control
• Market-specific features.
The CM850 utilizes a 50-pin connector for the OEM harness, a 60-pin
connector for the engine harness, and a 4-pin connector for the un-switched
power supply harness. The ECM power connector must be directly connected
to the vehicle batteries to meet the supply voltage requirements.

Several new sensors have been added to monitor and control the new fuel
system and turbocharger. The following is a list of sensors on the engine:
• Coolant temperature sensor
• Intake manifold temperature sensor
• Intake manifold pressure sensor
• Primary engine speed/position (crankshaft) sensor
• Secondary engine speed/position (camshaft) sensor
• Fuel pressure sensor
• Oil pressure sensor
• Water-in-fuel sensor
• Ambient air (barometric) pressure sensor

Application
Engineering
Bulletin
Subject This AEB is for the following applications:
Datalinks and Diagnostics
Automotive Industrial Power Generation
Date June 2001 Page 1 of 64 AEB Number 15.43
Engine Models included: QSB, QSC, QSL9, QSM11, QSX15, QSK19, QST30, QSK45, QSK60
Fuel Systems included:
Introduction
The Quantum Diagnostic and Serial Communication Technical Package was written to assist OEMs in integrating
Quantum engines into their equipment. This technical package includes the diagnostic codes supported by the
Quantum engines as well as the J1587 and J1939 messages supported.
Refer to the following other Industrial AEB’s:
AEB 15.40 – Electronic Features
AEB 15.42 – OEM Components and Interfaces
AEB 15.44 – Installation Recommendations
Authors: Scott Decker, Michael L. Hill, Brian Landes, Jeffrey Martin, Stewart Sullivan, Tiffany Walker
AEB15.43
Page 2 of 64
Table of Contents
Introduction ......................................................................................................................................... 1
Table of Contents................................................................................................................................. 2
Section I – Quantum Diagnostics...................................................................................................... 3-5

Advanced Diagnostics................................................................................................................... 3-5
Onboard Diagnostics .................................................................................................................... 3-4
Offboard Diagnostics ....................................................................................................................... 5
Section II ECM Serial Communications.................................................................................... 6-39

Quantum Serial Communications................................................................................................ 6-35
Introduction ..................................................................................................................................... 6
Applicable SAE Documents........................................................................................................... 6-7
Applicable Cummins Documents....................................................................................................... 7
J1939 Installation Information ........................................................................................................ 7-9
1. Mandatory EA (datalink) options for QSM11 and QSX15.......................................................... 7
2. J1939................................................................................................................................... 7
3. Cabling................................................................................................................................. 8
4. Connections.......................................................................................................................... 8
5. J1939 Cable and Connector Suppliers .................................................................................... 9
J1587 Installation Information ......................................................................................................... 12
1. Cabling............................................................................................................................... 12
2. Connections........................................................................................................................ 12
3. J1587 Cable and Connectors Supplier.................................................................................. 12
Messages Supported on Quantum Modules .................................................................................... 14
1. Messages Supported on J1939 ....................................................................................... 14-15
2. PIDS Supported on J1587 ................................................................................................... 32
Network Utilization..................................................................................................................... 36-39
J1939 Network Utilization.......................................................................................................... 36-39
Section III – Diagnostics Supported over Quantum Datalinks............................................................ 40

Supported Messages and Source Addresses for Clearing Faults................................................... 40
Frequently Asked Questions on Cummins Datalinks................................................................. 40-41
Figure 1 – Typical J1939 Topology for On-Highway Applications...................................................... 10
Figure 2 – Typical J1939 Topology for Construction/Agriculture Applications.................................. 11
Figure 3 – Example of J1587 Topology .............................................................................................. 13
Table 1 – Messages Supported on J1939...................................................................................... 16-29
Table 2 – Cummins Specific Information for PGN 65229 (DM4).......................................................... 31
Table 3 – PIDS Supported on J1587 .............................................................................................. 33-36
Table 4 – J1939 Messages Non-multiplexed – vs- Multiplexed.......................................................... 38
Table 5 – Fault Codes for Quantum Engines................................................................................. 42-64

