QST30.pdf

(1)

SERVICE TRAINING

Komatsu Engines

S12V140Z-1

KT000099

August 1999

Technical Presentation Kit

Engines

Course Objective

The SA12V140Z-1/QST30 Engine

course is designed to achieve the

following 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.

(2)

Presented by:

KAIC Service Training

KT000099

08/99

Komatsu

S12V140Z-1

Technical Presentation Kit

Engines

Introduction

1

5 Troubleshooting

Maintenance

2 Disassembly &

Assembly

6 Structure &

Function

3 Testing &

Adjusting

4 Exit

End Presentation

Technical Presentation Kit

Engines

S12V140Z-1 Engines

(3)

Section 1 KT000099

Technical Presentation Kit

Engines

S12V140Z-1

Introduction

Specifications

1 Features

2 Engine Views

3 Return To Main

Exit

Technical Presentation Kit

Engines

KT000099

08/99

(4)

(5)

Section 1.1

Specifications

KT000099

Technical Presentation Kit

Engines

S12V140Z

(6)

(7)

Section 1.1

Specifications

KT000099

Technical Presentation Kit

Engines

S12V140Z-1

Presented by:

KAIC Service Training

KT000099

08/99

Technical Presentation Kit

Engines

HD325-6 / HD465-5 / HD605-5 Technical Presentation 0 8 / 9 9 Page 1-3 KT200199 - Introduction

Komatsu Engine Model

S A 12 V 140 Z - 1

Super charged engine (turbocharger)

Aftercooled

Number of Cylinders

V Type Block

Bore diameter in mm

Cummins Manufacture

Series

(8)

Cummins Model

Displacement (Liters)

**Q S T 30 - (*)**

QUANTUM Family

Engine Series

System

Application Codes

Cummins Application Codes

C =Construction

D =Generator Drive

F =Fire Pump

G =Generator Set

L =Locomotive

M =Marine

P =Power Unit

R =Railcar

HD325-6 / HD465-5 / HD605-5 Technical Presentation 0 8 / 9 9 Page 1-6

QST30 /(12V140Z-1)

l

CKEC Seymore IN

l

QST30 / 12V140Z-1

l

Application

Platforms

l

(a) 330M

l

(b)WA800

l

(c) WA900

l

KCEC Osaka Japan

l

12V140-1

l

Application Platforms

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(a) D475A-3

– 3rd Qtr 98 QST30

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(b) HD785

– Z engine Units built in

Peoria

(9)

History of SA12V140

1981

Development started in 1981 SA6D140

1984

Development begins of a SA6D140 “V”

version.

1986

First

Prototype

1987

Pre -Production

1988

HD785 (dump Truck)

WA800 (wheel Loader)

1989

D475 (bulldozer)

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Komatsu began production in Japan in 1988

l

Production levels have been 200 units per

year (270 in 1996)

l

Komatsu engines were used in the HD785

haul truck , WA800/WA900 front end loader,

and D475A-2 crawler dozer applications

l

Less than 5% of the engines were sold for

marine or power generation applications

History of SA12V140

l

1988 though 1992 Komatsu produces

-400 SA12V140-1 engines

l

Customer surveys and engine

evaluations completed in Japan in ‘93

compare perceptions of the

SA12V140-1 v.s. K38

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Cummins Komatsu Engine Company

formed in Oct. 1993.

(10)

KT200199 - Introduction

Cummins Komatsu Engine Co.

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50/50 joint venture

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Komatsu retains design control of the

base engine options

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Design control of customer options is

retained by Cummins

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Cummins pays Komatsu a license fee to

Komatsu for each engine sold.

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Joint venture employs >100 people

working at Cummins Industrial Center

QST30 Development Program

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Development program began in 11/93

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Focus of efforts was to resource components

through the Cummins supply base

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Some engineering effort on re-design of fuel

pump drive and mounting to accommodate

Bosch fuel pump

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Power Gen. and Industrial Electronic controls

designed entirely by CECo.

