Chapter 9 R100E Cummins QST30

Volvo Construction Equipment

Engine
Engine Specification
Firing Order 1R-1L-5R-5L-3R-3L-6R-6L-2R-2L-4R-4L
● 30.5 litre

● 50 degree V

● 12 cylinder

● Bore & Stroke

140x165 mm

● ratings from 760-1200 hp

Rated to 1050hp 783Kw

● Tier 2/Stage II emissions

● 2 X Pulse type Turbos

● 2 X Electronic Control
Units

● Charge air cooled

Front Engine Trunnion Mounting is Greasable
Chapter 9 Cummins QST30 Volvo Construction Equipment
Engine
ECM

● 2 X CM 552 controllers

● 1 X Control unit Left

Hand Bank (Primary)

● 1 X Control Unit Right

Hand Bank (Secondary)

● Each controller controls

relevant bank fuel pump

● CAN communications
J1939

● -S41 Mounted at R/H

Step
Ground Level Kill Switch
Mounted at R/H Step
(Disconnect engine
ignition circuit)

Chapter 3 Electrics Electronics Volvo Construction Equipment

Cummins Engine
A/21
-X28
A
KEYSWITCH INPUT FREQUENCY THROTTLE INPUT
1
ECU Powers & Grounds
B/2 1 B 2
-X28
C
GROUND FAN CLUTCH SWITCH

3
● Battery Feeds
SOLENOID A SPARE

D/2 1 D 4
● -X 28 21 pin Connector

21 PIN CONNECTOR

31 PIN CONNECTOR
-X28 UNSWIT CHED 24V (B+) P WM TORQUE B ROADCA S T O/P

E/2 1
-X28
E
GROUND SPARE
5
Left Hand ECU Pin G
G/21
F

G
SOLENOID B TA CHOME TE R
6

7 -X29
Right Hand ECU Pin D
UNSWIT CHED 24V (B+) W A IT TO S TA RT LA MP 7/31
-X28
H/2 1 H 8 -X29
J1587 DAT ALINK (+) PRIM ARY COOLA NT LE V E L S W. HIGH 8/31
-X28
J/2 1
-X28
J
J1587 DAT ALINK (-) PRIM ARY COOLANT LEVEL SW. LOW
9 -X29
9/31 ● From G & D to 2 X 15 Amp
K

L
RE MOTE THROTTLE P OS ITION S UP P LY SPARE LAMP #1
10

11
inline Fuse on Cummins
M
RE MOTE THROTTLE P OS ITION S IGNA L SPARE LAM P #2

12
harness 1 X L/H 1 X R/H
N
RE MOTE THROTTLE P OS ITION RE TURN RED LAM P

13
(Feeds pins 38,39,40,50 on
RE MOTE IDLE V A L. S W. OFF IDLE S IGNA L

P
AM BER LAM P

14 -X29 each ECU)

RE MOTE IDLE V A L. S W. IDLE S IGNA L WHITE LA MP 14/31
R/2 1 R 15
THROTTLE P OS ITION S UP P LY DIA GNOS TIC S WITCH
-X28

● Ignition
S/2 1 S 16
THROTTLE P OS ITION S IGNA L ALT ERNAT E T ORQUE CURVE SEL
-X28
T /21 T 17

● -X 28 21 pin Connector
THROTTLE P OS ITION RE TURN ALT ERNAT E DROOP SWIT CH
-X28
U/2 1 U 18 - X29 - X28
-X28 IDLE V A L. S W. IDLE S IGNA L ALT ERNAT E IDLE

V/21
-X28
V
IDLE V A L. S W. OFF IDLE S IGNA L IDLE/DIAGNOST IC INCREMENT
19
Pin A to (Pin 5 on each ECU)
W 20 -X29
J1587 DAT ALINK (+) SECONDARY COOLANT LEVEL SW. SUPPLY 20/31
X 21 -X29

