QST30 PDF
QST30 PDF
QST30 PDF
Engines
SERVICE TRAINING
Komatsu Engines
S12V140Z-1
KT000099
August 1999
Course Objective
Course Objective
Students will be able to describe the
structure and function, of the 12V140Z-1 /
QST30 engine, how to safely maintain and
repair its operating components.
1
Technical Presentation Kit
Engines
Komatsu
S12V140Z-1
Presented by: KT000099
KAIC Service Training 08/99
1 Introduction 5 Troubleshooting
Disassembly &
2 Maintenance 6
Assembly
Structure &
3
Function
Testing &
4 Exit End Presentation
Adjusting
KT000099
08/99
2
Technical Presentation Kit
Engines
Introduction
Section 1
S12V140Z-1 KT000099
1 Specifications
2 Features
3 Engine Views
Return To Main
Exit
Menu
KT000099
08/99
1
Blank Page
1
Technical Presentation Kit
Engines
Specifications
Section 1.1
S12V140Z--1
S12V140Z KT000099
1
Blank Page
1
Technical Presentation Kit
Engines
Specifications
Section 1.1
S12V140Z-1 KT000099
S A 12 V 140 Z - 1
Series
Cummins Manufacture
Bore diameter in mm
V Type Block
Number of Cylinders
Aftercooled
KT200199 - Introduction
1
Cummins Model HD325-6 / HD465-5 / HD605-5
Technical Presentation
08/99
Page 1-4
Q S T 30 - (*)
Application Codes
Displacement (Liters)
Engine Series
System
QUANTUM Family
KT200199 - Introduction
C =Construction
D =Generator Drive
F =Fire Pump
G =Generator Set
L =Locomotive
M =Marine
P =Power Unit
R =Railcar
KT200199 - Introduction
KT200199 - Introduction
2
History of SA12V140 HD325-6 / HD465-5 / HD605-5
Technical Presentation
08/99
Page 1-7
KT200199 - Introduction
KT200199 - Introduction
KT200199 - Introduction
3
HD325-6 / HD465-5 / HD605-5
KT200199 - Introduction
KT200199 - Introduction
KT200199 - Introduction
4
HD325-6 / HD465-5 / HD605-5
KT200199 - Introduction
KT200199 - Introduction
Nuber of Cylinders 12 12 12 8 12
Bore x Stroke 140x165 139.7 x 137 x 153 170 x 190 123 x 127
152.4
Displacement 30.5 28 27 34.5 18.01
KT200199 - Introduction
5
Engine Ratings HD325-6 / HD465-5 / HD605-5
Technical Presentation
08/99
Page 1-16
l Industrial Ratings:
Intermittent Duty: 1050 @21200 rpm C torque rise
Continuous duty : 850 hp @ 2100 rpm 50hz prime 675 & 725
kWh. (1010 & 1080 bhp
KT200199 - Introduction
6
Technical Presentation Kit
Engines
Features
Section 1.2
S12V140Z-1 KT000099
1
Blank Page
1
Technical Presentation Kit
Engines
Features
Section 1.2
S12V140Z-1 KT000099
12V140Z-1 / QST 30
Base Engine Introduction
S12V140Z-1 KT000099
1
S12V140Z-1
Engine Components
Engine Components
General Engine Overview
Bore and Stroke
140 mm x 165 mm [5.51 in x 6.5 in]
Compression Ratio: 14.0:1
Displacement 30.5 Liters [1860 Cu ml
Crankshaft Rotation
(Viewed from the front of the engine Clockwise
l Compact
l High Output
l High Reliability and Durability
l Fuel Economy
l Easy Maintenance
2
SA12V140Z-1 / QST30
S12V140Z-1
Technical Presentation
08/99
Page 3-7
Design Features
S12V140Z-1
Technical Presentation
08/99
Page 3-8
Standard Features
S12V140Z-1
Technical Presentation
08/99
Page 3-9
3
Fuel System
S12V140Z-1
Technical Presentation
08/99
Page 3-10
Common Components
S12V140Z-1
Technical Presentation
08/99
Page 3-11
4
Advantages of Bosch Electronic
S12V140Z-1
Technical Presentation
08/99
Page 3-13
Fuel System
Performance
5
Ductile Cast Iron Piston
S12V140Z-1
Technical Presentation
08/99
Page 3-16
2. Good Combustion
S12V140Z-1
Technical Presentation
08/99
Page 3-17
Good Combustion
6
Optimized Combustion Chamber
S12V140Z-1
Technical Presentation
08/99
Page 3-19
Shape
Chamber(MDVCC)
3. Reduced Friction
S12V140Z-1
Technical Presentation
08/99
Page 3-21
7
How to Achieve High Durability &
S12V140Z-1
Technical Presentation
08/99
Page 3-22
Reliability
l Piston
Oil Jet Cooling
Cooling Gallery Around Combustion
Chamber & Ring Pack
l Cylinder Head
Forced Cooling Through Drilled Holes in
Valve Bridge
8
Internal Piston Cooling Passage
S12V140Z-1
Technical Presentation
08/99
Page 3-25
Resistance Design
l Roller Cam Follower
l Special Surface Control for Cylinder Liner
l Keystone Type Piston Rings
l Cutback Top Land Piston
9
Key Changes in the Cummins
S12V140Z-1
