09 Cooling System
09 Cooling System
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Service Manual Cooling system
Technical data
1 Technical data
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Oil cooling Water cooling
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Cooling system Service Manual
Technical data
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Schematic
2 Schematic
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Schematic
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Schematic
2.2 Hydraulic
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Schematic
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Location of the components
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Location of the components
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Location of the components
Regulation plate (A1019) Transmitter for hydraulic oil level (B14) and
temperature (B67)
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Location of the components
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Functional description
4 Functional description
The variable displacement pumps P6.1 and P6.2 supply oil to the constant volume hydraulic motors
FMF for cooler fan driven. The control pressure for the pumps displacement regulation is generated
by the regulation solenoid valves Y10.1 and Y10.2.
These valves control the pressure applied on the pressure cut off valve and so the pump angle. The
opening of the regulation solenoid valves Y10.1 depends on the engine coolant temperature and oth-
ers parameters (see next § temperature regulation). The opening of the regulation solenoid valves
Y10.2 depends on the hydraulic oil temperature (see next § temperature regulation).
Each hydraulic motor FMF is equipped with a suction valve to prevent cavitation and with a pressure
cut off valve to prevent mechanical damages if the corresponding fan is blocked.
4.1.1 Description
The pump A11VO75DRX is described in the § hydraulic pump A11VO75DRX
4.1.2 Regulation
The operation of the engine cooling pump and the hydraulic oil cooling pump are the same, and the
regulation pressure values are the same too.
The regulation solenoid valves Y10.1 and Y10.2 are installed between the port «Fa» (replenishing
pressure) and the regulators.
We use here the pump P6.2 to describe the functioning.
Pressure regulation
This regulation allows to adjust the pump flow in function of the pump high pressure Hd.
• The pump high pressure is applied on the regulator 24.2 via a disk.
• The spring is adjusted so that the pressure delivered by the pump drives the motors (and so the
fans) at the prescribed speed.
• While the nominal value of the pressure is not reached, the regulator 24.2 connects the bottom
side of the control piston 21.1 to the pump high pressure Hd via the regulator 24.2 through the
throttle 21.3. The pump is then swivelled out.
• As soon as the nominal pressure value in the circuit is reached, the pump high pressure Hd
pushes the regulator 24.2 to the right. The regulator 24.2 connects the bottom side of the control
piston 21.2 to the pump high pressure Hd via the regulator 24.2 through the throttle 21.4. The
pump is then swivelled in and the equilibrium is reached.
Flow regulation
This regulation allows to adjust the pump flow in function of the opening of the regulation solenoid
valves. The solenoid valves receive a regulating current from the BST depending on recorded pa-
rameters (the fuel temperature, the coolant temperature and the air intake manifold temperature for
Y10.1, the oil temperature for Y10.2). See next § temperature regulation.
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• Acting like a variable throttle, the regulation solenoid valve Y10.2 changes the pilot pressure (30
bar) into the positioning pressure (Pst).
• The positioning pressure (Pst) is applied on the regulator via a circle (this surface is bigger as
the crown surface on which the pump high pressure Hd is applied).
• Depending on its position (and so on the value of the positioning pressure), the regulator 24.2
makes the value of the regulation pressure (Preg) change. It connects the bottom side of the
control piston 21.1 or the control piston 21.2 either with the pump high pressure Hd or with or
with the tank pressure. The pump is then swivelled out or back until a new equilibrium is
reached.
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Functional description
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Functional description
• When the machine is cold, the current on Y10.2 is maximal, Y10.2 is opened.
• The positioning pressure is maximal and thanks to the high pressure the regulator 24.2 is
pushed to the right.
• Then the bottom side of the piston 21.2 is connected to the high pressure via the regulator 24.2.
• As the rode side of the piston 21.2 is connected to the high pressure, the pump swivels to min-
imum angle.
• The fan speed is minimal.
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Functional description
• When the temperature of the machine increases, the current on Y10.2 decreases and Y10.2
gets partially closed.
• Y10.2 acts as a throttle on the pilot pressure. The pilot pressure applied on regulator 24.2 side
decreases.
• The spring partially pushes the regulator 24.2 to the left. The pressure applied on the bottom
side of the control piston 21.2 decreases. So the piston 21.1 moves to the right, and the piston
21.2 move to the left.
• The pump swivels out to a greater angle. The fans speed increases until a new balance with the
temperature is reached.
• The fan speed is intermediate.
• When the temperature of the machine reaches the upper limit, the current on Y10.2 has a min-
imum value. Y10.2 get completety closed.
• The positioning pressure becomes very low. The spring pushes the regulator 24.2 completely
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to the left.
• The pressure applied on the bottom side of the control piston 21.2 decreases. So the piston 21.1
moves completely to the right, and the piston 21.2 move to the left.
• The pump swivels out to maximum angle.
• The fan speed reached its maximum value.
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Functional description
The BST supplies the RSV Y10_2 with a regulating current, which depends directly of the hydraulic
oil temperature. The responses I (RSV for Y10_2)=f(T) are pre-programmed in the BST unit U16 (see
graph IY10.2 = f(T)).
This current is used to regulate the pump because the solenoid valve Y10.2 acts as a variable throttle
and controls the pressure applied on the pressure cut off valve. This allows to control the positioning
piston and then the pump angle. Consequently, the fan speed is directly controlled by the BST.
