Welcome To Daventry

Training Centre

Introduction:

Instructor

KEITH JONES
Introduction:
WC Location

Lunch Arrangements

Safety Card

Fire Alarms & Exits

Issues List

Messages for Participants

None Smoking Policy

Mobile Phones
Introductions around the table:

Trade experience?
How long in the trade?
How long with Cummins Engines?
Hobbies?
Any claim to Fame?
What would you like to learn this week?
Aim
To provide the participant with a level of instruction on the QSKV60 Engine
which will give an understanding of some existing and future product
functionality and complexity.

Objective
.
Participants completing this course will be able to recognise and
describe the ISBe Engine, its unique components, and have a
formal understanding of its operation and applications

Quality Policy
The Central Area Training Group are totally committed to the philosophy of
training, “customer ” , and actively pursues this policy via (Total Quality
QS) procedures.
QST 30
 QST 30 QUALIFICATION
Primary Aim
To ensure participants have an understanding of the QST 30
Engine, to include the basic system flows, engine operation and
maintenance. To be able to interpret operating parameters and some
troubleshooting procedures.

Objectives
Attendees will be able to confidently identify the QST 30, its
components be able to describe and evaluate the major flow systems.
Have the confidence to converse with end users to assist in evaluating
operation and maintenance procedures.
 QST 30 QUALIFICATION

Objective

Participants will be able to successfully sit qualification

examinations both practical and theoretical. Each of the examinations
require a pass mark of 84% according to Cummins Engine Company
standards. Once qualified the participant will have achieved the level of
competency when conducting in his place of employment failure analysis,
troubleshooting procedures and repair practices, as required by Cummins
Engine Company Inc.
QST 30 Series

12 Cylinder - Vee
30 Litre
Introduced 1996
Metric Engine
Ratings - 750 to 1050 bhp
Applications :-
Construction & Industrial
Gen. set
Bosch High Pressure Fuel System
(One pump on each bank)
Individual ECM for each bank
 GENERAL SPECIFICATIONS

QST30 Aspiration Turbocharged and Aftercooled

Bore and Stroke: 140mm x 165mm [ 5.51in x 6.5in ]
Compression Ratio: 14.0:1
Displacement: 30.5 litres [ 1860 cu in ]
Firing Order Rl -Ll -R5-L5~R3-L3-R6-L6-R2-L2-R4~L4
Type: 4 Cycle, 50 Deg Vee, 12 Cylinder

Intake Valve Adjustment 0.43mm [0.017in]

Exhaust Valve Adjustment 0.80mm [ 0.032 in]
 QST30 SPECIFICATIONS - FUEL SYSTEMS

NOTE: For performance and fuel rate values, refer to the engine data sheet, or
the fuel pump code for the particular model involved.
Maximum Allowable Restriction to Pump
With clean filter 64 mm Hg [2.5 in Hg]
With dirty filter 100 mm Hg [4.0 in Hg]

Maximum allowable return line restriction: 64 mm Hg [2.5 in Hg]

Maximum allowable return line restriction:
With check valves and overhead tanks 518 mm Hg [20.4 in Hg]

Minimum allowable fuel tank vent capability:

With 64 mm Hg [2.5 in Hg] or less back pressure 425 L/hr [15 cu.ft/hr]
QST30 SPECIFICATIONS - LUBRICATING OIL SYSTEMS

Oil Pressure, Main Oil Rifle (15W oil at 107"C [225'F]:

Maximum at Rated RPM: 448 kPa [65 psi]
Minimum at Rated RPM: 241 kPa [35 psi]
Minimum at Idle RPM: 69 kPa [10 psi]
High Pressure Relief Valve 120 psi
Oil Flow @ 2100 RPM 430 litre/min [ 113 US gal/
min]
Oil Temperature - Maximum 120 °C [250 °F]
Oil Pan Capacity
Sump only 75 litre [20 U. S. gal]
 QST30 SPECIFICATIONS - LUBRICATING OIL
SYSTEMS CONT..
Oil Filter Capacity (Each Filter)
Full flow filter (4 spin-on filters required) 2.65 litre [0.70 U.S. gal]
Bypass filter (2 spin-on filters required) 2.27 litre [0.60 U. S.
gal]

NOTE: The total lubricating oil system capacity is the summation of the
oil pan capacity at the high mark on the dipstick, the full flow oil filter
capacity, and the capacity of any bypass filters that are used.