AEB15.43
Page 3 of 64
Section I – Quantum Diagnostics
Advanced Diagnostics
Advanced diagnostics are included to make Quantum engines straightforward to repair and service. Diagnostic
examination of a fault or maintenance condition can occur through onboard or offboard systems.
Onboard Diagnostics
• Extensive fault detection fault capability within the ECM

• Flash out of fault codes
• Fault lamps located on the cab dash to indicate warning/stop
• Maintenance lamp
Offboard Diagnostics
• INSITE a windows-based PC service tool for Cummins Quantum engines. It is used to help troubleshoot and
repair the Quantum engines. This tool is capable of doing diagnostics and programming.
Onboard Diagnostics
1. Fault Detection
Faults are detected while the key switch is on, during the operation of the machine itself. If a fault becomes active
(currently detected) at this time, a fault is logged in memory and a snapshot of engine parameters is logged. In
addition, certain faults may illuminate the warning lamp (amber) or the stop lamp (red), the maintenance lamp or
WIF lamp depending on the severity of the active fault.
2. Flash Out of Fault Codes
Fault flash out mode can be entered through the use of a diagnostic switch or the accelerator pedal. To enter the
fault flash out the key switch must be on with the engine not running. When a diagnostic switch is used to enter
the mode, the ECM will automatically flash the first fault code after the switch is turned on. The diagnostic
increment/ decrement is used to sequence forward or backwards through the active faults. To enter fault flash out
mode using the accelerator pedal, the pedal must be cycled from 0 to 100% 3 times. Once in diagnostic mode,
cycling the accelerator pedal will sequence forward through the active faults. The diagram below depicts the
pattern of the fault code flash out scheme as indicated by the stop lamp.
Example Fault Code Sequences

Fault Code 244: P = Pause
WARNING WARNING WARNING WARNING WARNING
STOP P STOP P STOP P STOP P STOP

Maintenance Maintenance Maintenance Maintenance
Maintenance
1 Blink 2 Blinks 4 Blinks 4 Blinks 1 Blink

Fault Code 112:
WARNING WARNING WARNING WARNING WARNING
STOP STOP STOP STOP STOP

P P P P
Maintenance Maintenance Maintenance Maintenance Maintenance
1 Blink 1 Blink 1 Blink 2 Blinks 1 Blink

AEB15.43
Page 4 of 64
3. Fault Lamps
The Quantum systems use up to five indicator lamps with one of the lamps serving two functions: the stop lamp,
the warning lamp, the maintenance lamp/engine protection lamp (all engine families use one of these lamps, but
not both), wait-to-start lamp, and a water-in-fuel lamp. If the key switch is turned on but the diagnostic switch
remains off, the indicator lamps will illuminate for approximately two seconds and then go off, one after the other,
to verify they are working and wired correctly. See illustration below where they are all on and then go off one at
a time.
Fault Lamp Sequence
WARNING WARNING WARNING WARNING
STOP STOP STOP STOP