● Grounds
J1587 DAT ALINK (-) SECONDARY COOLANT LEVEL SW. RET URN 21/31
22
IDLE/DIAG NO STIC DECREM ENT

23
INT. SPEED CO NTRO L 1 ● -X 28 21 pin Connector
24
REMO TE THRO TTLE SELECT

25
Left Hand ECU Pin B Right
VALID ATE

26
Hand ECU Pin E
SPAR E

27
to (Pins 20,28,29,30 on each
INT. SPEED CO NTRO L INCREMENT

28 ECU)
INT. SPEED CO NTRO L DECREM ENT

29 15 Amp R/H
INT. SPEED CO NTRO L O N/O FF

30
SPAR E

31
SPAR E
CUMMINS QST30 T2
CONTROL INTERFACE

Volvo Construction Equipment

 Engine
CAN Circuits
CAN 1
● J1939 Protocol
-R5.X

-R6.X
+6 +4
+6

A/3

A/3
1.0 mm² +6 -W330 YE -Xs5 1.0 mm² +6 -W332 YE 31/35 31/35 1.0 mm² +4 -W101 YE -Xs22 1.0 mm² +4 -W103 YE
A J1587 ECM CAN_1 + J1587 ECM CAN_1 + J1587 ECM CAN_1 + J1587 ECM CAN_1 + A
Ultrasonic -X4 -X4 Ultrasonic
welding splice welding splice
Resistor 120 OHMS +6 Resistor 120 OHMS
+6 DT04-3P-EP10 DT04-3P-EP10
-R5 -R6
+6 +4
B 1.0 mm² +6 -W330 GN -Xs6 1.0 mm² +6 -W332 GN 33/35 33/35 1.0 mm² +4 -W101 GN -Xs23 1.0 mm² +4 -W103 GN B
J1587 ECM CAN_1 - J1587 ECM CAN_1 - J1587 ECM CAN_1 - J1587 ECM CAN_1 -
-X4 -X4
-R5.X

-R6.X
Ultrasonic Ultrasonic
+6

B/3

B/3
● CAN 2 Circuit
welding splice welding splice
+6

0.75 mm² +6 -W338 GN

0.75 mm² +6 -W337 YE

J1587 ECM CAN_1 +
J1587 ECM CAN_1 -

1.0 mm² +4 -W35 GN

1.0 mm² +4 -W35 YE
J1587 ECM CAN_1 +

J1587 ECM CAN_1 -

6.1 8.1
-IGNPWR_A -PermPwrBBar.8

● On CAN 2

-W161 RD
F5-1/24 PermPwrBar
-W159 YE
F1-1/24 IGN Supply A

-FiA-FP.X
-FiA-FP.X

1.0 mm²

/4.C5

/4.C5
+4-X28:H

+4-X28:J
Shift lever

1.0 mm²
J1939 ENGINE DIAGNOSTIC
1
-X30

1 CUMMINS INSITE 7.5A

+6

Telematics 7.5A ATO Blade Fuse DIN 72581

4/9
2/9

6/9
1/9

3/9

5/9

7/9

8/9

9/9
CAN 2
10A 5050650265
15247613
10A ATO Blade Fuse DIN 72581 -FiA1 -FP13
15247612 5050650264 TRANSMISSION DIAGNOSTICS 2
2