Technical Presentation
08/99
Page 3-28
QST-30Komatsu Sa12V140-Z1
l 1. Fuel Pumps
l 2. Controls
l 3. Advantages of Bosch Electronic Fuel
System
l Bosch RP39/RE30
l Bosch P8500/RE36
10
Controls for Industrial Ratings:
S12V140Z-1
Technical Presentation
08/99
Page 3-31
Fuel System
Page 3-32
Turbochargers
S12V140Z-1
Technical Presentation
08/99
Page 3-33
l Cumminization
l Improved Efficiencies
l Improved Cost
l Wastegates Available for Quick
Response Applications
11
Technical Presentation Kit
Engines
12
Technical Presentation Kit
Engines
Engine Views
Section 1.3
S12V140Z-1 KT000099
1
Blank Page
1
Technical Presentation Kit Technical Presentation Kit
Engines Engines
Engine Views
Section 1.3
1. Front cover
2. Cylinder block 9. Turbocharger
3. Cylinder liner 10. Cam follower
4. Rocker lever 11. Camshaft
12. Flywheel
housing
5. Cylinder head 13. Flywheel housing
cover 14. Main bearing cap
6. Exhaust valve 15. Crankshaft
16. Oil pan
7. Intake valve
17. Connecting rod
8. Piston
1
Front View Rear View
S12V140Z-1 S12V140Z-1
Technical Presentation Technical Presentation
08/99 08/99
Page 3-7 Page 3-8
1. 23-pin Deutsch
Connector
(Primary/
Secondary ECM
Connector)
29. Rocker lever
2. Engine Speed
30. Aftercooler
Sensor
31. Nozzle holder
3. Flywheel
32. Push rod
4. Engine Position
33. Piston cooling
Sensor
nozzle
1. Intake manifold
(Right bank) 1. Exhaust
2. Electrical intake air manifold
(Left bank)
heater
3. Aftercooler cover 2. Exhaust
(Right bank) manifold
4. Aftercooler cover (Right bank)
(Left bank) 3. Turbocharger
5. Intake manifold (Right bank)
(Left bank) 4. Turbocharger
(Left bank)
6. Air intake
2
Technical Presentation Kit
Maintenance--S12V140Z
Maintenance S12V140Z--1 Engines Engines
Maintenance
1
Schedule
Maintenance
2
Fluids
Return To Main
Exit
Menu
KT000099
08/99
1
Blank Page
1
Technical Presentation Kit
Engines
Maintenance Schedules
Section 2.1
S12V140Z-1 KT000099
1
Blank Page
1
Technical Presentation Kit
Engines
Maintenance Schedules
Section 2.1
S12V140Z--1
S12V140Z KT000099
S12V140Z--1
S12V140Z
Operation &
Maintenance
Manual Follow
recommendations in
the Komatsu
Operation &
Maintenance Manual.
1
MAINTENANCE
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -4
Y ?
H
W
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -5
MAINTENANCE
WHEN
REQUIRED
S12V140Z--1
S12V140Z
2
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -7
MAINTENANCE
DAILY
S12V140Z--1
S12V140Z
Daily
Check engine:
Oil level in oil pan, add oil
Coolant level in radiator, add
coolant
Drain water and sediment
from fuel filters
S12V140Z--1
S12V140Z
Daily
Inspect engine for:
Damage
Leaks
Loose or damaged belts
Unusual noises and exhaust
color
Check electronic engine
protection system (fault code
Lamps)
Check monitor panel
KT000099 - Structure & Function
3
S12V140Z--1
S12V140Z
Weekly
MAINTENANCE
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -11
50
HOURS
S12V140Z--1
S12V140Z
50 Hour Service
Drain water, sediment from fuel
tank
4
MAINTENANCE S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -13
Every
250
HOURS
KT000099 - Structure & Function
S12V140Z--1
S12V140Z
S12V140Z--1
S12V140Z
5
MAINTENANCE
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -16
2000
12V140 HOURS
S12V140Z--1
S12V140Z
S12V140Z--1
S12V140Z
6
MAINTENANCE S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -19
6000 HOURS
or 2 years
which ever
comes first
S12V140Z--1
S12V140Z
7
Blank Page
1
Technical Presentation Kit
Engines
Maintenance Fluids
Section 2.2
S12V140Z-1 KT000099
1
Blank Page
1
Technical Presentation Kit
Engines
Maintenance Fluids
Section 2.2
S12V140Z-1 KT000099
S12V140Z-1
1
S12V140Z-1
FUEL
S12V140Z-1
S12V140Z-1
2
S12V140Z-1
S12V140Z-1
S12V140Z-1
3
S12V140Z-1
S12V140Z-1
S12V140Z-1
4
S12V140Z-1
S12V140Z-1
Engine Coolant
S12V140Z-1
ANTIFREEZE
In climates where the temperature is
above -37C (-34F), use a coolant
mixture that contains 50 percent
antifreeze. Antifreeze is essential in any
climate. It broadens the operating
temperature range by lowering
the coolant freezing point and by raising
its boiling point.