Total System Capacity

When using 75 litre [20 U. S. gal] oil pan: 90 litre [24
U.S. gal]
When using 132 litre [35 U.S. gal] oil pan: 148 litre [39 U.S. gal]
 QST30 SPECIFICATIONS - COOLING SYSTEM

Coolant Capacity (Engine Only) 85 litre [22.4 U.S. gall ]

Standard Modulating Thermostat Range 77 to 90 °C [170 °F to 194 °F]
Minimum Pressure Cap 48 kPa [7 psi]
Coolant Temperature Minimum Top Tank 71 °C [160 °F] 100 °C [212 °F]
Maximum Deaeration Time 25 min
Minimum Drawdown Of System Capacity 8%
 QST30 SPECIFICATIONS - AIR INTAKE SYSTEM

NOTE: Engine intake air must be filtered to prevent dirt and debris from entering
the engine. if the intake air piping is damaged or loose, unfiltered air will enter the
engine and cause premature wear.
Maximum Intake Restriction with Heavy Duty Air Cleaner:
With Clean Filter Element 305 mm H2 O [12 in H2 O]
With Dirty Filter Element 635 mm H2 O [25 in H2 O]

QST30 SPECIFICATIONS - EXHAUST SYSTEM

Back Pressure - Maximum (at rated speed and load) 75 mm Hg [3 in Hg]

Exhaust Pipe Size Normal Acceptable 52 mm [6 in]
 QST30 SPECIFICATIONS - ELECTRICAL SYSTEM

Minimum Recommended Battery Capacity

Engine Model QST30 Temperature Range -18 to O°C [0 to 32°F]

System Voltage 24v D.C.
Cold Cranking Ampere 1800 Amp
Ampere Hours 400 Amp Hours
Reserve Capacity 640 Amps.

NOTE: The number of plates within a given battery size determines reserve
capacity.
Reserve capacity is the length of time which sustained cranking can occur.
NOTE: CCA ratings are based on two 12 volt batteries in series.
 QST30 SPECIFICATIONS - ELECTRICAL SYSTEM
CONT..

Battery cable sizes - American wire gauge (Maximum length in cranking motor
circuit)
24 to 32 volt
No. 00 6.1 meters [20 ft]
No. 000 8.2 meters [27 ft]
No. 0000 or two No. 0* 10.7 meters [35 ft]
Two No. 00 13.7 meters [45 ft]

Minimum cranking speed without starting aid 150 RPM

NOTE: Two strands of No. 0 cable can be used in place of one No. 0000 cable
providing all connections are carefully made to ensure equal current flow in
each parallel cable.
RIGHT BANK ( OLD )

1 Air Crossover Housing

2 Turbocharger
3 Full Flow or Combination Oil Filters
4 Water Outlet Connection
5 Lifting Bracket
6 ECM ( Industrial only )
7 Fan Belt Idler assembly
8 After cooler Inlet Tube
9 Fan Belt Idler Pulley
10 Water Filters
11 Water Pump
12 Water Inlet Connection
13 Oil Fill Tube
14 Fuel Lift Pump
15 Lubricating Oil Drain
16 Fuel Filters
17 Fuel Injection Pump Overflow Valve
18 Fuel Injection Pump
19 Lubricating oil bypass filters (when
equipped with full-flow oil filters)
20 Lubricating Oil Transfer Tubes
21 J 1939 Data link (Industrial Engines
22 Air Intake Manifold
LEFT BANK