Maintenance Maintenance Maintenance Maintenance
Warning Lamp - All Quantum Engines - The warning lamp provides important operator messages. These
messages require timely operator attention. The warning lamp is also used to delineate diagnostics fault codes.
P = Pause
Stop Lamp - All Quantum Engines - The stop lamp provides critical operator messages. These messages
require immediate and decisive operator response. The stopP lamp is also used to flash out diagnostic fault codes.
Wait-to-Start Lamp - QSB/C/L, QSM11, QSX15, QST30 - The wait-to-start lamp indicates that the pre-start
intake manifold heater warm-up sequence is active. An OEM-supplied grid heater will automatically heat the
intake manifold when needed prior to engine starting. Intake manifold heating improves engine starting in cold
temperatures and reduces white smoke.
Water-in-Fuel (WIF) Lamp - QSB/C/L - The water-in-fuel lamp indicates there is water in the fuel. When the
lamp is illuminated the vehicle driver/operator should release the water from the fuel filter.
Maintenance Lamp - QSB/C/L, QSM11, QSX15 - Upon ECM power up the maintenance lamp will flash when it
is time to change the oil. It also will illuminate during engine operation when certain lower priority faults are
present.
Engine Protection Lamp - QSK19/45/60, QST30 - The engine protection lamp will illuminate when an engine
protection fault is present. It is possible, through OEM wiring, to configure the system to use the red/stop lamp for
engine protection faults. This is done through wiring the red lamp to both the red/stop lamp input and the engine
protection lamp input on the ECM. If the engine protection lamp signal is being used to control other functions
such as the vehicle propel circuit, a diode must be inserted in the circuit.
Optional - 2 Lamp Strategy - QSK19/45/60 - The Optional 2-lamp strategy will eliminate the Engine Protection
(white) Lamp. Therefore, the operator will only have a warning (yellow) and stop (red) lamp on the dashboard.
All of the faults that were mapped to the Engine protection lamp will become annunciated through the stop (red)
lamp. This change will only affect the wiring of the fault lamps and not the software or calibration. See wiring
below.
AEB15.43
Page 5 of 64
Engine ECU
Stop Lamp Drive
Warning Lamp
Drive
Engine Protection
Lamp Drive
Diagnostic
Switch To Vehicle
Propel Circuit
(when used)
To Ground
Power Connection
Optional 2-Lamp Strategy Wiring
Offboard Diagnostics
INSITE is the windows-based PC service/programming/diagnostic tool for Cummins Quantum engines. It is used
to help troubleshoot and repair the Quantum engines with extended fault diagnostics and processing power.
INSITE allows the user to view active and inactive faults and clear the inactive faults. It provides a monitor
function that allows the service technician to monitor measured parameters, actuator status and some calculated
values. It also provides the technician with the capability to turn on certain drivers such as the grid heaters and lift
pump as well as running diagnostic tests such as single cylinder cutout. Currently, Insite capability is different per
each Quantum engine. Therefore, the examples mentioned are only applicable to certain engine families.
AEB15.43
Page 6 of 64
Section II – ECM Serial Communications
Quantum Serial Communications
The intent of this document is to provide information pertaining to application of the Quantum controller’s serial
communications interface to machines. The contents of this document are divided into two broad categories.
The first category caters to OEMs who are involved in building machines; therefore installing datalinks is their
primary concern. This category provides information on cables, connectors and it lists datalink devices that have
been tested by Cummins as being compatible with Quantum controllers. The second category captures
information to be used by OEMs and component suppliers who design datalink devices that will interface with
Quantum controllers. This category has details pertaining to message support, parameter characteristics,
network utilization and diagnostics.
Introduction
Datalinks provide the means for electronic devices on the machine to interact with each other. Some typical
functions performed are sharing of sensor data, sharing of calculated information, allowing subsystems (e.g.
engine, transmission, etc.) to influence each others operation, communication of subsystem operation state.
Datalinks also provide a means for on and off board diagnostic work to be done.
The Quantum controllers have been designed with two independent serial communications ports. One port
provides access to SAE J1939 and is J1939-11 compatible, while the other is for SAE J1587 and is compatible
with J1708. There is no support for SAE J1922 on Quantum controllers.
SAE J1939 datalink is a high-speed network for machines that operate at 250K baud. It is capable of supporting
control, information sharing, diagnostics, multiplexing and proprietary communications. The J1939 (physical
layer) datalink uses a differential line driver circuit and allows a maximum bus length of 40 meters. The network
can have a maximum of 30 node connections at a given time.
SAE J1587 is a J1708 based network that operates at 9600 baud. It supports information sharing, diagnostics
and proprietary communications. The network can have a maximum of 20 node connections at a given time.
Both J1939/J1587 datalinks on Quantum controllers are active when the machine key-switch is turned on.
Applicable SAE Documents
This document, along with the SAE specifications listed below, contain the information required to apply the
Quantum datalink interfaces (both J1939 and J1587) to machine applications.
SAE 1939 Recommended Practice for a Serial Control and Communications Network (April
1997). Provides a list of all of the J1939-xx documents that are planned. It provides
a brief tutorial about the overall set of documents and basic operation of the network.
SAE J1939-11 Physical Layer (March 1997). Operates at 250K bits/sec, linear bus with shielded
twisted pair cable with a drain.
SAE J1939-12 Physical Layer (Working draft is ISO 11783 Part 2, May 1997). Operates at 250K
bits/sec, linear bus with twisted quad cable
SAE J1939-13 Off-board Diagnostic Connector (January 1997). Specifies 9-pin Deutsch that will
provide a connection to J1939, J1587, a second CAN network for implements,
unswitched power and ground.
SAE J1939-21 Data Link Layer (July 1998). Specifies CAN 2.0b as the message protocol to be
used. Also defines an interface to the application layer of J1939.
AEB15.43
Page 7 of 64
SAE J1939-71 Vehicle Application Layer (May 1996 plus 1/97 addendum). Defines transmitted
parameter value interpretation rules that allow receiving devices to determine if the
sending device is able to supply all parameters associated with the parameter group,
if any of the parameters has an error condition or if the signal is valid.
SAE J1939-73 Diagnostic Application Layer (October 1998)–Diagnostics. Defines capability