5
S12V140Z-1
ANTIFREEZE
Do not use more than 50 percent
antifreeze in the mixture unless
additional freeze protection is required.
Never use more than 68 percent
antifreeze under any condition.
An antifreeze concentration greater than
68% will adversely affect freeze
protection and heat transfer rates.
S12V140Z-1
ANTIFREEZE
Antifreeze concentrations between 68%
and 100% actually have a higher
freezing point than a 68% antifreeze
concentration and should not be used
due to reduced heat transfer rates.
S12V140Z-1
ANTIFREEZE
Low silicate ethylene glycol antifreeze is
recommended. The antifreeze should
contain no more than 0.1% anhydrous
alkali metasilicate. Low silicate
antifreeze is recommended to avoid the
formation of silica-gel (hydro-gel). This
gel formation can occur when the
cooling system contains an over
concentration of high silicate antifreeze
and/or supplemental coolant additive.
6
S12V140Z-1
ANTIFREEZE
Antifreeze may retain its freeze
protection for more than one season but
coolant conditioners must be added
to maintain corrosion protection.
S12V140Z-1
S12V140Z-1
WATER
Use water which has a low mineral content. Water
used in conjunction with antifreeze, coolant filters and
inhibited water must meet the following standards:
7
S12V140Z-1
WATER
Chlorides - Not to exceed 40 parts per million (2.5
grains/gallon maximum) to prevent corrosion.
Sulfites - Not to exceed 100 parts per million (5.8
grains/gallon maximum) to prevent corrosion.
S12V140Z-1
WATER
If any of the above requirements cannot be met, use
distilled, de-ionized, or de-mineralized water. To
determine if local water supplies meet these
standards, water samples can be tested by water
treatment laboratories. Softened water that is
prepared using common salt (sodium chloride)
contains excessive amounts of chlorides and should
not be used.
NOTE: Never use water alone in the
cooling system because corrosion will
occur.
KT000099 - Structure & Function
S12V140Z-1
MAINTENANCE OF
SUPPLEMENTAL COOLANT
ADDITIVES
8
S12V140Z-1
MAINTENANCE OF
SUPPLEMENTAL COOLANT
ADDITIVES
S12V140Z-1
MAINTENANCE OF
SUPPLEMENTAL COOLANT
ADDITIVES
S12V140Z-1
MAINTENANCE OF
SUPPLEMENTAL COOLANT
ADDITIVES
9
Technical Presentation Kit
Engines
10
Technical Presentation Kit
Engines
Section 3
S12V140Z-1 KT000099
1
Blank Page
1
Technical Presentation Kit
Engines
Base Engine
Section 3.1
S12V140Z-1 KT000099
1
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1
Technical Presentation Kit
Engines
Base Engine
Section 3.1
S12V140Z--1
S12V140Z KT000099
Engine Components
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -3
1
Engine Block
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -4
Engine Block
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -5
Engine Block
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -6
Two internal
coolant flow
passages direct
coolant around
each wet cylinder
liner. Coolant flow
testing was used to
avoid cavitation
affects which cause
liner corrosion in
service
2
End View of Engine
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -7
The main
cylinder block
incorporates a
ribbed skirt
design which
gives it lower
weight high
strength and
reduced noise
levels.
3
Main Bearing Saddle
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -10
Counter Bore
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -12
Cylinder block
incorporates a
lower press fit
liner for added
strength and
reduces stress
in the
counterbore.
4
CRANKSHAFT
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -13
Crankshaft is
made of forged
alloy steel with 8
integral balance
weights for
smooth operation
and low vibration.
To reduce
torsional vibration
a Holset viscous
type vibration
damper is used.
Crankshaft has 7
main journals with
a diameter of 5.83
inches which is
ample area to
distribute the load.
