QSX15 presentation.pdf
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Welcome To QSX15 training
Instructor Knut Hultmann
Daventry Training Centre WC Location Lunch Arrangements Safety Card Fire Alarms & Exits Issues List Messages for Participants None Smoking Policy Mobil Phones
QSX 15 Engine. Exh. side view
The QSX15 600 hp/15 liter/in-line 6 cylinder, industrial diesel engine Designed from a “clean sheet” Complete new engine Tailored for the construction market Based on “Cummins Signature 600” Introduced in the automotive market July, 1998 Designed for world markets to operate on locally available coolants and fuels . . . including kerosene Worldwide emissions capable Manufactured at Cummins new plant in Columbus, Indiana Marketed, supported and serviced Worldwide by Cummins
QSX 15 Engine Specifications Feature
AHD
Displacement Configuration Bore (mm) Stroke (mm) Weight (lbs) Rated Power (hp) Braking Power (hp) Rated Speed (rpm) Peak Torque (lb-ft) Peak Torque Speed
15.0 L In-line 6 cylinder 137 169 3362 (dry) 1525 kg 350 - 600 600 2100 2050 1400
65 mm less length and 100 mm less height than N14
Performance 350 - 600 Horsepower Haul trucks, combines, forage harvesters, airport crash truck, blast hole drills, 4 wheel drive ag tractors, excavators, wheel loaders, cranes, air compressors, rail car, chippers and etc. Good transient response Displace the lower end of the QSK19 (450 - 600 hp) Wastegate turbocharger and air-to-air aftercooler Wide power-band --> room for HP growth
Emissions Plan The current N14 engine design will not be certified for Tier II emissions The N14 will be replaced by QSX15 engine QSX 15 Industrial phased introduction is January, 2000 QSX 15 Tier II Entering service in ( central area business organization ) CABO 2002 onwards N14 will be available for markets requiring Tier I emissions Flexibility rule allows OEM to continue to use N14 if requirements are met
Performance Comparison HPI TP fuel system High injection pressure 28,000 psi
700
Horsepower
650 600
Open nozzle
550
Ultra short injection duration
500 450
25-40% higher cylinder pressure
400 350 300 1300 1400 1500 1600 1800 1900 2000 2100 Engine Speed QSX15-600
QSK19-600
N14-525
Electronic boost control 4 step waste gate controller Low speed torque
QSX15 Differences vs. N14 Latest technology Integrated design (block, FS and etc designed for electronics) 30% fewer parts (more reliable)
Waste gate turbo 4 step control Improved response and low end torque
High capacity oil coolers for worldwide markets ( high ambient air temp )
Fan drive comparable to N14 ( Mutable fan hub center height ) Hydraulic pump drive N14 single “B” 154 lb-ft QSX15 “BB” 249 lb-ft
REPTO option
QSX 15 Advantages over N14 Celect Feature
Benefit
PWM - Pulse Width Modulated
Allows for control of transmission (can be used as a power indicator)
Multi Unit Synchronization
Dual engine applications
Remote throttle
Blast hole drill
Multiple torque curve
Driveline ,power train protection (special operating conditions)
Duty cycle monitor
Productivity monitoring asset utilization
Pressure governor/ tail shaft governor
Power units for constant engine speed for fire pumps or ski lifts
Interact (CM570) Control Module Technology
No circuit board Higher reliability
QSX15
N14 Celect
Sealed module significantly reduces water intrusion Expandable in future 10 times memory, 10 times processing power of ECM c Pins have multiple function capability (Reconfigurable I/O)
Industrial electronic feature set is common with QSK19
CM570
ECMc
Block Gray iron Lighter, stronger Single piece Bridge plate ( bed plate ) Stronger crank More bolted joint capacity on flywheel Dual Vibration dampers reduced noise / improved gear train life
Front End Features... • 2-belt Drive • Poly-Vee Auto Tensioned Belt System • Multiple fan Centres • Belt Driven Water Pump • Fan Bracket and Front Engine Support Mounts Directly to Block • Duel vibration damper, smoother running engine less vibration • No Valve Cover Oil Fill • Front Gear Cover Oil Fill • Barring Device Located Behind Oil Fill
Dual Overhead Camshafts Unique approach One cam dedicated to injector One cam drives valves and engine brake Dedicated brake lobe