1 Turbocharger Inlet Connection

2 Turbocharger Outlet Connection
3 After cooler Housing (Intake manifold
on Charge Air Cooled Engines )
4 Cam Follower Cover
5 Engine Speed Sensor ( Engine position
Sensor Ind Engines )
6 High Pressure supply lines
7 Oil Pressure Sensor
8 Pre Lubricating Starter ( Ind Eng only )
9 Flywheel Hsg
10 Lubricating Oil Drain
11 Fuel Lift Pump
12 Fuel Injection Pump overflow valve
13 Vibration Damper
14 Fuel Pump Drive
15 ECM ( Ind only )
16 Ind Datalink ( J1587 & 2 6 pin Deutsch
conn, or J1939/J11587 LB & 1 9 – Pin
Deutsch conn )
17 Coolant Temp Sensor
18 Crankcase Brether
19 19 Fan Hub
20 Thermostat Hsg
21 Water outlet conn
22 Water Vent tubes
23 Engine Dataplate
Skid Mounted Engine - Alternator Unit Viewed From Right Side
Right Side - Oil Bypass Filters
Right side - Fuel Pump and Fuel Filters
Right Side - Full Flow Oil Filters
Left Side - Starter Motor and Interface Plug
 Left Side Front
- Timing Pointer and Timing Marks
on Vibration Damper
Right Side - Right Bank Fuel Pump, Oil Filler Tube and
Dipstick (note spanner position on coupling bolt)
FLOW DIAGRAMS

FUEL FLOW

LUBRICATING OIL

COOLING SYSTEM

INTAKE SYSTEM

EXHAUST SYSTEM
FLOW DIAGRAM - FUEL
SYSTEM ( OLD )

1 Fuel Tank
2 Prefilter
3 Fuel Connection Block
4 Feed Pump
5 Fuel Filter
6 Shutoff Valve
7 Fuel Injection Pump
8 Overflow Valve
9 Fuel Injection Nozzle
10 Electronic Governor
A Shutoff Valve Flow
Mechanical Lift Pump Fuel Supply
 Electric Lift Pump Fuel Supply

Electric Lift Pump Fuel Supply System Layout

VS Mechanical Lift Pump Fuel Supply
LUBRICATION VIDEO
COOLANT FLOW
AIR & EXHAUST FLOW
 The Bosch® fuel injection pump rotates at camshaft
speed (one-half crankshaft speed). Each 360-degree
rotation of the fuel injection pump (not the engine)
brings the timing tab back into the center of the
timing pin port and the injection pump back into its
proper timing. As long as the timing pin engages the
timing tab, the injection pump will be properly timed
for installation.
An offset has been incorporated into the fuel
injection pump's internal timing at the Bosch®
factory to compensate for the “V” configuration of
the engine. Both fuel injection pumps are installed at
the specified engine timing of the number 1 right-
bank cylinder.
 Injection Pump – Identification

The QST30 engine family utilizes four different types of Bosch® fuel injection
pumps. These pumps vary by drive system, governor type, and application.

P8500 open drive (or base mount)

P7100 flange mount
P8500 flange mount
RP39 flange mount.

All three types are of the in-line configuration. All three types include a
mechanical lift pump for low-pressure supply with hand-priming capability.
All three types utilize an overflow (or pressure relief) valve to maintain the
correct fuel pressure in the pump gallery. Each engine requires two fuel
injection pumps (of the same type), one per bank.
Bosch® P8500 Fuel Injection Pump

Both types of the P8500 fuel injection pump have the following
characteristics:
•The electronic pump governor is capable of controlling fueling only.
•Fuel shutoff is accomplished by a rapid restart type of shutoff valve
assembly incorporated within a fuel transfer block (manifold).
•Internal components are the same.

P8500 Open-Drive (or base-mount)

Fuel Injection Pump
 P8500 Open-Drive (or base-mount) Fuel Injection Pump

Installed on generator set and generator-drive engines

manufactured prior to August 1997
Utilizes an exposed, flexible coupling to connect the pump's
driveshaft to the engine gear train
Fuel pump lubricating oil supply is provided by a line from the
main oil rifle of the engine block into the injection pump housing.

NOTE: Replacement injection pumps of this type have open-drive

coupling installed by Bosch®. Do not attempt to remove the open-
drive coupling without first contacting a Bosch® ADS shop.
 Bosch® P8500 Flange-Mount Fuel Injection Pump

Installed on generator set and generator-drive engines

manufactured starting in August 1997
Utilizes a fully enclosed spline drive assembly to connect the
pump's driveshaft to the engine gear train
Fuel pump lubricating oil supply and return passages are
provided by a drilling incorporated into the flange-mount drive
housing.
 Bosch® P7100 Flange-Mount Fuel Injection Pump

Installed on generator set/generator-drive engines (G1 and G2 ratings only)

manufactured starting in February 2000
Same features as P8500 flange-mount fuel injection pump.
BLOCK FAMILIRISATION VIDEO
GCS VIDEO & AEB