A thrust bearing is
located on number
7 main journal.30
Crankshaft Fillets
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -15
The main
journals and
fillet radii have
been induction
hardened for
increased
strength and
wear.
5
Rod Bearing Journals
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -16
Connecting rod
journal has a
diameter of
3.94 inches
which provides
ample surface
area.
Oil Drilling
6
Rod Caps and Bolts
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -19
Four cap
screws for
more universal
clamping load.
Use torque to
yield method
of tightening
7
Piston
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -22
Piston
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -23
Gallery Cooling
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -24
8
Internal Piston Cooling Passage
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -25
More On Pistons
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -26
3 Ring design
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -27
9
Piston Rings
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -28
No. 1 Ring
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -29
No. 2 Ring
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -30
10
Oil Control Ring
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -31
Cylinder Liner
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -32
QST30/12V140Z-1 Uses a
QST30/12V140Z-
replaceable wet sleeve type
cylinder liner for greater heat
dissipation , long life and
lower rebuild cost. The
cylinder Liner is a lower
pressed fit design.This
improves liner/block interface
eliminating fretting at the
counter bore. The liner
material is centrifugal cast
iron and is TUFTRIDED
Cylinder Liner
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -33
TUFTRIDING of the
liners creates a durable
surface for the rings to
travel on, reducing oil
consumption, improving
wear resistance (life to
overhaul) and scuff
resistance. The hard surface
on the out side of the liner is
less prone to cavitation
erosion. Finished liners are
plateau honed to one micron
finish.
11
Cylinder Liner Seals
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -34
CAMSHAFT
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -35
Camshaft Journals
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -36
12
S12V140Z--1
S12V140Z
Technical Presentation
08/99
Page 3-
3 -37
3 gear design
Suction Screen
13
Technical Presentation Kit
Engines
14
Technical Presentation Kit
Engines
Cooling System
Section 3.3
S12V140Z-1 KT000099
1
Blank Page
1
Technical Presentation Kit
Engines
Cooling System
Section 3.3
S12V140Z-1 KT000099
1
Cooling System Specifications -2
S12V140Z-1
Technical Presentation
08/99
Page 3-4
Coolant Temperature
Minimum Top Tank
71 C [160 F]
Maximum at Engine Outlet
100 C [212 F]
Maximum Deaeration Time
25 min
Minimum Drawdown
Of System Capacity 8 %
Water Pump
S12V140Z-1
Technical Presentation
08/99
Page 3-6
Coolant is
drawn into
the water
pump both
from the
radiator core
and from the
bypass tube.
2
Water Pump
S12V140Z-1
Technical Presentation
08/99
Page 3-7
The Water
Pump is
located on the
right side of
the engine as
shown.
Water Pump
S12V140Z-1
Technical Presentation
08/99
Page 3-8
Coolant Flow
S12V140Z-1
Technical Presentation
08/99
Page 3-9
3
Oil Cooler Inlet
S12V140Z-1
Technical Presentation
08/99
Page 3-10
Coolant
directed to the
block flows into
the oil coolers
through passages
cast into the
block. Once in
the oil cooler, the
coolant flows
around the
cooling plates
cooling the oil.
KT000099 - Structure & Function
Coolant Flow
S12V140Z-1
Technical Presentation
08/99
Page 3-11
Coolant then
flows into the
right bank
cylinder liner
cavity to the
left bank
cylinder liner
cavities
through six
passages cast
into the block.
Cylinder Heads
S12V140Z-1
Technical Presentation
08/99
Page 3-12
The coolant
flows through
the cylinder
heads ,
cooling the
valve seats,
injector bores
and fuel
4
Center Block Passage
S12V140Z-1
Technical Presentation
08/99
Page 3-13
Cooling Passage
S12V140Z-1
Technical Presentation
08/99
Page 3-15
Cylinder Cooling
Passages
KT000099 - Structure & Function
5
S12V140Z-1
Technical Presentation
08/99
Page 3-16
Thermostat Housing
S12V140Z-1
Technical Presentation
08/99
Page 3-18
The thermostat
housing is
located on the
front of the
engine as
shown, it
incorporates
three
thermostats.
6
Thermostat Closed
S12V140Z-1
Technical Presentation
08/99
Page 3-19
If the coolant in
the thermostat
housing is less
than 165
Fahrenheit then
the thermostat will
be closed allowing
coolant to bypass
the radiator.
The thermostat
starts to open
when the engine
coolant
temperature
reaches 166 to
173 Fahrenheit.
Thermostat Open
S12V140Z-1
Technical Presentation
08/99
Page 3-21
If the coolant in
the thermostat
housing is more
than 173
Fahrenheit,
The thermostat
will open allowing
coolant to flow
into the radiator.