required to perform diagnostics on J1939 strategy to identify the least repairable
subsystem that failed, how it failed, read and clear diagnostics fault codes,
communication of diagnostic lamp status and providing a variety of parameters for
monitoring by the service tool.
SAE J1939-81 Network Management (November 1996)
SAE J1587 (March 1996 plus 1/97 addendum)–Joint SAE/TMC Electronic Data Interchange
Between Microcomputer Systems in Heavy Duty Machine Applications. Defines
format of messages and data and guidelines for the frequency and circumstances in
which messages are transmitted.
SAE J1708 Physical Layer (October 1993)–Serial Data Communications Between

Microcomputer Systems in Heavy Duty Machine Applications.
Applicable Cummins Documents
Additional information on the data links can be found in the following Cummins Engineering Standards and
documents:
Interface Specification: 1377-9804 - J1939 Multiplexing of Inputs and Outputs. Provides the signal processing
requirements for information that will be supplied to/from engine by the J1939 datalink rather than by discrete
wires (e.g. cruise control switch inputs, lamp outputs etc.).
AEB 15.44 Quantum Installation Recommendations document.
J1939 Installation Information
This section provides information required by those involved in installing J1939 datalinks on their machines.
Please refer to AEB 15.44 - Quantum Installation Recommendations for further details.
1. Mandatory EA (datalink) Options for QSM11 and QSX15
There are two required main types of EA options for QSM11 and QSX15 that must be ordered because the
datalink does not ship on either of these engines.
The first option consists of the datalink and backbone being supplied by the OEM as a part of the OEM harness;
therefore, the engine will ship without a 9-pin datalink connector. The other option consists of the datalink and
backbone being supplied by Cummins; therefore, it will ship with the datalink connection installed on the engine.
When using the second option the OEM will have a 47-pin Deutsch connector as the interface instead of
connecting directly to the 50-pin OEM connection on the ECM. This option will include a 9-pin connector, 3-pin
connector, a 50-pin connector and a 47 pin round connector. The 3-pin connector is setup as a termination with a
120 ohm terminating resistors supplied. Please refer to AEB 15.44 for wiring this option.
2. J1939
To install J1939 datalink on a machine, it is important to understand the requirements relating to cabling and
connectors. The following section provides details on both. It also provides information on some suppliers to
procure cabling and connectors.
AEB15.43
Page 8 of 64
3. Cabling
Backbone - It is a linear bus with a maximum length of 40 meters (approximately 131 feet). At a given time, the
maximum number of nodes (electronic controllers) that can be connected to the backbone is 30. Note that B and
B MATE (STYLE 2 Keying) is the backbone and termination connector keying, where B is the receptacle and B
MATE is the plug.
For J1939-11 compliance, the backbone is a twisted shielded pair with a drain and requires passive termination
resistors at each end of the network. The J1939-11 topology is typically used for automotive/ on highway
applications. Please refer to Figure 1.
For J1939-12 compliance, the backbone is a twisted quad and requires an active termination and bias circuit at
each end of the network. This physical layer eliminates the need for shield required in J1939-11. The physical
layer also uses a transceiver circuit design, which allows J1939-11 nodes to exist on the same network as the
J1939-12 nodes.
Stub - The connection from the backbone to each node (electronic controller) is called a stub and it can be a