VCU

F5-2/24
J1587 ENGINE DIAGNOSTICS ALLISON DOC

F1-2/24
VCU FIELD DIAGNOSTIC TOOL
DASH SHIFT

TCU

-XJ1939
PANEL LEVER

B/9

D/9
A/9

E/9
C/9

J/9
J1939_CAN2_H

J1939_CAN2_H
J1939_CAN2_L

J1939_CAN2_L
/11.D11

/11.D11
-K20.XK:7

-K20.XK:4

/6.B6

/6.B6
-S21.X:8

Instrument panel

-W162 RD
-W321 GN

-WC21 BK
-W160 YE

-W321 YE

GND DIAGNOSTIC CONX

FiA1 J1939 Diagnostics

FP13 J1939 Diagnostics

J1939_CAN2_L
J1939_CAN2_H
1.0 mm²

1.0 mm²

1.0 mm²
0.75 mm²

0.75 mm²
left hand column switch
CLEAN
lever
-W311 GN

-W315 GN

GND
-W311 YE

-W315 YE

Retarder Lever
J1939_CAN2_L

J1939_CAN2_L
J1939_CAN2_H

J1939_CAN2_H

1.0 mm² -WC21 BK GND DIAGNOSTIC CONX

GND DIAGNOSTIC CONX /27.B8
-Xs63.SB:8
1.0 mm² -WC22 BK GND DIAGNOSTIC CONX
/27.B8
1.0 mm²

1.0 mm²

1.0 mm²

1.0 mm²

GND DIAGNOSTIC CONX

-Xs63.SB:6
CLEAN

1.0 mm² -W310 YE

J1939_CAN2_H
GND

Pay Load System

-R3.X

-R4.X
+4
A/3

A/3
-Xs10 1.0 mm² -W461 YE -Xs67 1.0 mm² -W314 YE -Xs12 1.0 mm² -W316 YE -Xs14 1.0 mm² -W318 YE -Xs16 1.0 mm² -W320 YE -Xs18 1.0 mm² -W322 YE 25/35 25/35 1.0 mm² +4 -W102 YE 5/6 -X741.0 mm² +2 -W1176 YE A/3
A J1939_CAN2_H J1939_CAN2_H J1939_CAN2_H J1939_CAN2_H J1939_CAN2_H J1939_CAN2_H J1939_CAN2_H 5/6 J1939_CAN2_H A
Ultrasonic Ultrasonic
Ultrasonic Ultrasonic Ultrasonic Ultrasonic -X4 -X4 -X74 -X79
welding splice welding splice welding splice welding splice welding splice
Resistor 120 OHMS welding splice
ENGINE +4 Resistor 120 OHMS
DT04-3P-EP10
-R3 CONNECTIONS -R4 DT04-3P-EP10

B -Xs11 1.0 mm² -W461 GN -Xs66 1.0 mm² -W314 GN -Xs13 1.0 mm² -W316 GN -Xs15 1.0 mm² -W318 GN -Xs17 1.0 mm² -W320 GN -Xs19 1.0 mm² -W322 GN 23/35 23/35 1.0 mm² +4 -W102 GN 6/6 -X74 1.0 mm² +2 -W1176 GN B/3 B

● J1587 Protocol
J1939_CAN2_L J1939_CAN2_L J1939_CAN2_L J1939_CAN2_L J1939_CAN2_L J1939_CAN2_L J1939_CAN2_L 6/6 J1939_CAN2_L
-X4 -X4 -X74 -X79
-R3.X

-R4.X
Ultrasonic Ultrasonic Ultrasonic Ultrasonic Ultrasonic

+4
B/3

B/3
Ultrasonic
welding splice welding splice welding splice welding splice welding splice welding splice

1.0 mm² -W310 GN

J1939_CAN2_L
-W312 GN

-W313 GN

-W462 GN

-W317 GN

-W319 GN
-W312 YE

-W313 YE

-W462 YE

-W317 YE

-W319 YE

● CAN 1 Circuit
J1939_CAN2_L

J1939_CAN2_L

J1939_CAN2_L

J1939_CAN2_L

J1939_CAN2_L
J1939_CAN2_H

J1939_CAN2_H

J1939_CAN2_H

J1939_CAN2_H

J1939_CAN2_H
1.0 mm²

1.0 mm²

1.0 mm²

1.0 mm²

1.0 mm²

1.0 mm²

1.0 mm²

1.0 mm²

1.0 mm²

1.0 mm²

2 X 12 ohm termination
Resistors Per Circuit ● Only For Engine
/9.D1

/9.D1
/24.D8

/24.D8

/23.C8

/23.C7

/5.B7

/5.B7
/29.A9
/29.A10
-X70:1
J1939_CAN2_L

J1939_CAN2_L

J1939_CAN2_L

J1939_CAN2_L

J1939_CAN2_L
J1939_CAN2_H

J1939_CAN2_H

J1939_CAN2_H

J1939_CAN2_H

J1939_CAN2_H
-X70:2
-S5.X_1:5

-S5.X_1:4

-S22.X:5

-S22.X:4

-K19.X:28

-K19.X:8

-VC1.St-X1:46

-VC1.St-X1:28

LIGHT/HORN/ RETARDER
WIPER STALK CONTROL STALK
PAYLOAD
SYSTEM ALLISON
TCU
VCU
Diagnostic connector
Chapter 9 Cummins QST30 Volvo Construction Equipment
Engine
Starter Motors

● 2 X Delco Remy Starter

motors

● Mounted to Left Hand

side of Engine

● Minimum Crank Speed

150 RPM

Chapter 9 Cummins QST30 Volvo Construction Equipment

Engine
Turbo

● 2 X Cummins HE851

● Pulse type Turbos

(No waste gate control)

● Water cooled Turbo

Bearings
(Coolant feed from
Thermostat housing)

Chapter 9 Cummins QST30 Volvo Construction Equipment

Engine
Fuel System

● 2 X 12volt electric
pumps (Wired in series)

● 1 X Pre Filter (Water

separator)(Drain Water Daily)

● 1 X Fuel Filter (Water

separator)(Drain Water Daily)

● Replace Filters at 250hrs

● 2 X Mechanical driven
Bosch fuel pumps
(Electrically actuated)

● 12 X Bosch Injectors
(sensor on No1 injector)

