Cummins PoweGen Product Range

QSK78
Series 3000 kVA **

QSK60
Series 1875 & 2000 kVA
K50
Series 1250 & 1500 kVA
K38
Series 800 & 1010 kVA
QSK23
Series 750 kVA
V28 600 to 625 kVA
Series

K19 450 to 500 kVA

Series

N Series 320 to 380 kVA

C Series 180 to 250 kVA

B Series 75 to 160 kVA

S Series 30 to 62.5 kVA

X Series 7.5 to 25 kVA

** 3000 kVA rating for standby

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 Horsepower

QSK78
QSK60
K50
QSK45
K38
QST30
Product

QSK23
QSK19 Cummins Products
QSX15 - Complete Product Range 18 - 3500HP
QSM11/M11 - Common Electronic Controls
C8.3/QSC8.3 - Common Maintenance Practices
B5.9/QSB5.9 - Supported by Cummins Distributors
B3.9
B3.3
A Series
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400

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 Markets we serve…

Mining Marine
Oil & Gas Compressor

Agriculture Automotive PowerGen

Railway
Defence

ReCon Service Solutions

Genuine Cummins Parts Replacement & Repowering

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Model Nomenclature

N T A 855 C
Application - Locomotive

Displacement in Cu. inches

After cooled

Turbocharged

Engine Series / Family

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4/19/2017 Cummins Confidential 5
4/19/2017 6
4/19/2017 7
 What is an Engine?
a machine converting various forms of energy into mechanical force and motion.

Four-Stroke Cycle

Intake Stroke Compression Stroke Power Stroke Exhaust Stroke

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 Engine systems
• Air System( Intake system & Exhaust system)
• Cooling System
• Lube oil System
• Fuel System

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4/19/2017 Cummins Confidential 10
 Air system

Function of Air System
 To supply air for complete combustion of fuel
 To take exhaust gases out of engine

Requirements of Air intake system

 Sufficient - to burn all the fuel completely
 Clean - free of dust particles
 Cool - at proper temperature
 Dry - free of moisture

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AIR SYSTEM FLOW

12
 Air system Flow

Intake Flow Exhaust Flow

Left Bank (L.B.)Air Cleaner Cylinders 1 to 6

L.B. Turbocharger Turbocharger

Aftercooler
Exhaust outlet

Intake Manifold
Silencer / Muffler

Cylinders 1,2,3, 4, 5, 6
4/19/2017 14

Effects of choked air cleaner

 Insufficient air for burning of fuel

 Results in unburnt diesel

 Indicated by black smoke

 Loss of power

 Excessive exhaust temperature

Never run the engine with choked air cleaner element

Effects of choked air cleaner

 Dirt forms abrasive paste oil

 Wear of piston rings / liners / valves / guides

 High lube oil consumption

 Excessive blow - by
4/19/2017 15

Reasons for dust / dirt entry in combustion chamber
 Missing vacuum indicator
 Torn / porous air cleaner element
 Improper sealing of element in housing
 Bent guides of element
 Missing sealing rings of element
 non-fitment / improper fitment of sealing washer

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Cummins Turbocharger

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 Lube Oil System

Functions of Lubricating oil

 Lubricates (Friction)

 Cools (Heat)

 Cleans

 Seals

 Provides a cushioning between contacting surfaces of components & dampens

the shocks

 Provides a protective barrier, isolating non - like metals to prevent corrosion

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Lube Oil Flow
Lube Oil System – Check Points

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 Lube Oil system

4/19/2017 Cummins Confidential 21

 Cooling system

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 Functions of cooling system

 Absorption : absorbs heat from liners / Cyl Heads

 Circulation : circulates the coolant throughout the system
 Control : controls coolant temperature in the desired range
 Dissipation : dissipates absorbed heat to atmosphere or raw water

Disposal of Heat

Useful
Coolant Work

Exhaust

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Coolant Flow – Jacket Water

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Coolant Flow – LTA

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 Fill Neck Core Vent Pipe
Initial Fill Engine Vent

Thermostat
Line to Reserve Volume
Housing
Radiator

Header
M
B a Radiator Core
y k
P e
Engine a U
s p
s

Bottom Tank
Water Pump
 Fill Neck
Thermostat Engine Vent
Core Vent

closed
Thermostat Hsg Engine-
Rad line Reserve Volume

Header
M
B a
y k
P e
Engine
a U Radiator Core
s p
s

Bottom Tank
Water Pump
Thermostat Open Engine Vent Fill Neck Stand Pipe

Thermostat Hsg Engine-Rad line Reserve Volume

Header
M
B a
y k
P e
Engine a U Radiator Core
s p
s

Bottom Tank
Water Pump
 Fuel system

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 Fuel System
• Cummins Pressure-Time system is simple & adjustment free
• Is better accessible than other systems
• Pump & Injectors both are factory calibrated & tested at the
time of engine testing & need not be calibrated at the time of
commissioning
• Does five functions-supply, control, metering, injection, timing
of injection
• Relatively low pressure ( 50 - 200 psi ) in the fuel lines & high
injection pressure in the cylinder to minimize fuel leakages
and efficient fuel combustion
• High injection pressure & faster rate of injection is achieved by
specially designed camshaft
Fuel System

• Lesser number of parts in Cummins system provide faster

response to load variation and helps for ease in maintenance
• Positive gear pump which is a part of a fuel pump eliminates
necessity of hand priming pump
• Injector has 8 to 10 number of spray holes which ensure
better atomization & higher combustion efficiency
• Injector cup is hardened and tempered for better durability
• Calibration period for fuel pump and injectors is 6000 hours
• There is neither power loss nor fuel efficiency loss in
between two calibration periods
• Calibration facilities are available at 45 places all over India
Fuel System - Flow

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 Maintenance Schedule
Cummins Diesel Engines

A-Check ( Daily Maintenance)

Air Induction System

1. Clean Pre-Cleaner Dust Pan

2. Check Air Cleaner Restriction. Clean / Change Air

Cleaner Element if required.