7
Thermostat Fully Open
S12V140Z-1
Technical Presentation
08/99
Page 3-22
The thermostats
are fully open
when the coolant
temperature
reaches 194
Fahrenheit.
S12V140Z-1
Technical Presentation
08/99
Page 3-23
Thermostat Housing
S12V140Z-1
Technical Presentation
08/99
Page 3-24
8
S12V140Z-1
Technical Presentation
08/99
Page 3-25
Center Block
Passage
Thermostat By-Pass
Bypass Connector
S12V140Z-1
Technical Presentation
08/99
Page 3-26
The bypass
coolant flows
through a
passage into the
block and then
out through a
bypass connector
back to the
water pump
inlet.
Coolant flows
through the
radiator core
and back to
the water
pump
9
The Water Filter Head
S12V140Z-1
Technical Presentation
08/99
Page 3-28
10
Technical Presentation Kit
Engines
Section 3.4
S12V140Z-1 KT000099
1
Blank Page
1
Technical Presentation Kit
Engines
Section 3.4
S12V140Z-1 KT000099
1
Exhaust System Specifications
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-4
Back Pressure -
Maximum (at rated speed and load)
75 mm Hg [3 in Hg]
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-6
Turbo Charger
The turbocharger
exhaust turbine
drives the
compressor
wheel which
draws air in
through the air
filter elements.
2
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-7
S12V140Z-1 Engines
DATAPLATE
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-9
TURBOCHARGER DATAPLATE
3
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-10
TURBOCHARGER DATAPLATE
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-11
TURBOCHARGER DATAPLATE
D = Turbocharger Type:
Indicates the model or frame-size
of the turbo.
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-12
Why Do We Turbocharge?
Increases the pressure (therefore density)
of the air entering the engine.
Higher density = more oxygen per liter,
- so more fuel per engine rev can be burned.
4
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-13
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-14
Advantages of Turbocharging
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-15
5
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-16
1. Bearing clearances.
2. Foreign-object damage.
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-17
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-18
6
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-19
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-20
Troubleshooting: (b)
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-21
7
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-22
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-23
Restriction
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-24
8
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-25
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-26
Intake
Vacuum
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-27
9
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-28
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-29
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-30
Noise (a)
An area of confusion, relative to Diagnosis.
We have found that in some shops,
almost all high-frequency noises are
attributed to the turbocharger.
10
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-31
Noise (b)
All turbochargers make some noise.
High-power engines run at higher
boost pressures (thus higher speeds)
- hence turbo noise tends to be
higher (in both volume and pitch).
If a customer complains of excessive noise, it
is important to determine if the noise
CHANGED recently.
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-32
Noise (c)
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-33
11
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-34
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-35
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-36
Air Flow
From the
turbocharger
compressor
wheel, air
flows through
the crossover
connection
and into the
after cooler
12
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-37
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-38
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-39
Exhaust
After
combustion
the exhaust
gasses flow
out the
opposite side
of of the
cylinder
head.
13
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-40
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-41
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-42
Air System
Operation & Maintenance
on the
SA12V140Z-1 / QST30
14
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-43
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-44
The operation
and
maintenance
manual for the
SA12V140Z-1 /
QST30 contains
a maintenance
schedule
similar to the
one shown
(NEXT PAGE)
KT200199 - Work Equipment
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-45
15
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-46
Pre-cleaner
Weekly Check
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-47
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-48
16
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-49
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-50
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-51
17
Technical Presentation Kit
Engines
18
Technical Presentation Kit
Engines
S12V140Z-1 KT000099
1
Blank Page
1
Technical Presentation Kit
Engines
S12V140Z-1 KT000099
1
Fuel System Specifications
S12V140Z-1
Technical Presentation
08/99
Page 3-4
In this section we
will discuss the in
line fuel system for
the SA12V140Z-
1/QST30. Starting
at the supply tank
and continuing on
until the entire
system has been
explained.
The Fuel
transfer
pump draws
fuel from the
fuel supply
tank through
a pre-filter or
a screen.
2
The Pre-filter
S12V140Z-1
Technical Presentation
08/99
Page 3-7
The pre-filter
prevents
particles larger
than 140
microns from
entering the fuel
transfer pump
and blocking
the check valve
open.
3
Fuel Transfer Pump Operation
S12V140Z-1
Technical Presentation
08/99
Page 3-10
As the high
point of the cam
lobe rotates
away from the
fuel transfer
pump, the
spring forces the
plunger toward
the cam shaft.
4
Transfer Pump Fuel Flow
S12V140Z-1
Technical Presentation
08/99
Page 3-13
Hand Primer
S12V140Z-1
Technical Presentation
08/99
Page 3-14
A second plunger
allows manual
priming and
bleeding of air
from the system.