QST30 Resourcing Effort

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-75% of the total engine cost is sourced

through Cummins supply base. Examples

include :

– Golden: block casting

– CKEC: block machining

(11)

KT200199 - Introduction

l

Holset: turbochargers, air compressors, &

dampers

– Cifunsa: head casting

– Cummsa: head machining

– Concentric: lube oil and water pumps

– Delco: starters

QST30 Resourcing Effort

A number of key components continue to be

supplied by Komatsu:

l

Pistons

l

Rough block castings

l

Liners

l

Bearings

l

Crankshaft machining

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Most gaskets

QST30 Resourcing Effort

Engine Model

Komatsu

SA12V140

Cummins

V 2 8

Cat

3412

Cat

3508

DDC

12V92

Type

Nuber of Cylinders

1 2

8 1 2

Bore x Stroke

140x165

139.7 x

152.4 137 x 153

170 x 190

123 x 127

Displacement

30.5 2 8

2 7

34.5

18.01 Rated Output (hp/rpm)

1050/2100

900/2100

750/2100

1000/1800

825/2300

Peak Torque (kgm/rpm)

425/1500

343/1500

297/1500

462/1200

307/1200

Dry Weight (kg)

2930

2633

2157

3680

1940

Length (mm)

1670

1833

1650

1905

1730

Width (mm)

1252

1273

1136

1422

1190

Height ( mm)

1524

1608

1318

1702

1370

Output/Displacement (hp/l)

34.4

32.1

27.8 2 9

45.8 Weight Displacement (kg/l)

96.1 9 4

79.9

106.7

107.7 Output/Bulk Volume

(hp/mm

2)

329

240

304

217

293 Specifications

(12)

Engine Ratings

l

Power Generation Ratings

:

–

-60Hz Standby 750, 800, 900 Kw (1135,1200,1490 bhp)-50Hz

standby : 620, 705, 800 kWh.(940, 1030, 1200, bhp)

–

50hz standby: 675 & 725 kWh. (1010 & 1080 bhp

–

60Hz prime 675 & 725 kWh. (1010 & 1080 bhp

–

50hz prime 560 & 640 kWh. (840 & 960 bhp)

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Industrial Ratings:

–

Intermittent Duty: 1050 @21200 rpm C torque rise

–

Continuous duty : 850 hp @ 2100 rpm 50hz prime 675 & 725

kWh.

(1010 & 1080 bhp

Presented by:

KAIC Service Training

KT000099

08/99

Technical Presentation Kit

(13)

Section 1.2

Features

KT000099

Technical Presentation Kit

Engines

(14)

(15)

Section 1.2

Features

KT000099

Technical Presentation Kit

Engines

S12V140Z-1

Presented by:

KAIC Service Training

KT000099

08/99

Technical Presentation Kit

Engines

KT000099

Technical Presentation Kit

Engines

S12V140Z-1

12V140Z-1 / QST 30

Base Engine Introduction

(16)

S12V140Z-1 Technical Presentation 0 8 / 9 9 Page 3-4

KT000099 - Structure & Function

Discussion of Selected

Engine Components

General Engine Overview

Valve Settings:

Intake Valve Adjustment

0.43 mm [0.017 in]

Exhaust Valve Adjustment

0.80 mm [0.032 in]

QST3O Aspiration

-

Turbocharged and Aftercooled

Discussion of Selected

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

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Compact

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High Output

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High Reliability and Durability

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Fuel Economy

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Easy Maintenance

(17)

SA12V140Z-1 / QST30

Bore & Stroke 140 mm X 165 mm

Cylinder Arrangement 12 Cylinder

50 Degree Vee

Volume 30 Liters

Industrial Power Output 750 - 1050 Hp

1. Bank Angle

50 Degree Vee

Firing Order:

1R-1L-5R-5L-3R-3L-6R-6L-2R-2L-4R-4L

2. Piston

Ductile iron piston, High Top Ring

3. Cylinder Head Dry sleeve injector bore

4. Cylinder block FEM Design, STORM threads two bolt main

with future four bolt main.

5. Crankshaft

Induction hardened Journal Fillets

Design Features

Standard Features

6. Injection Pump Layout

Two Bosch RP39 or Two Zexel

KP21E with electro -hydraulic

governor

7. Intake/Exhaust Layout

offset 15’ Intake - Outside

Exhaust - Inside

8. Oil Pump

High flow three gear design

9. Aspiration

Turbocharger & Aftercooled

10. Turbochargers

Twin Holset HX60

11. Oil Filtration Full flow and bypass filtration

12. Cooling system

Conventional radiator

(18)

Fuel System

l

Four fuel systems are available

» Zexel PS7S with Mechanical governor

» Komatsu High Pressure KP22 with

electro-hydraulic control

» Bosch RP39/RE36 full authority electronic

control

» Bosch P8500/RE30

Common Components

(SA6D140 & SA12V140)