Inj & Valve Camshafts Note: when removing gear. Remove rear cover plate or breakage of cover plate will result. Also remove fuel pump / IFSM , or damage to fuel pump drive gear will result Engine Cycle Indicator Lobe
Oil Flow
Fuel Pump Drive Gear
Injector Cam
Oil Flow
Valve Cam
• • • •
Hollow Injector Cam Oil Flows From Each End Integral Fuel Pump Drive Gear Cam shafts may be removed from front or to rear of the engine
Cylinder head
Cylinder Head
Single piece High strength alloy Integrated air/fuel system Integrated ECM/fuel mounting Integrated Cam supports Centered injector location Improved combustion Performance Power density Fuel consumption Emissions
Uniform ring temperature Durability Oil control Emissions
Cylinder Head Fuel Flow Paths
Two Cylinder head gasket types – Not Compatible New one piece Head Gasket…Requires new flat top Cyl liner
Compatibility- New head gasket is Not compatible with old grooved-top liners
Two Cyl liner types – Not Compatible Old style
New style
Grooved – top liner
Flat – top liner
Cyl block
Two different designs of cyl liner are used on QSX engines dependent on engine production vintage & ESN CAUTION Liners of different design can not be mixed within an engine. All six liners must be of the same design. Why; differences in cyl head gasket Refer to SPT 03T1 – 10 New single O – Ring Cyl liner Intro Ref SPT 04T1 - 26
Two Piston Style types – Not • Articulated Piston forged steel crown Compatible aluminum skirt
• New Monotherm Piston Single – piece piston. Alloy steel • 4-bolt, Horizontal Split Rod ... • Upper/Lower Rod Bearings Are Not Interchangeable
CAUTION All pistons within a given engine must be of the same design - all are to be either the articulated design or the single-piece design. Do not mix piston designs in the same engine. Ref SPT 03T1 - 5
Two conrod types – Not Compatible
Single-piece pistons must have drilled rods and rod bearings. Articulated pistons can use either drilled or nondrilled rods and bearings. Ref SPT 03T1 – 5. Leads to : Procedure Piston & Conrod 001-054
Crankshaft • Midstop Liner • Non-replaceable Gear, Tone Wheel and Adapter • Thrust, 360° Front/Rear on No. 4 Main
Micro alloy material Robust design Designed for reduced weight Improved manufacturing
Geartrain Front gear train Scissors gear to minimize lash Excellent idle quality Adjustable upper idler
Scissors Gear Minimise excessive lash Lower noise Lower impact Reduced tooth wear/fitting
Air Handling Electronically controlled wastegate for optimum performance Simple, ECM control waist gate control block Significantly extends engine envelope Holset turbo HX55 / 60 Ref To CPL, dependant
Brake System Fully optimized brake event 40-50% increase in braking Up to 448 kW (600 hp) Simple design Low weight No package size impact
QSX 15 Intebrake Detent Rocker Brake Cross-Section
IFSM – Integrated Fuel System Module Fuel Pump)
1. Field Replaceable Assembly 2. Max Inlet Restriction – 12 in. Hg
Aluminium IFSM Housing
FSO – Fuel Shut Off Solenoid
Inlet Restriction Sensor #10 Inlet – 45° 45° Flare
250 psi Pressure)
# 8 Return – 45° 45° Flare 10 Micron Suction Filter – FS1007
IFSM 1. Field Replaceable Assembly 2. Max Inlet Restriction – 12in. Hg
Rear Metering Actuator
Rear Timing Actuator
Front Metering Actuator
Front Timing Actuator
Metering Actuator Resistance @ 70° 70° F 21 ° C
Timing Actuator
0.8 ± 0.1 ohms 1.3 ± 0.1 ohms
IFSM 1. Field Replaceable Assembly 2. Max Inlet Restriction – 12 in. Hg
Supply Pressure Compuchek Port
320 psi Dead Head Regulator
Fuel Pressure Sensor 36 Micron Filter Screen Front Bank UFD Sensor ( Will be removed in the future )
WIF (Water in Fuel) Sensor
Inlet Restriction Compuchek Port New IFSM test point moved to top Rear Bank UFD (Unintended Fuelling Detection/Diagnostics) Sensors will be removed in the future Ref SPT 00T19 - 30
HPI Injector Link Notes: 1. Injectors will operate on up to 2% water in fuel. 2. Must pull injector rocker shafts to change injector and loosen valve rocker levers 3. Adj Inj on OBC 4. Before injector removal , drain coolant below cyl head
Upper Plunger