When the plunger
is depressed ,
check valve B
prevents back flow
and fuel is forced
through check
valve A.
5
Fuel Return
S12V140Z-1
Technical Presentation
08/99
Page 3-16
Fuel Filters:
S12V140Z-1
Technical Presentation
08/99
Page 3-17
Fuel under
pressure
from the
transfer
pump flows
through the
fuel filters
6
Fuel Filters
S12V140Z-1
Technical Presentation
08/99
Page 3-19
Filter Replacement
S12V140Z-1
Technical Presentation
08/99
Page 3-20
Cummins Operation
S12V140Z-1
Technical Presentation
08/99
Page 3-21
7
KOMATSU Presents
S12V140Z-1
Technical Presentation
08/99
Page 3-22
After flowing
through the
fuel filter
elements fuel
flows up
through the
filter head and
into the fuel
injection
pump.
Fuel Flow
S12V140Z-1
Technical Presentation
08/99
Page 3-24
8
Low Pressure Supply Line
S12V140Z-1
Technical Presentation
08/99
Page 3-25
Vent Fitting
S12V140Z-1
Technical Presentation
08/99
Page 3-26
S12V140Z-1
Technical Presentation
08/99
Page 3-27
On new
installations or
servicing, the
gallery can be filled
with fuel by the
hand operated
primer on the fuel
transfer pump prior
to attempting to
start the engine.
The fuel gallery is
the source of fuel
for the pumping
KT000099 - Structure & Function
elements.
9
Pumping Elements: S12V140Z-1
Technical Presentation
08/99
Page 3-28
Pumping Element
S12V140Z-1
Technical Presentation
08/99
Page 3-29
Each pumping
element consists of
Barrel, Plunger,
Control Sleeve,
Plunger Spring,
lower spring seat
and roller tappet.
The lifting and
retraction of the
plunger provide
the pumping
action for fuel
delivery.
KT000099 - Structure & Function
Pumping Element:
S12V140Z-1
Technical Presentation
08/99
Page 3-30
Each The
following sequence
will illustrate the
pumping action
for delivering fuel
to the engine
cylinders.
Lets began with
the roller tappets
at the inner base
circle.
10
S12V140Z-1
Technical Presentation
08/99
Page 3-31
S12V140Z-1
Technical Presentation
08/99
Page 3-32
Injection Pressure
S12V140Z-1
Technical Presentation
08/99
Page 3-33
When pressure in
the delivery valve
exceeds 500 PSIG
plus residual
pressure in the
high pressure lines,
the delivery valve
opens and fuel
flows into the
injection nozzle.
11
Fuel Injection
S12V140Z-1
Technical Presentation
08/99
Page 3-34
Delivery Valve:
S12V140Z-1
Technical Presentation
08/99
Page 3-35
Delivery Valve
S12V140Z-1
Technical Presentation
08/99
Page 3-36
The continued
movement of the
valve cone to its
seat on the valve
body increases the
volume of available
fuel, allowing the
pressure in the high
pressure line to
reduce rapidly. The
plunger continues
to force fuel into
the gallery until top
dead center.
KT000099 - Structure & Function
12
Delivery Valve
S12V140Z-1
Technical Presentation
08/99
Page 3-37
The plunger is
returned to bottom
dead center to begin
another cycle. The
plunger spring
keeps the roller
tappet in contact
with the cam lobe
and causes the
plunger to retract
as the high point of
the cam rotates
away from it
Control Sleeve
S12V140Z-1
Technical Presentation
08/99
Page 3-38
Zero Delivery
S12V140Z-1
Technical Presentation
08/99
Page 3-39
The plunger is
rotated so the
vertical slot on
the plunger is
aligned with the
spill port. In this
position as the
plunger lifts, fuel
is not sealed
above plunger
and there is no
fuel delivered to
the cylinder.
KT000099 - Structure & Function
13
Lift Distance
S12V140Z-1
Technical Presentation
08/99
Page 3-40
For delivery of a
quantity fuel less
than maximum
the plunger is
positioned so the
fuel is sealed
above the plunger
for some Lift
Distance between
port closure and
port opening.
Maximum Delivery
S12V140Z-1
Technical Presentation
08/99
Page 3-41
For maximum
delivery the plunger is
positioned so fuel is
sealed above the
plunger for maximum
Lift Distance between
port closure and port
opening. The amount
of fuel delivered to the
cylinder can be varied
by positioning the
plunger between
maximum delivery
and zero delivery.
KT000099 - Structure & Function
14
Injector Components
S12V140Z-1
Technical Presentation
08/99
Page 3-43
The injector
consists of the
Nozzle Holder,
Shims, Spring,
Intermediate
Plate, Needle
Valve and the
Nozzle.