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Cylinder Head, Rocker Housing, Head Cover

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Piston, Piston Pin and Piston Ring

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Rocker Arm, Push-rod, Cam Follower

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Oil Cooler Element (2 elements for SA12V140Z-1)

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After-cooler Element (2 elements for SA12V140Z-1)

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Note: Valve components are improved can be used

to uprate SA6D140

Controls for Industrial Ratings

l

Dual Cummins CM552 ECM

(19)

Advantages of Bosch Electronic

Fuel System

l

Higher Injection Pressure Capability for Reduce

Emissions.

l

Elimination of Mechanical Linkage Between Fuel

Pumps

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Capability to Interface with other Vehicle/Power

Train Electronics

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Improved Cost

How to Achieve High

Performance

1. Good Intake / Exhaust System

2. Good Combustion

3. Reduced Friction

1. Good Intake / Exhaust System

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Backward Rake Turbo Charger

– Holset HX60

– Komatsu KTR110-2

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Pulse Reserving Exhaust Manifold

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Ductile Cast Iron Piston

(20)

Ductile Cast Iron Piston

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High Pressure Fuel System

• SA12V140 Two Komatsu KP21 pumps

• SA12V140Z-1 Two Bosch RP39

• QST30G & D Two Bosch P8500

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Optimized Combustion Chamber Shape

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Ductile Cast Iron Piston

2. Good Combustion

Intake Port Development For

Good Combustion

(21)

Optimized Combustion Chamber

Shape

Minimum Dead Volume Combustion

Chamber(MDVCC)

3. Reduced Friction

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Four Valves / Cylinder

– Tribaloy intake valves seats

• Reduced valve and valve seat wear

– Stem Seals

– Chrome stems

– Nitride intake valve face material

–

Eatonite 6 exhaust Valve face material

• Extended service intervals

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Three Ring Piston

(22)

How to Achieve High Durability &

Reliability

1. Combustion Chamber Components (Reduced

Thermal Load)

2. Strong and Rigid Main Components

(FEM Design & Stress Tested Components)

3. Low Wear & High Scuff Resistance Design

Combustion Chamber Components

(Reduced Thermal Load))

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Piston

– Oil Jet Cooling

– Cooling Gallery Around Combustion

Chamber & Ring Pack

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Cylinder Head

– Forced Cooling Through Drilled Holes in

Valve Bridge

(23)

Internal Piston Cooling Passage

Strong and Rigid Main Components

FEM Design & Stress Tested as

Components

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Cylinder Block, Connecting Rod

– Mechanical Stress

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Cylinder Head & Piston

– Mechanical & Thermal Stresses

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Crankshaft

– Bearing Oil Film Calculation

Low Wear & High Scuffing

Resistance Design

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Roller Cam Follower

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Special Surface Control for Cylinder Liner

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Keystone Type Piston Rings

(24)

Key Changes in the Cummins

QST-30Komatsu Sa12V140-Z1

l

Fuel System/ Controls

– Zexel to Bosch Cummins Electronic

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Turbochargers

– Komatsu to Holset

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Upgraded Components:

– Improved Rating Capability and Problem

Counter Measures

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Resourced Components with Cummins Suppliers

– Reduced Engine Cost

Fuel System /Controls

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1. Fuel Pumps

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2. Controls

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3. Advantages of Bosch Electronic Fuel

System

Fuel Pumps for Industrial Ratings:

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Bosch RP39/RE30

(25)

Controls for Industrial Ratings:

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Dual Cummins CM520 ECMs

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On Engine Mounting

Advantages of Bosch Electronic

Fuel System

l

Higher Injection Pressure Capability

for Emissions

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Elimination of mechanical Linkage

Between Fuel Pumps

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Capability to link with Other

Vehicle/Power Train Electronics

l

Improved Cost

Turbochargers

l

“Cumminization”

l

Improved Efficiencies

l

Improved Cost

l

Wastegates Available for Quick

Response Applications

(26)

Presented by:

KAIC Service Training

KT000099

08/99

Technical Presentation Kit

(27)

Section 1.3

Engine Views

KT000099

Technical Presentation Kit

Engines

(28)

(29)

Section 1.3

Engine Views

KT000099

Technical Presentation Kit

Engines

S12V140Z-1

Presented by:

KAIC Service Training

KT000099

08/99

Technical Presentation Kit

Engines

1. Front cover

2. Cylinder block

3. Cylinder liner

4. Rocker lever

housing

5. Cylinder head

cover

6. Exhaust valve

7. Intake valve

8. Piston

Left Side View

S12V140Z-1

Technical Presentation 0 8 / 9 9 Page 3-4

9. Turbocharger

10. Cam follower

11. Camshaft

12. Flywheel

13. Flywheel housing

14. Main bearing cap

15. Crankshaft

16. Oil pan

17. Connecting rod

Left Side View

18. Connecting rod

cap

19. Oil strainer

20. Lubricating oil

pump

21. Crankshaft gear

22. Vibration

damper

23. Crankshaft

pulley

Left Side View

S12V140Z-1

Technical Presentation 0 8 / 9 9 Page 3-6

24. Cylinder head

25. Intake manifold

26. Electrical intake

air heater

27. Lubricating oil

cooler

28. Intake

connector pipe

Front View

(30)

29. Rocker lever

30. Aftercooler

31. Nozzle holder

32. Push rod

33. Piston cooling

nozzle

Front View

1. 23-pin Deutsch

Connector

(Primary/

Secondary ECM

Connector)

2. Engine Speed

Sensor

3. Flywheel

4. Engine Position

Sensor

Rear View

INTAKE SYSTEM

1. Intake manifold

(Right bank)

2. Electrical intake air

heater

3. Aftercooler cover

(Right bank)

4. Aftercooler cover

(Left bank)

5. Intake manifold

(Left bank)

6. Air intake

EXHAUST SYSTEM

1. Exhaust

manifold

(Left bank)

2. Exhaust

manifold

(Right bank)

3. Turbocharger

(Right bank)

4. Turbocharger

(Left bank)

Technical Presentation Kit

(31)

Maintenance

Schedule

1

1 Maintenance

Maintenance

Fluids

2

2 Exit

Exit

Technical Presentation Kit

Engines

KT000099

08/99

Maintenance

-

S12V140Z

-

1 Engines

Return To Main

Section 2.1

Maintenance Schedules

KT000099

Technical Presentation Kit

Engines

(34)

(35)

Section 2.1

Maintenance Schedules

KT000099

Technical Presentation Kit

Engines

S12V140Z

-

1

1 Presented by:

Presented by:

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Technical Presentation Kit

Engines

S12V140Z S12V140Z--11 Technical Presentation Technical Presentation 0 8 / 9 9 0 8 / 9 9 Page 3 Page 3--33 KT000099 KT000099 --Structure & Function Structure & Function

Follow

recommendations in

the Komatsu

Operation &

Maintenance Manual.

Maintenance Schedule

Operation &

Maintenance

Manual

(36)

MAINTENANCE

WHY?

MAINTENANCE

WHEN

REQUIRED

S12V140Z S12V140Z--11 Technical Presentation Technical Presentation 0 8 / 9 9 0 8 / 9 9 Page 3 Page 3--66

Maintenance Schedule

INITIAL 250 OF SERVICE

(only after the first 250 hours)

• Check engine valve clearance,

(37)

MAINTENANCE

DAILY

Maintenance Schedule

Daily

Check engine:

•

• Oil level in oil pan, add oil

Oil level in oil pan, add oil

•

• Coolant level in radiator, add

Coolant level in radiator, add

coolant

•

• Drain water and sediment

Drain water and sediment

from fuel filters

Maintenance Schedule

Daily

Inspect engine for:

•

• Damage

Damage

•

• Leaks

Leaks

•

• Loose or damaged belts

Loose or damaged belts

•

• Unusual noises and exhaust

Unusual noises and exhaust

color

•

• Check electronic engine

Check electronic engine

protection system (fault code

Lamps)

•

(38)

Maintenance Schedule

Weekly

•

• Check air intake piping

Check air intake piping

•

• Check air intake restriction (dust

Check air intake restriction (dust

indicator)

•

• Check air cleaner element. clean

Check air cleaner element. clean

or replace

MAINTENANCE

50

50 HOURS

HOURS

Maintenance Schedule

50 Hour Service

•

• Drain water, sediment from fuel

Drain water, sediment from fuel

tank

(39)

MAINTENANCE

Every

250 HOURS

Maintenance Schedule

250 Hour Service

•

• Change engine lubricating oil

Change engine lubricating oil

•

• Change engine filters:

Change engine filters:

•

• Full flow oil

Full flow oil

•

• By

By

-

pass oil

•

• Fuel (spin

Fuel (spin

-

on)

•

• Coolant (Corrosion resistor

Coolant (Corrosion resistor

cartridge)

•

• Check and clean crankcase

Check and clean crankcase

breather tube

Maintenance Schedule

250 Hour Service

•

• Check engine fan

Check engine fan

•

• Check drive belts and tension

Check drive belts and tension

•

• Check alternator belt tension,

Check alternator belt tension,

adjust

•

• Check air conditioner

Check air conditioner

compressor belt tension,

adjust

•

• Check battery electrolyte level

Check battery electrolyte level

•

(40)

MAINTENANCE

2000

HOURS

12V140

Maintenance Schedule

2000 Hour Service

•

• Steam clean engine

Steam clean engine

•

• Overhead set

Overhead set

•

• Adjust engine cross heads

Adjust engine cross heads

•

• Adjust engine valves

Adjust engine valves

•

• Measure crankshaft end

Measure crankshaft end

clearance

•

• Check engine mounts

Check engine mounts

Maintenance Schedule

2000 Hour Service

•

• Grease fan drive idler pivot arm

Grease fan drive idler pivot arm

assembly

•

• Check cold starting aids

Check cold starting aids

•

• Engine oil heater (if equipped)

Engine oil heater (if equipped)

•

• Coolant heater (if equipped)

Coolant heater (if equipped)

•

• Check engine hoses

Check engine hoses

•

(41)

MAINTENANCE

6000 HOURS

or 2 years

which ever

comes first

Maintenance Schedule

6000 Hour Service

•

• Inspect:

Inspect:

•

• Turbocharger

Turbocharger

•

• Vibration damper

Vibration damper

•

• Water pump

Water pump

•

• Coolant thermostats and seals

Coolant thermostats and seals

•

• Air compressor

Air compressor

•

• Clean and flush the cooling system

Clean and flush the cooling system

•

• Check belt driven fan hub

Check belt driven fan hub

•

• Check fan drive idler pulley assembly

Check fan drive idler pulley assembly

Presented by:

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KT000099

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Technical Presentation Kit

Engines

(42)

(43)

Section 2.2

Maintenance Fluids

KT000099

Technical Presentation Kit

Engines

(44)

(45)

Section 2.2

Maintenance Fluids

KT000099

Technical Presentation Kit

Engines

S12V140Z-1

Presented by:

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KT000099

08/99

Technical Presentation Kit

Engines

Follow

recommendations

in the Komatsu

Operation &

Maintenance

Manual.

Fuel Oil, Lubricating Oil and Coolant

Operation &

Maintenance

(46)

Fuel, Lubricating Oil and Coolant

FUEL

Fuel, Lubricating Oil and Coolant

• Do not mix gasoline or alcohol with

diesel fuel. This mixture can cause an

explosion.

• IMPORTANT: Due to the precise

tolerances of diesel injection systems, it

is extremely important that the fuel be

kept clean and free of dirt or water. Dirt

or water in the system can cause severe

damage to both the injection pump and

nozzles.

Fuel, Lubricating Oil and Coolant

• For normal service above -12°C (+lO”F),

the use of ASTM Grade No. 2-D diesel fuel

with a minimum Cetane number of 40 is

recommended. The use of No. 2-D diesel

fuel will result in optimum engine

performance under most operating

conditions. Fuels with Cetane numbers

higher than 40 may be needed in high

altitudes or extremely low ambient

temperatures to prevent misfires and

excessive smoke.

(47)

Fuel, Lubricating Oil and Coolant

• At operating temperatures below -12°C

(+lO”F), use ASTM Grade No. 1-D diesel

fuel. The use of lighter fuels can reduce

fuel economy.

• Where a winterized blend of Grade No.

2-D and No. 1 -2-D fuels is available, it may be

substituted for Grade No. 1 -D fuel.

However, it is the supplier’s responsibility

to provide the fuel for the anticipated

ambient temperature.

Fuel, Lubricating Oil and Coolant

• Use a low sulfur content fuel having a

cloud point that is at least 10 degrees

below the lowest expected fuel

temperature. Cloud point is the

temperature at which crystals begin to

form in the fuel.

• The viscosity of the fuel must

must be kept

above 1.3 cSt at 100°C (212°F) to provide

adequate fuel system lubrication.