maximum of 1-meter (approximately 3.3 feet) in length. Please refer to Figure 1.
Shield - Electrical connection to the shield is achieved by the drain wire at bus connection points for the nodes
(electronic controllers) and at the main bus interconnects. Also note that the shield should be grounded only at
one point with a connection to the battery negative. Although the shield does not provide coverage in the area
where connections are made to the linear bus or at the stub connector (read section below for details) locations, it
is connected electrically to the next segment of the shielded cable, and provides sufficient coverage to provide the
necessary electromagnetic compatibility (EMC) improvements.
4. Connections
Engine Connections - The Quantum controller may be connected to the backbone by a 3-pin unshielded
connector called a stub connector. This is illustrated by the manner in which ECU 1 is connected to the backbone
in Figure 1. The stub connector has a special keying (STYLE 1 Keying) and is shown in Figure 1 as A and A
MATE, where A MATE is the mating half. For a connection type as shown for ECU 1 in Figure 1, one of the three
pins will be used to pass the drain wire through to the mating half (A MATE) of the stub connector, in order to
allow the electrical continuity of the shield to be maintained. Two other alternatives for connecting electronic
controllers to the backbone as supported by SAE J1939 are shown in Figure X. It should be noted that the
connection of ECU 2 provides the best case EMC improvement (i.e. shortest possible stub).
Note: The OEM must supply a J1939 service connection on engine when creating a backbone harness.
Diagnostic Connections - The diagnostic connector is a 9-pin Deutsch and will provide a connection to J1939, a
second CAN network for implements (for Agriculture/Construction Application), unswitched power and ground.
The maximum allowed distance of the diagnostic connector from the backbone is two-thirds of 1 meter (0.67
meter). The remaining one-third of 1 meter (0.33 meter) is the maximum allowed distance between the diagnostic
connector and the interface circuitry of the tool that is connected to the diagnostic connector.
For the automotive/ truck industry the SAE preferred location of the connector is in the cab area on the operator’s
side and should be accessible from the ground on the operator’s side. For a 6-pin installation for J1587 the
Deutsch HD10-6-12P connector is recommended. A 9-pin installation for J1939 and J1587 is suggested to use
the Deutsch HD10-9-1939P connector - Please refer to AEB 15.10 section 4.0 for more details.
Bulkhead Connection - The J1939 datalink may be routed through the OEM bulkhead connector. To reduce the
chance of electrical noise affecting the datalink, it is recommended that the wires not be placed adjacent to
circuits with extremely high current loads or switching currents. It is recommended that the installer design
flyback diodes on all relays to prevent system noise issues.
AEB15.43
Page 9 of 64
5. J1939 Cable and Connector Suppliers
J1939 compatible connectors and cabling are now available through many local and national distributors. For
application information and to locate distributors in your area, contact the following companies:
Connectors
Deutsch Industrial Products Division Packard Electric
37140 Industrial Avenue P.O. Box 431
Hemet, CA 92543 Warren, OH 44486
Phone: (714) 929-1200 1-800-722-5273
(909) 765-2250
Fax (714) 652-9784
Deutsch Distributor
Ladd Industrial Sales
1-800-223-1236
Cabling
Belden Wire and Cable Company Champlain Cable Corporation
2200 U.S. Highway 27 South 12 Hercules Drive
P.O. Box 1980 Colchester, Vermont 05446
Richmond, IN 47345 Phone: 1-800-451-5162
Phone: 800-235-3361
Fax: (765) 983-5737
BICC Brand-Rex Ltd. Waytec Inc.