S12V140Z-1
Technical Presentation
08/99
Page 3-44
Lets begin the discussion with the fuel flow to the injector
where the plunger is lifting and the delivery valve just
opened.
S12V140Z-1
Technical Presentation
08/99
Page 3-45
Fuel displacement
into the high
pressure line
raises the pressure
in the line until it
overcomes the
spring force on the
needle valve in the
injector causing it
to open.
15
Needle Valve
S12V140Z-1
Technical Presentation
08/99
Page 3-46
Popping Pressure
S12V140Z-1
Technical Presentation
08/99
Page 3-47
16
S12V140Z-1
Technical Presentation
08/99
Page 3-49
S12V140Z-1
Technical Presentation
08/99
Page 3-50
17
S12V140Z-1
Technical Presentation
08/99
Page 3-52
S12V140Z-1
Technical Presentation
08/99
Page 3-53
S12V140Z-1
Technical Presentation
08/99
Page 3-54
18
S12V140Z-1
Technical Presentation
08/99
Page 3-55
S12V140Z-1
Technical Presentation
08/99
Page 3-56
Timing Pin
S12V140Z-1
Technical Presentation
08/99
Page 3-57
19
S12V140Z-1
Technical Presentation
08/99
Page 3-58
S12V140Z-1
Technical Presentation
08/99
Page 3-59
S12V140Z-1
Technical Presentation
08/99
Page 3-60
20
The fuel pump drive gear S12V140Z-1
Technical Presentation
08/99
Page 3-61
S12V140Z-1
Technical Presentation
08/99
Page 3-62
S12V140Z-1
Technical Presentation
08/99
Page 3-63
21
S12V140Z-1
Technical Presentation
08/99
Page 3-64
22
Align Timing Marks
S12V140Z-1
Technical Presentation
08/99
Page 3-67
S12V140Z-1
Technical Presentation
08/99
Page 3-69
23
S12V140Z-1
Technical Presentation
08/99
Page 3-70
S12V140Z-1
Technical Presentation
08/99
Page 3-71
24
Technical Presentation Kit
Engines
Engine Sensors
Section 3.6
S12V140Z-1 KT000099
1
Blank Page
1
Technical Presentation Kit
Engines
Engine Sensors
Section 3.6
S12V140Z-1 KT000099
1
Quantum System Components
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-4
The SA12V140Z-1
/ QST30 Industrial
fuel system uses
two Bosch
RP39fuel
pumps.These
pumps contain
actuators that
control the timing
sleeves and fueling
racks.
KT200199 - Work Equipment
Varying the
current supply To
these actuators via
the ECM allows the
SA12V140Z-1
/QST30 Industrial
Fuel system to
regulate engine
timing and fuel
metering.
2
Engine Speed /Engine Position
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-7
Sensor
l Hall effect sensors
l ESS and EPS are the same sensor,
both located in the flywheel housing
l ESS counts teeth on the ring gear
l EPS, 6 + 1 logic using holes in
flywheel
l No resistance check
l Supply voltage, 4.75 to 5.25 V
l Square wave signal voltage
3
BOSCH RP39 Fuel Pumps
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-10
This action
controls timing
and fuel
metering and
then produces
the correct
horsepower and
torque for the
latest engine
condition.
4
ECM Sensor Inputs
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-13
5
Secondary ECM inputs
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-16
6
Engine Position Sensor (ESP) S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-19
7
Intake Manifold Sensor
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-22
8
Coolant Level Sensor
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-25
The CLS, if
equipped, is
mounted in the
radiator top tank.
It is a fluid level
actuated switch
required for the
engine protection
system.
NOTE: This is an
optional sensor
which will not be
on all equipment.
A shorting plug
will be installed if
the CLS is not
used.
The OPS
sends signals
to the ECM
for the engine
protection
system. The
sensor is
located on the
engine block.
9
S12V140Z-1 Engines
Technical Presentation
Oil Pressure
08/99
Page 5-28
Sensor
The coolant
pressure sensor
(CPS) sends signals
to the ECM for the
engine protection
system. The sensor
is located on the
thermostat
housing.
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-30
10
Ambient Air Pressure Sensor
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-31
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-32
11
Oil Level Sensor
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-34
12
Needle Movement Sensor
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-37
Coil
Spring Seat
Pressure
Spindle
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-39
Right 1Needle
Movement Sensor
13
ECM Outputs
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-40
EDC Components
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-42
1. Control Rack
2. Return Spring
3. Short Circuit Ring
4. Actuator
5. Speed Sensor
6. Speed Wheel
7. Camshaft
14
Magnets
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-43
An
Electromagnet
When electric
current flows
though the coil,
the iron core
acquires all the
properties of a
magnet
INDUCTION
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-44
Principle of
Electromagnetic
Induction
Mutual Induction
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-45
15
Rack Travel Sensor (Idle)
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-46
Voltage ration
between the
measuring
and reference
coils, as a
function of
rack travel.