Fuel, Lubricating Oil and Coolant

(48)

Fuel Oil, Lubricating Oil and Coolant

Limited use of low viscosity oils, such as SAE 1OW-30

may be used for easier starting and providing sufficient

oil flow at ambient temperatures below -5°C (+23”F).

However, continuous use of low viscosity oils can

decrease engine life due to wear.

SAE 15W-40 multi-viscosity oil is recommended for most

operating climates, refer to the table for oil viscosity

recommendations for extreme climates.

Fuel Oil, Lubricating Oil and Coolant

Oil performance recommendations are as

follows:

The use of a high quality engine

lubricating oil combined with appropriate

oil and filter change intervals are critical

factors in maintaining engine performance

and durability

.

Fuel Oil, Lubricating Oil and Coolant

SAE 15W-40 multi-viscosity heavy duty

engine oil meeting the American

Petroleum Institute (API)

performance classification of CG-4 or

CG-4/SH is recommended.

NOTE: CE oil may be used in areas

where CG-4 oil is not yet available.

(49)

Fuel Oil, Lubricating Oil and Coolant

A sulfated ash content of 1.O mass

percent is suggested for optimum valve

and piston deposit and oil consumption

control. The sulfated ash must not exceed

1.85 mass percent. The sulfated ash limit

of 1.85 mass percent has been placed on

all engine lubricating oils recommended

for use in the engine. Higher ash oils can

cause valve and/or piston damage and

lead to excessive oil consumption

.

Fuel, Lubricating Oil and Coolant

Engine Coolant

Fuel Oil, Lubricating Oil and Coolant

ANTIFREEZE

In climates where the temperature is

above -37°C (-34”F), 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.

(50)

Fuel Oil, Lubricating Oil and Coolant

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.

Fuel Oil, Lubricating Oil and Coolant

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.

Fuel Oil, Lubricating Oil and Coolant

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.

(51)

Fuel Oil, Lubricating Oil and Coolant

ANTIFREEZE

Antifreeze may retain its freeze

protection for more than one season but

coolant conditioners must be added

to maintain corrosion protection.

Antifreeze formulated with methoxy

propanol, or propylene glycol, is not

recommended for this system.

Fuel Oil, Lubricating Oil and Coolant

Fuel, Lubricating Oil and Coolant

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:

Total Hardness - Not to exceed 170 parts per million

(10 grains/gallon maximum) to prevent scale

deposits. Water containing dissolved magnesium and

calcium (the usual reason for water hardness)

above the specified amount will cause scale deposits

to develop in the engine.

(52)

Fuel Oil, Lubricating Oil and Coolant

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.

Dissolved Solids - Not to exceed 340 parts per

million (20 grains/gallon maximum) to minimize sludge

deposits, scale deposits, corrosion or a combination of

these.

Fuel Oil, Lubricating Oil and Coolant

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.

Fuel Oil, Lubricating Oil and Coolant

MAINTENANCE OF

SUPPLEMENTAL COOLANT

ADDITIVES

Keeping the engine coolant properly

inhibited will keep the engine and

radiator free of rust, scale deposits

and corrosion.

(53)

Fuel Oil, Lubricating Oil and Coolant

MAINTENANCE OF

SUPPLEMENTAL COOLANT

ADDITIVES

New machines are delivered with

antifreeze protection. Service at

regular scheduled interval specified

in the “SCHEDULED MAINTENANCE

GUIDE” with a service DCA4 filter.

Fuel Oil, Lubricating Oil and Coolant

MAINTENANCE OF

SUPPLEMENTAL COOLANT

ADDITIVES

Each time the coolant is drained and

replaced, the coolant must be

recharged with SCA. New coolant can

be correctly charged with

supplemental coolant additives by

using a DCA4 service filter or SCA

concentrate listed in the table

entitled, “DCA4 Unit Guide”.

Fuel Oil, Lubricating Oil and Coolant

MAINTENANCE OF

SUPPLEMENTAL COOLANT

ADDITIVES

If coolant is added between drain

intervals, additional SCA will be

required.