Timing Check Valve 4 O-Rings
Filter Screen Timing Plunger
Metering Check Valve TVS (Trapped Volume Spill) Nozzle & barrel, one piece Lower Plunger
Heavy-duty HPI-TP Fuel System IFSM Schematic Fully integrated No external plumbing
Fuel Pump
Smart filtration system Fuel Pump
( WIF )
Timing Actuators SOV
Fuel Pump Nameplate
Hex Head IFSM Vent Plug Nameplate
Fuel Pressure Sensor Connector Pressure Side Compuchek Fitting Fuel Filter
Suction Side Compuchek Fitting Fueling Actuators Water Separator
HPI TP Fuel System Designed for up to
Timing Pulse Supply
Operate at 22 & 28,000 psi
Gear Pump
Pulsed Low Pressure Fuel Supply
Fueling
Timing
+-
+-
ECM
32,000 psi
Timing Fueling +-
+-
320 System Pressure Regulator
+ SOV
IFSM
Open nozzle Individual cylinder control
250 psi System Pressure Regulator Fuel Filter
Electric + Priming Pump
Return Fuel Line Fuel Tank
Fully authority Simple design
Electronic Control Module J1939/1708 Robust design Diagnostics Data logging New features Air compressor control Turbo control Fan clutch control
Integrated design Air cooled Accessible
10 x memory Small and lightweight Simple OEM connections
Reliability and Durability Edge molded rubber gaskets and seals designed for 100% reliability Designed for sub-assembly tests Integral accessory drive Statistical engine test analysis Structural bridge plate High injection pressure capable 32,000 psi design 22 & 28,000 psi operate
Diagnostics
Front-end Features 2-belt drive Poly-Vee automatic tensioned belt drives Fan centers from 12” to 22” at .55 - 1.0:1 ratio Belt driven water pump Front engine support mount directly to block Flexible fan drive Fixed fan center Tighter clearances Fixed fan drive
Dual alternator drive option High capacity front mount Rotating breather
Left Side Features
Integrated fuel system Integrated electronic controls Integrated air inlet 4-point engine mount capability WABCO air compressor A/C provides full SAE A-flange hydraulic pump drive capability at 1:1 ratio
SAE B-B capability without A/C compressor 100 hp 249 ft-lb
Engine barring device option Electric fuel priming option Options for remote mount or chassis mounted fuel filter
Flywheel End
Flywheel mounted rear seal Unitized axial lip rear seal Housing Flywheel housing - cast iron standard SAE specified components Higher bolted joint capacity than N14
Cooling System Optimized pump hydraulics Filters indicate when water is in the fuel No external plumbing Belt driven water pump Chemically treated filters (technology for better filter performance) All cast iron cooling system components Fixed center fan drive with auto tensioning Increased water pump flow
Lube System
Optimized oil pump design Minimized system flow restriction (16% better than N14)
Edge molded, steel body Oil pan gasket, reusable Increased oil capacity - 12 gallon No external plumbing 500 hour oil drain interval with premium oil
No mess oil change, vertical mount oil filter
CD oil compatible for global markets Increased oil cooler capacity
Lubricating Oil Pump • Located In Pan • Shims may be required for gear back lash Colour coded shims Pump stamped with number, Cyl block with letter • Internal Pressure Regulator • Internal High Pressure Dump
Specific Industrial Features/Options
REPTO High capacity oil cooler Front power take off “BB” hydraulic drive Multi fuel capable Water in fuel sensor No oil carryover (45o angularity) Remote fuel, lube, coolant filter options
REPTO Four pad REPTO 400 horsepower total Simplifies installation Reduces installation cost of application Available November 2000
Hydraulic Drive 11, 13, 15 tooth adaptation
SAE A, SAE B, SAE B-B mounting
100 horsepower capability
Water-in-fuel Sensing Option The Quantum system provides the capability to check for water in the fuel system and alert the operator to help protect the fuel system from damage The system uses a Fleetguard FS1007 fuel/water separator filter with an integrated sensor to detect water in fuel (p/n 3331096) A wiring harness jumper is included The Quantum system alerts the operator and records a fault