16
Rack Travel Sensor
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-49
17
Rack Position Sensor Structure
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-52
18
Flow Diagram
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-55
Flow Diagram
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-56
Flow Diagram
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-57
19
Flow Diagram
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-58
20
Technical Presentation Kit
Engines
Engine Controls
Section 3.7
S12V140Z-1 KT000099
1
Blank Page
1
Technical Presentation Kit
Engines
Engine Controls
Section 3.7
S12V140Z-1 KT000099
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-3
QST30 / SA12V140-Z1
Engine Control System
1
Contents
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-4
Overview
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-5
What is a datalink?
J1587/J1708/J1939
2
What is a datalink?
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-7
l Multiplexing
l Multiple modules
3
J1939 Backbone Harness
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-10
Backbone - Troubleshooting
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-11
Throttle position
Engine speed / Engine position
Intake manifold pressure
Intake manifold temperature
Engine oil pressure
Coolant temperature
Ambient air pressure
Coolant level
Coolant pressure
Various OEM switches
Needle lift sensor
Rack position feedback
KT200199 - Work Equipment
4
Review of Secondary ECM Inputs
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-13
Throttle position
Engine speed / Engine position
Intake manifold pressure
Intake manifold temperature
Needle lift sensor
Rack position feedback
Engine Controls
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-15
5
ECM Identification
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-16
10 19 47 48 10 19 47 48
+ 5 Volts DC + 5 Volts DC
l The Primary
Various Sensors
ECM uses various
ECM inputs to
determine fueling Engine Speed
Throttle Position
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-18
6
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-19
RP39 RP39
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-20
RP39 RP39
Estimated Rack Position Estimated Rack Position
NLS NLS
Estimated Start Of Injection Estimated Start Of Injection
From these, closed loop fueling and timing control are obtained.
l Rack position
l Timing Sleeve Position
l Rack position feedback sensor
7
Start of Injection Calculation
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-22
SOI Feedback
Distance From
Last Tooth
Fuel Flow
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-23
EHAB Specifications
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-24
l 24 Volt EHAB
Internal Resistance: 38.5 - 43.5 Ohms
Minimum Pull in Voltage: 15.2 Volts
Minimum Hold in Voltage: 16.5 Volts
l 12 Volt EHAB
Internal Resistance: 10.2 - 11.2 Ohms
Minimum Pull in Voltage: 8.2 Volts
Minimum Hold in Voltage: 8.5 Volts
8
Technical Presentation Kit
S12V140Z-1 Engine
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-26
J1939 Datalink
Primary ECM Secondary ECM
Service Tool
9
INSITE Features
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-28
INSITE Features
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-29
INSITE Features
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-30
10
INSITE Features
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-31
l Coolant pressure
l Coolant temperature
l Coolant level
l Intake manifold temperature
l Oil pressure
l Engine overspeed
11
Fuel Consumption Monitor
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-34
ESDN
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-36
12
CENSE
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-37
J1939 Datalink
Primary ECM Secondary ECM
13
Engine Protection Features
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-40
Parameters
Page 5-41
Parameters
When the ECM
detects a out-of-
bounds condition, a
series of protective
actions are
initiated. The
action initiated is
dependent on the
severity and
duration of the
condition.
14
INSITE - Features and Adjustable
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-43
Parameters
The protective actions
are as follows:
Engine protection
lamp is lit and a fault
is logged
Engine torque and
[or] speed is derated
Engine shutdown is
activated
15
Torque and Speed Derate
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-46
After a derate is
initiated, the ECM
will continue to
monitor both
duration and severity
and will shutdown the
engine if the
condition s not
corrected The engine
shutdown feature can
be overridden
through OEM
calibration options
KT200199 - Work Equipment
Altitude derate
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-47
Overspeed protection
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-48
16
Overspeed protection
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-49
Overspeed protection
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-50
QST 30
Fault
17
Engine protection lamp
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-52
The engine
protection lamp
is used to warn
the operator of
the following
conditions
Coolant/intake
temperature out
of range
Oil/ambient
pressure out of
range.
KT200199 - Work Equipment
18
Warning/Stop engine lamps
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-55
Diagnostic switch
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-56
19
Flash code sequence
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-58
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-59
S12V140Z-1 Engines
Technical Presentation
08/99
Page 5-60
20
Technical Presentation Kit
Engines
21