(54)

Presented by:

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KT000099

08/99

Technical Presentation Kit

(55)

Section 3 Structure & Function

KT000099

Technical Presentation Kit

Engines

(56)

(57)

Section 3.1

Base Engine

KT000099

Technical Presentation Kit

Engines

(58)

(59)

Section 3.1

Base Engine

KT000099

Technical Presentation Kit

Engines

S12V140Z

-

1

1 Presented by:

Presented by:

KAIC Service Training

KT000099

08/99

Technical Presentation Kit

Engines

Engine Components

Power Cylinder Components

Block

Oil Pump

Crank shaft

Oil Pressure Regulator

Connecting Rod

Full flow oil filter head

Piston& Rings

Water Pump

Cylinder Liner

Water Filter Head

Cam shaft

(60)

Engine Block

The main cylinder

block was designed

using Finite Element

Analysis to create a

compact and light

weight foundation,

yet it has a high

rigidity through the

use of internal ribs

and reinforcement.

Engine Block

The ribbed skirt

design of the

QST30/12V140Z-1

block gives it low

weight , reduced

noise and high

strength.

Block encompasses

seven main bearing

design to handle the

increased cylinder

pressure loads.

Engine Block

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

(61)

End View of Engine

The block provides an area cast in for the oil cooler.

Oil Cooler Area

The main

cylinder block

incorporates a

ribbed skirt

design which

gives it lower

weight high

strength and

reduced noise

levels.

Internal Block Webbing

(62)

Main Bearing Saddle

The main bearing

saddle has a grove

machined into it for

improved oil flow .

There is also a

provision for future

high horse power

ratings to employ

the use of a four

bolt main cap.

Instead of a two

bolt main

Block Skirt Ribs

Cylinder block

incorporates a

lower press fit

liner for added

strength and

reduces stress

in the

counterbore.

Counter Bore

(63)

CRANKSHAFT

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 Main Journals

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

The main

journals and

fillet radii have

been induction

hardened for

increased

strength and

wear.

(64)

Rod Bearing Journals

Connecting rod

journal has a

diameter of

3.94 inches

which provides

ample surface

area.

Connecting Rod & Bearing

•Oil Drilling

Connecting rods are of a forged steel

”I” beam designed

Connecting Rod & Bearing

•Oil Drilling

Each rod has an oil

drilling to provide

pressure lubrication

to the piston pin and

to help cool the

piston. Four cap

screws a used to

connect the rod cap

using torque to yield

method for a more

uniform clamping

load.

(65)

Four cap

screws for

more universal

clamping load.

Use torque to

yield method

of tightening

Rod Caps and Bolts

Because of the oil

drilling two

different rods are

used in the same

engine. One set of

rods for the left

bank and one set of

rods for the right

bank. There are

two different part

numbers for each

set of rods.

Connecting Rods Cont.

Liner & Pistons

l

Liner Size / Piston Size

l

right bank large

l

left bank small

l

Large liner large piston

l

(66)

Piston

The QST30 / 12V140Z

-

1

1 uses a single piece ductile

uses a single piece ductile

cast iron piston. Fewer

parts compared to

articulated designs. This

design has several

advantages over

aluminum and is

comparable to steel.

Piston

This piston design

maintains high strength

at elevated

temperatures. Uses a

Minimum Dead Volume

Combustion Chamber

(MDVCC) resulting in

minimum top clearance

at the top ring. Also,

piston to liner clearance

is reduced.

Each piston has a

“Gallery Cooling”

channel cast into the

piston behind the

ring pack. This is

referred to a

“Shaker” design.

Lubricating oil flows

into this passage and

cools the piston

crown and ring

pack.

Gallery Cooling

QST30.pdf

SERVICE TRAINING

Komatsu Engines

S12V140Z-1

KT000099

August 1999

Technical Presentation Kit

Engines

Course Objective

The SA12V140Z-1/QST30 Engine

course is designed to achieve the

following 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.

Presented by:

KAIC Service Training

KT000099

08/99

Komatsu

S12V140Z-1

Technical Presentation Kit

Engines

Introduction

1

5

Troubleshooting

Maintenance

2

Disassembly &

Assembly

6

Structure &

Function

3

Testing &

Adjusting

4

Exit

End Presentation

Technical Presentation Kit

Engines

S12V140Z-1 Engines

Section 1

KT000099

Technical Presentation Kit

Engines

S12V140Z-1

Introduction

Specifications

1

Features

2

Engine Views

3

Return To Main

Menu

Exit

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Engines

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Section 1.1

Section 1.1

Specifications

Specifications

KT000099

KT000099

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Technical Presentation Kit

Engines

Engines

S12V140Z

Section 1.1

Specifications

KT000099

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Engines

**Q S T 30 - (*)**