Viewfield Industrial Estate P. O. Box 690
Glenrothes Chanhassen, MN 55317
Fife Phone: 800-328-2724
KY6 2RS Fax: 800-858-0319
Scotland Local: 952-949-0765
Phone: +44 (0) 1592 772124
Fax: +44 (0) 1592 775314
AEB15.43
Page 10 of 64
Figure 1 Typical J1939 Topology for On-Highway Applications
The points intended to be emphasized:
1). Backbone-twisted shielded pair with a drain wire and a maximum length of 40 meters (approx. 131 ft)
It has termination resistors at each end. The figure illustrates a linear topology.
2). Stub – maximum length of 1 meter (approx. 3.3 ft)
3). Four Types of Connectors:

i. A- Stub Connector (Receptacle
A MATE: Mating Half of Stub Connector (Plug) STYLE 1 Keying
ii. B: Backbone )through) Connector (Receptacle)

B MATE: Mating Half of Backbone Connector (Plug) STYLE 2 Keying
iii. Diagnostic Connector – Deutsch 9 pin
iv. J1939 backbone passing through the OEM bulkhead connector
4). Three possible ways of connecting ECUs to backbone:

i. ECU 1 is connected to backbone via a stub connector (A-A MATE)
ii. ECU 2 has the stub receptacle at the module
iii. ECU n has the stub cable wired directly to the OEM connector
AEB15.43
Page 11 of 64
Figure 2 Typical J1939 Topology for Construction/Agriculture Applications
1). Backbone-twisted quad with a maximum length of 40 m (approx. 131 ft). Both the tractor bus and implement
bus is examples of twisted quad backbone. The backbone is both cases have active termination resistors.
The figure illustrates a linear topology.
2). Stub – maximum length of 1 meter (approx. 3.3 ft)
3). Three Types of Connectors:

i. A and A MATE
ii. Diagnostic Connector
iii. Bulkhead connector
4). Two possible ways shown of connecting ECUs to back bone

i. ECU 1 (J1939/11 compatible) is connected to backbone via a stub connector (A-A MATE)
As can be seen J1939/11 compatible cable (3 leads) connects via stub connector to twisted quad.
Only the CAN_H and CAN_L wires connect. The power and ground are unterminated.
ii. ECU2 through ECU n are J1939/12 compatible nodes and their connections to backbone are show.
AEB15.43
Page 12 of 64
J1587 Installation Information
This section provides information on cabling and connectors for installing J1708/1587 datalink on a machine.
1. Cabling
Backbone - This terminology does not apply to J1708/J1587. The bus can have a maximum length of 40 meters
(approximately 131 feet). At a given time, the maximum number of nodes (electronic controllers) that can be
connected to the bus is 20. The bus is a twisted pair cable. Termination resistors are not needed.
Stub - Not Applicable to J1587
Shield - Not Applicable to J1587
2. Connections
Engine Connections - The J1587 connections to a Quantum module are shown in Figure 1. Please note that the
J1587 interconnect pins for Quantum must be gold. No stub connector is needed to connect an electronic
controller to the J1587 bus.
Diagnostic Connections - The diagnostic connector to be used is SAE 9-pin Deutsch.
Bulkhead Connection - The J1587 datalink may be routed through the OEM bulkhead connector.
3. J1587 Cable and Connector Supplier
J1587 compatible connectors and cabling are now available through many local and national distributors. For
application information and to locate distributors in your area, contact the following companies:
Connectors:
Deutsch Industrial Products Division Packard Electric
37140 Industrial Avenue P.O. Box 431
Hemet, CA 92543 Warren, OH 44486
Phone: (714) 929-1200 1-800-722-5273
(909) 765-2250
Fax (714) 652-9784
Deutsch Distributor
Ladd Industrial Sales
1-800-223-1236
Cabling
Belden Wire and Cable Company Champlain Cable Corporation
2200 U.S. Highway 27 South 12 Hercules Drive
P.O. Box 1980 Colchester, Vermont 05446
Richmond, IN 47345 Phone: 1-800-451-5162
Phone: 800-235-3361
Fax: (765) 983-5737
BICC Brand-Rex Ltd.