A green light diode on the regulation connection box E1038 lights up if there is current on Y10.2. This
diode is used to check rapidly if there is a problem in the electrical circuit.
At the start, the current supplying Y10.2 is blocked at 500 mA during one minute. The regulation
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works normally after one minute. This makes some oil flow in the cooling circuit at the start.
In case of safety operation (by pushing the switch S74), the relay on the plate A1019 is energised
and the current on RSV Y10_2 is open circuited. The RSV is closed thus the pump swivels out to
maximum angle. In this case, the fans turn at maximum speed.
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Functional description
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Functional description
Fuel tem- Coolant tem- Air intake mani- PWM 24V/ A1019 Y10_1
per pera- fold tem- 256
atu ture perature Hz
re
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Functional description
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Functional description
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Troubleshooting
5 Troubleshooting
N Y Reconnect the RSV and check the intensity at the RSV. The
relation between intensity and temperature is correct
(see curve I(RSV)=f(T)).
N Y
N Y
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Troubleshooting
Y Reconnect the RSV and check the intensity at the RSV. The intensity
value is approx. 250 mA.
N Y
Check the square signal from the Quantum with an oscilloscope or a volt-
meter in direct current. The value is approx. 5%×24 = 1,2V.
N Y
N Y
The trouble was cause by the Quantum or the censors. Replace the
Quantum or the sensors or get the engine monitoring system
repaired by a Cummins representative.
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Troubleshooting
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Troubleshooting
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Adjustment
6 Adjustment
For adjustment instructions, refer to the section "Adjustment procedure R9250" in chapter 3
"Technical Data" of this manual.
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Adjustment
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Components description
7 Components description
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Components description
The slide shoes 1.16, mounted hydrostatically on the thrust washer 1.15 (via bore holes in the pistons
and slide shoes) reduce the large sliding surface between the slide shoes and the thrust washer to a
minimum.
When not under pressure, the cylinder 1.11 is pressed against the control lens 1.12 by the springs
1.17, installed in the return ball 1.13. As pressure increases, cylinder and control lens are so well bal-
anced by hydraulic forces, that even at high loads an oil film is maintained on the surfaces of the con-
trol lens, while at the same time leak oil is kept to a minimum. Part of the leak oil is used to lubricate
all moving parts and then flows externally to the tank.
If the cylinder 1.11 turns, the pistons 1.9 move in a double stroke from the lower to the upper limit and
then reverse. The stroke is carried out in relations to the swivel angle of the swivel crossbar 1.2 and
is responsible for the flow volume.
The axial piston unit moves the oil via kidney shaped control inlets in the control lens 1.12. Four of
the moving pistons draw oil through the kidney shaped oil inlets on the suction side of the pump. The
other four pistons displace the oil which is supplied via the kidney shaped oil outlets to the pressure
side of the pump, moving oil via connection A into the hydraulic system. A ninth piston is moving ei-
ther at the upper or the lower limit, at dead center, i.e. just changing directions.
Pump displacement
The control pistons 20.1 and 20.2, connected with the swivel crossbar 1.2, displace the pump from
maximum to minimum swivel angle. The regulator 23 controls the displacement of the control piston
20.1 and 20.2 while connecting their large surface either with high pressure of the pump, or with tank
pressure.
According to the regulation type, the control procedure of the pump swivel angle by the control piston
is different. For exact description, refer to part «cooling system».
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Components description
Torques values:
Allen head screw 14 185 Nm
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Components description
7.2.1 Description
The FMF fixed displacement motor is used to drive cooling fans. The axial piston motor is designed
as a swash plate type motor.
Axial piston motors are energy converters: they transform hydraulic energy into mechanical energy
by their axially directed pistons in a cylinder housing.
The pistons with glide shoes rotate on the swash plate. Because of the inclination of the gliding sur-
face, a piston stroke is created in the cylinder, and thus the constant flow volume of the oil motor.
8.1, which is installed in return ball 8. As the system pressure increases, cylinder 4 and control lens
9 are so well balanced by hydraulic forces that even at high loads an oil film is maintained on the sur-
faces of the control lens as well as on the glide shoes. At the same time, leak oil is kept to a minimum.
Part of the leak oil is used for lubrication of all moving parts and then returned to the tank via an ex-
ternal line.
If pressurized oil enters at connection A or B, four pistons 5 are pressurized via kidney shaped inlets
in the control lens 9. On the opposite side, four more pistons 5 push the low pressure return oil
through kidney shaped inlets in control lens 9 and connection A or B to the tank. A ninth piston is at
dead center, which means at the point or reversing direction.
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Components description
Once the oil pressure reaches the four pistons on the pressure side, a certain force is created by oil
pressure and piston surface. This force is transferred via piston 5 and glide shoe 5.1 onto the swash
plate 6.
This radial force, which uses cylinder 4 as a lever, creates the torque, which is transferred via cylinder
4 to the output shaft 3. The amount of torque is in direct proportion to the system pressure, which
means high pressure = high torque. By applying oil to the opposite port (connection A or B), the
torque and direction of the hydraulic motor is reversed (right or left turn).
During a complete revolution of cylinder 4, pistons 5 perform a dual stroke from the lower dead center
to the top dead center and reverse. This stroke depends on the inclination of the swash plate 6 and
influences the oil quantity.
The displacement of the hydraulic motor remains the same until the oil supply from the variable flow
pump changes.
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Components description
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