3. Drain Air Tank

 Maintenance Schedule
Cummins Diesel Engines

A-Check ( Daily Maintenance)

Fuel System

1. Drain Sediments / Water from Fuel Tank

2. Drain Fuel Filter / Water Separator

3. Check & Correct Leaks

 Maintenance Schedule
Cummins Diesel Engines

A-Check ( Daily Maintenance)

Cooling System

1. Check Coolant Level

2. Check Belts Tension. Adjust if required.

3. Check & Correct Leaks.

 Maintenance Schedule
Cummins Diesel Engines

A-Check ( Daily Maintenance)

Lubrication System

1. Check Engine Oil Level

2. Check & Correct Leaks

 Maintenance Schedule
Cummins Diesel Engines

B-Check ( Every 300 hrs or 6 Months)

Air Induction System

1. Clean / Change Crank Case Breather

2. Check Air Piping.

 Maintenance Schedule
Cummins Diesel Engines

B-Check ( Every 300 hrs or 6 Months)

Fuel System

1. Clean / Change Fuel Tank Breather

2. Change Fuel Filter.

3. Check Aneroid / Hyd. Gov... Oil

 Maintenance Schedule
Cummins Diesel Engines

B-Check ( Every 300 hrs or 6 Months)

Cooling System

1. Check Coolant Inhibitor. Add Coolant Concentrate,

if required

2. Check Heat Exchanger Zinc Plugs.

 Maintenance Schedule
Cummins Diesel Engines

B-Check ( Every 300 hrs or 6 Months)

Lubrication System

1. Change Engine Oil. Use Recommended Oil Only

2. Change Full-Flow & By-Pass Oil Filters.

3. Record Oil Pressure.

 Maintenance Schedule
Cummins Diesel Engines

C-Check ( Every 1500 hrs or 12 Months)

Air Induction System

1. Check Air Cleaner Evacuator Valve. Change

if required.

2. Adjust Injectors and Valves Adjustment.

 Maintenance Schedule
Cummins Diesel Engines

C-Check ( Every 1500 hrs or 12 Months)

Fuel System

1. Change Aneroid / Hyd. Gov.. Oil.

2. Replace Aneroid Breather.

3. Clean Fuel Tank from Inside

 Maintenance Schedule
Cummins Diesel Engines

C-Check ( Every 1500 hrs or 12 Months)

Cooling System

1. Clean Radiator / Charge Air Cooler Externally.

2. Check Fan Hub / Idler and Water Pump / Idler.

 Maintenance Schedule
Cummins Diesel Engines

D-Check ( Every 6000 hrs or 24 Months)

Air Induction System

1. Check Turbocharger Bearing Clearance.

2. Clean Turbo. Compressor Wheel & Diffuser, if

required.

3. Check Air Compressor.

 Maintenance Schedule
Cummins Diesel Engines

D-Check ( Every 6000 hrs or 24 Months)

Fuel System

1. Check Fuel Pump Calibration.

2. Clean & Calibrate Injectors, if required.

3. Replace Fuel Pump Filter Screen.

 Maintenance Schedule
Cummins Diesel Engines

D-Check ( Every 6000 hrs or 24 Months)

Cooling System

1. Change Coolant.

2. Descale Cooling System

 Maintenance Schedule
Cummins Diesel Engines

Lubrication System

C-Check ( Every 1500 hrs or 12 Months)

None

D-Check ( Every 5000 hrs or 24 Months

None
 Maintenance Schedule
Cummins Diesel Engines

Other Maintenance

At D-Check ( Every 6000 hrs or 24 Months)

1. Check Vibration Damper.

1500 hrs. After Every “D” Check

1. Adjust Injectors and Valves

 Do It Knowingly!

Activity WHY”

Replace Lube Oil Filter Low Oil Pressure

Fuel Filter Loss Of Power
Bypass Filter Proper Filtration Of Circulating Oil

Always Fill Filter With Clean Engine Oil / Diesel While Replacement, Otherwise
Bearings / Hard Starting Will Occur

Handle Oil / Fuel In A Clean Container

Cut Open Oil Filter For Wear Of Engine Moving Parts
Foreign Metal Particles

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Remember to….
1. Keep Dirt Out Of The Engine
2. Maintain A Lubricating Film On All Bearing Surfaces.
3. Regulate The Engine’s Fuel
4. Control Operating Temperatures
5. Guard Against Corrosion
6. Let The engine Breathe
7. Prevent Over Overloading
8. Know Your Engine’s Condition
9. Correct Troubles While They Are Simple
10. Schedule And Control Your Maintenance

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