Viewfield Industrial Estate Waytec Inc.
Glenrothes - Fife P. O. Box 690
KY6 2RS Chanhassen, MN 55317
Scotland Phone: 800-328-2724
Phone: +44 (0) 1592 772124 Fax: 800-858-0319
Fax: +44 (0) 1592 775314 Local: 952-949-0765
AEB15.43
Page 13 of 64
ECU 2
ECU n
J 1708 bus
ECU 1
ECU
ECU n-1
Figure 3 Example of J1587 Topology
1). The J1708/J1587 network topology. As can be seen, it is a free topology vs. being a J1939 linear topology.
2). There are no stubs or a restriction on their length.

AEB15.43
Page 14 of 64
Messages Supported on Quantum Modules
This section details the J1939 and J1587 industry standard messages that are supported by the Quantum
controller. Parameter characteristics for messages sent on J1939 and J1587 are also listed.
1. Messages Supported on J1939
Cummins has identified six categories of J1939 capability. They are:
• Powertrain Control (PT) - The powertrain control category comprises of parameters exchanged between the
engine and devices such as transmission, ASR and ABS.
• Information Sharing (IS) - This category has parameters pertaining to general engine operation. These
parameters can be broadcast as well as be provided upon request from a remote system, e.g. engine coolant
temperature, engine oil pressure, etc.
• Diagnostics (DG) - This category comprises of parameters that are used to convey fault information, have
capability to command system tests, access test results, clear active and inactive diagnostic trouble codes
and access emissions related active diagnostic trouble codes separately from other diagnostic trouble codes
(DTCs).
• Multiplexing (MX) - What is Multiplexing - J1939 Multiplexing is sending or receiving of input and output
control commands using J1939 datalink instead of individual hard wires. The enables for multiplex
parameters are service trims and can be adjusted with VEPS. The source address from which the parameter
is multiplexed is also VEPS trimmable. Please refer to 1377 – 9804 – J1939 Multiplexing of Inputs and
Outputs (Interface Specification) for details. All parameters that help accomplish multiplexing fall in this
category.
• General (G) - All other nonproprietary J1939 requirements that are not covered in the other 5 categories are
grouped under General. For example: Acknowledgment (ACK/NACK), Transport Protocol.
• Service/Proprietary (SP) - This category comprises J1939 messages that can be used to convey proprietary
information, e.g. PGN for Proprietary A.
Table 1 lists all J1939 PGNs and parameters that are supported on all Quantum engine platforms. Please read
the following notes in order to understand the contents of the table.
AEB15.43
Page 15 of 64
Notes to Aid Understanding of Table 1:
Column 1 lists the SAE PGN number.
Column 2 lists the SAE defined PGN names.
Also, SA/DA refers to the Source Address/Destination Address and listing of SAE defined PGN numbers is given.
As an example, the combination of PGN 00000–TSC1 and Trans(3)/Engine(0) should be interpreted as TSC1 is
sourced from the Transmission (J1939 address 3) and received by Engine (J1939 address 0). Also note that any
PGN can be requested by any source with a J1939 address. Where this is not true, the specific addresses have
been listed.
Some PGNs are not completely defined in SAE J1939-71 and -73. They are denoted with a superscripted
asterisk “*”. Please refer to the notes at the end of the table for details.
Column 3 lists the update rate of the PGN in Quantum
Column 4 indicates which Cummins defined category the parameter falls in.
Please note that there are cases where the parameter may belong to more than one category. For example -
Parameter “engine Derate Switch” belongs to both IS/MX. Also read Note 6.
Column 5 lists the parameters within the PGN.
Columns 6-14 describes parameter support for Quantum engines.
TX means that the parameter is transmitted from the engine, RX means that the engine receives the parameter,
an entry no means that the parameter is not supported. Support of a J1939 parameter listed as both TX/RX,
means the following:
Under a non-multiplexed case, the parameter value is transmitted (TX) from engine.
Under a multiplexed case, the parameter value is received (RX) by engine.
The broadcast of certain J1939 Parameters shall be dependent upon the override trims for those parameters.
These trims can only be changed (enabled/disabled) prior to the powerup sequence. When the overrides have
been enabled, J1939 Parameters for those System Names shall be broadcast with N/ A (112 for switches & FF16
for analog values.)
Note: Multiplexing – if the hardwire is still attached to the ECM for that particular switch/sensor and the
parameter is set to be multiplexed, the ECU will ignore the hardwire input.
Thank you very much
for your reading.
Please click here and go
back to our website.
Then, you can download
the complete manual
instantly.
No waiting.
Have questions.
Please write to me.
All the problems will be answered
within 12 hours.
[email protected]