Chapter 9 Cummins QST30 Volvo Construction Equipment

Engine
Fuel Filters

● Pre Filter

● 2nd stage Fuel Filter

(10 Micron) 250hrs

Chapter 9 Cummins QST30 Volvo Construction Equipment

Engine
Electric Fuel Lift Pumps

● 2 X 12 volt motors wired

in Series

● Continue to run when

ignition on to provide
constant pressure
30 to 40 Psi

● Pumps can provide 15 in

Hg of suction for priming

Chapter 9 Cummins QST30 Volvo Construction Equipment

Engine
Fuel Pumps

● 2 X RP39 Fuel Pumps

● 1 Mounted to Left bank

● 1 Mounted to Right bank

● Each pump supplies fuel

to One bank of injectors

● Separate Servo Motors

on each pump control
fuelling

Chapter 9 Cummins QST30 Volvo Construction Equipment

Engine
Lubrication

● 4 X Venturi Combo
Oil Filters Full Flow &
Bypass

● Oil Replacement 500hrs

● Filter Replacement
500hrs

● Premium Oil must be

used (CH4 specification)

● Oil Pressure at regulator

valve 58 +/- 7 Psi

Chapter 9 Cummins QST30 Volvo Construction Equipment

Engine
Standard Equipment

● 3 X Grid Heaters per

bank
(DO NOT USE ETHER)
-B39

● 100 Amp Alternator

● Pre Lube motor mounted

to the Right Hand side of
Engine
● -B 39 Pressure Sensor
signals -K18 VCU when
pressure reaches
4+/- 1 Psi

● Maximum operation time

30 seconds

Chapter 9 Cummins QST30 Volvo Construction Equipment

Engine
Air Filters

● 4 X Air Filters

● Primary and Secondary

elements

● Filter Restriction
indication 60 mbar

Chapter 9 Cummins QST30 Volvo Construction Equipment

Engine
Engine Sensors
● Intake Manifold Pressure
Sensor (IMPS)
IMPS ● Intake Manifold Temperature
FPS Sensor (IMTS)
IMTS
● Oil Pressure Sensor (OPS)
CPS ● Coolant Temperature Sensor
(CTS)
FTS CTS
● Coolant Level Sensor (CLS)
● Coolant Pressure Sensor
(CPS)
● Ambient Air Pressure Sensor
AAPS (AAPS)
● EDC Management
● Needle Movement Sensor
(Needle Lift )
● Engine Speed Sensor (ESS)
OPS ● Engine Position Sensor
(EPS)
● Optional: crankcase Blowby
Flow Sensor (CBFS)
● Optional: Oil Level Sensor
● Optional: Oil Temperature
EPS ESS Needle Sensor
Movement ● Fuel Pressure Sensor
Sensor ● Fuel Temperature Sensor
Chapter 9 Cummins QST30 Volvo Construction Equipment
Cooling
Cooling Package

● Radiator
Top CAC
Bottom Engine Coolant

● 3 X thermostats
(Start to open 78 to 82
Deg C)
Fully open 90 Deg C

● Tube and Shell Cooler

Transmission

● Tube and Shell Cooler

OCDB

Chapter 6 Cummins QST30 Volvo Construction Equipment

Engine
General Servicing

● Oil 500hrs
● Oil Filters 500hrs
● Fuel Filters 250hrs
● SCA Canisters 250hrs
● Crank Case Breathers
● Air Filters As Required
● PTO 500hrs
● Coolant 6000hrs
● Front Trunnion Mounting
(Grease)
● Fan (Check for damage
250hrs
● Check Coolers for
damage Or leaks

Chapter 9 Cummins QST30 Volvo Construction Equipment

Diagnostics

Cummins Insite

● Diagnostic Requirements

● Cummins Insite,

● Contact your local Cummins dealer for

complete diagnostic solution
J1939 ENGINE DIAGNOSTIC
CUMMINS INSITE
TRANSMISSION DIAGNOSTICS
ALLISON DOC
VCU FIELD DIAGNOSTIC TOOL

-XJ1939

B/9

D/9
A/9

E/9
C/9

J/9 -W162 RD
-W321 GN

-WC21 BK
-W160 YE

-W321 YE

GND DIAGNOSTIC CONX

FiA1 J1939 Diagnostics

FP13 J1939 Diagnostics

J1939_CAN2_H

J1939_CAN2_L
1.0 mm²

1.0 mm²

1.0 mm²
0.75 mm²

0.75 mm²
Chapter 9 Cummins QST30 Volvo Construction Equipment
 -

Thank you for your attention

Any Questions?

Volvo Construction Equipment

06_Chassis