Service and Maintenance Longer oil drain intervals Longer life fuel and coolant filters Pan has central bottom drain and two side drains for quick oil drain systems Dipsticks and fills on both sides of engine Filter locations more accessible Vertical mounted oil and fuel filters for easy no mess changes One side servicing capability with remote filters
LF9001 Lube Oil Filter - Stratapore Media Stratapore provides: Durability for extended periods Excellent moisture tolerance Maintains higher efficiency over time Less resistance to flow Cold starts On going parasitic
Substantial contaminant capacity improvement Very consistent composition and performance
LF9001 Lube Oil Filter - Venturi Oil Filtration Technology Advancements What does it do? Generates flow through the highly efficient/restrictive bypass media
How does it do it? The flow through full flow element is restricted by the nozzle throat, forcing more flow through the bypass section
Industry-leading Cummins and Fleetguard next generation filtration technology Longer life Stratapore media with Venturi capable of extended service Rugged mounting with easier removal
Coolant Filters Coolant Filter (Corrosion Resistor) Larger Thread (M36 x 2) Change Interval Filter Part No. WF2126: 50,000 miles (STD)
Thicker Can Material for Corrosion Protection (ES)
Filter Part No. 2125: 150,000 miles (ES) Filter Part No. WF2127: Filter contains NO additives (Must use DCA 4 Liquid)
Coolant Sys Maintenance (SCA) Must Contain 1.5 Units Per Gallon Metric 0.3 to 0.8 Units per liter
Unique Manufacturing Process Find/correct defects at point of creation Six stations Torque-to-turn tests Leak tests Electronics test
End-of-line cold test Uses engine’s own diagnostics Exhaustive “final exam”
Automated data analysis
Manufacturing Fully integrated All engine factory built
All new plant Flexible Efficient Focus on quality
Comparison to N14 and QSK19 Engine
AHD
N14
QSK19
Length (mm)
1549
1521
1643
Height (mm)
1207
1320
1480
Width (mm)
1051
705
833
Weight (dry lbs)
3362
3020
4170
600
525
600
Equivalent horsepower Maximum torque (ft-lb)
2050 @ 1000 rpm
1650 @ 1300 rpm
1630 @ 1300 rpm
Advantages QSX 15 Excellent power plant for applications requiring high power density and transient response Performance flexibility 600 horsepower 2050 lb-ft torque
350 horsepower 1140 lb-ft torque Tier II and Tier III emissions capable Kerosene capable fuel system Integrated electronics Integrated engine brake Excellent fuel consumption Worldwide operation and service support Designed for construction markets worldwide
QSX 15 Development Schedule Electronic technical package
Available
Technical package 1999
November
Sales handbook 1999
November
Managed introduction for key OEM’s First Qtr 2000 Review DOEM requests 2000
January
Full production pending option
April 2000 availability
Tools
Part No.
• Brake Breakout Cable/Shield
3162991
• Sensor Breakout ( 4 Wire )
3162898
• Sensor Breakout ( 3 Wire )
3824773
• Benchtop Calibration (ECM)
3163151
• Wire Repair Kit (Harness)
3162899
• Socket, Flywheel Bolt (Piloted)
3162813
• Brake Setting Gauge (0.250” Feeler)
3162460
• Liner Puller Foot
3162462
• Liner Driver/Clamp
3162461
• Piston Ring Compressor
3163158
• 4 Valve Spring Compressor
3162986
• Single Valve Spring Compressor
3163098
• Cylinder Head Lifting Bracket
3162996
• Engine Lifting Tool
3162871
Tools (cont’d)... Front Seal R & I Tool (Crankshaft) Rear Seal R & I Tool (Crankshaft) Socket, Cylinder Head Bolt 3/4” Impact Wrench Cam Gear Puller (Injector Cam) Con Rod Guide Pin Cam Bushing R & I Tool Timing Wedges & Pin (Cam/ Crank) Plate, Rollover Stand (Block)
3162992 3162994 3163484 3163059 3163069 3163097 3162980 3163021 3162464
Publications QSX/QSK45 & QSK60 G-Drive T & R Man 3666393 QSX / QSK45 & QSK60 Power Command Control 3666394 ISX / Signature O & M Manual: 3666311 QSX / Power Generation O & Manual 3666423 Base Engine 3666239 Electronic Features 3666320 ISX / QSX Electronic T & R Manual 3666259
Publications SRT Manual 3666326 Warranty Failure Code Manual 3666327 Wiring Diagram Signature/ISX 3666268 Wiring Diagram QSX 15 3666414 Wiring Diagram QSX 15 G-Drive 3666349 Wiring Diagram QSX 15 PCC 3666466
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