SM-McCormick ZTX230 ZTX260 ZTX280 TRACTOR Service Repair Manual

Uploaded by

Copyright:

Available Formats

SM-McCormick ZTX230 ZTX260 ZTX280 TRACTOR Service Repair Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SM-McCormick ZTX230 ZTX260 ZTX280 TRACTOR Service Repair Manual

Uploaded by

Copyright:

Available Formats

What are the main sections covered in the manual?

What are the main sections covered in the manual?

What are some of the main components discussed for the tractor?

What are some of the main components discussed for the tractor?

Table of Contents

ZTX Series Tractors

9 CHASSIS AND MOUNTED EQUIPMENT

SAFETY, GENERAL INFORMATION

© 2001 McCormick Tractors International Limited.

STANDARD TORQUE DATA FOR NUTS AND BOLTS

SM 8-10080 Issued 03-2001

This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY

To prevent injury always follow the Warning,

observe pertinent laws and regulations.

Operator’s and Service Manuals may be

DO NOT OPERATE WARNING: If you wear clothing that is too

WARNING: When working in the area of

WARNING: Use insulated gloves or

SM 8-10080 Issued 03-2001

CAUTION: Lower all attachments to the CAUTION: When servicing or repairing

SM 8-10080 Issued 03-2001

SM 8-10080 Issued 03-2001

STANDARD TORQUE DATA FOR NUTS AND BOLTS

Chart 1 (Plain Nuts/Bolts)

BOLT TYPE 8.8 TYPE 10.9

Chart 2 (Phosphate Coated Nuts/Bolts)

BOLT TYPE 8.8 TYPE 10.9

SM 8-10080 Issued 03-2001

Chart 3 (Zinc or Cadmium Plated Nuts/Bolts)

BOLT TYPE 8.8 TYPE 10.9

SM 8-10080 Issued 03-2001

GENERAL SPECIFICATIONS AND TORQUES

ZTX Series Tractors

© 2004 McCormick Tractors International Limited.

SM 8-12501 Issued 06-2004

Lubricants and Capacities

AIR CONDITIONER SYSTEM

BATTERY SAE (COLD CRANKING AMPERE RESERVE

644 660 Amps 440 Amps 400 Amps 95 180 mins

Alternator ..................................................................................................................................... 12 Volt, 150 Amp

SM 8-12501 Issued 06-2004

DIFFERENTIAL AND DIFFERENTIAL LOCK

SM 8-12501 Issued 06-2004

COMPRESSOR AND SYSTEM LUBRICATION

HIGH PRESSURE SWITCH

LOW PRESSURE SWITCH

SM 8-12501 Issued 06-2004

MFD DRIVE SHAFT

Cab and Chassis

SM 8-12501 Issued 06-2004

ZTX Series Tractors

© 2004 McCormick Tractors International Limited.

Page!2 !!!DT50-50260 McCormick!Service!Training

!McCormick!Service!Training! DT50-50260 Page!3

Page!4 !!!DT50-50260 McCormick!Service!Training

!McCormick!Service!Training! DT50-50260 Page!5

Page!6 !!!DT50-50260 McCormick!Service!Training

!McCormick!Service!Training! DT50-50260 Page!7

Page!8 !!!DT50-50260 McCormick!Service!Training

!McCormick!Service!Training! DT50-50260 Page!9