Cummins PoweGen Product Range - … Engine... · Marine Railway Agriculture Defence ... Cummins Diesel Engines B-Check ( Every 300 hrs or 6 Months) ... Check Turbocharger Bearing

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X Series

S Series

B Series

C Series

N Series

7.5 to 25 kVA

30 to 62.5 kVA

75 to 160 kVA

180 to 250 kVA

320 to 380 kVA

K19 Series

V28 Series

K38 Series

K50 Series

QSK60 Series

QSK78 Series

450 to 500 kVA

600 to 625 kVA

800 & 1010 kVA

1250 & 1500 kVA

1875 & 2000 kVA

3000 kVA **

750 kVAQSK23 Series

** 3000 kVA rating for standby

Cummins PoweGen Product Range

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0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400

A Series

B3.3

B3.9

B5.9/QSB5.9

C8.3/QSC8.3

QSM11/M11

QSX15

QSK19

QSK23

QST30

K38

QSK45

K50

QSK60

QSK78

Pro

du

ct

Horsepower

Cummins Products

- Complete Product Range 18 - 3500HP

- Common Electronic Controls

- Common Maintenance Practices

- Supported by Cummins Distributors

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Markets we serve…

Automotive

MiningOil & Gas

Marine

Railway

Agriculture

Defence

Compressor

PowerGen

Replacement & RepoweringService SolutionsReCon

Genuine Cummins Parts

N T A 855 C

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Engine Series / Family

Turbocharged

After cooled

Application - Locomotive

Model Nomenclature

Displacement in Cu. inches

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What is an Engine?

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a machine converting various forms of energy into mechanical force and motion.

Four-Stroke Cycle

Intake Stroke Compression Stroke Power Stroke Exhaust Stroke

Engine systems

• Air System( Intake system & Exhaust system)

• Cooling System

• Lube oil System

• Fuel System

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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

Intake Manifold

Intake Flow

Left Bank (L.B.)Air Cleaner

L.B. Turbocharger

Aftercooler

Cylinders 1,2,3, 4, 5, 6

Exhaust Flow

Cylinders 1 to 6

Turbocharger

Exhaust outlet

Silencer / Muffler

Air system Flow

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� 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

� 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

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


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

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Disposal of Heat

Exhaust

Coolant

Useful

Work

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Coolant Flow – Jacket Water

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Coolant Flow – LTA

Engine

Engine VentFill Neck Core Vent Pipe

Reserve Volume

Radiator Core

Bottom Tank

Water Pump

M

a

k

e

U

p

Line to

Radiator

Thermostat

Housing

Header

Initial Fill

B

y

P

a

s

s

Engine

Engine Vent

Fill NeckCore Vent

Reserve Volume

Radiator Core

Bottom Tank

Water Pump

M

a

k

e

U

p

Engine-

Rad line

Thermostat Hsg

B

y

P

a

s

s

Header

Thermostat

closed

Engine

Engine VentFill Neck Stand Pipe

Reserve Volume

Radiator Core

Bottom Tank

Water Pump

M

a

k

e

U

p

Engine-Rad lineThermostat Hsg

Header

Thermostat Open

B

y

P

a

s

s

Fuel system

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• Cummins Pressure-Time system is simple & adjustment free

• Is better accessible than other systems

• Pump & Injectors both are factory calibrated & tested at thetime of engine testing & need not be calibrated at the time ofcommissioning

• Does five functions-supply, control, metering, injection, timingof injection

• Relatively low pressure ( 50 - 200 psi ) in the fuel lines & highinjection pressure in the cylinder to minimize fuel leakagesand efficient fuel combustion

• High injection pressure & faster rate of injection is achieved byspecially 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

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Fuel System - Flow

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




Fuel System

1. Drain Sediments / Water from Fuel Tank

2. Drain Fuel Filter / Water Separator

3. Check & Correct Leaks




Cooling System

1. Check Coolant Level

2. Check Belts Tension. Adjust if required.

3. Check & Correct Leaks.




Lubrication System

1. Check Engine Oil Level

2. Check & Correct Leaks



B-Check ( Every 300 hrs or 6 Months)


1. Clean / Change Crank Case Breather

2. Check Air Piping.




Fuel System

1. Clean / Change Fuel Tank Breather

2. Change Fuel Filter.

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




Cooling System

1. Check Coolant Inhibitor. Add Coolant Concentrate,

if required

2. Check Heat Exchanger Zinc Plugs.




Lubrication System

1. Change Engine Oil. Use Recommended Oil Only

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

3. Record Oil Pressure.



C-Check ( Every 1500 hrs or 12 Months)


1. Check Air Cleaner Evacuator Valve. Change

if required.

2. Adjust Injectors and Valves Adjustment.




Fuel System

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

2. Replace Aneroid Breather.

3. Clean Fuel Tank from Inside




Cooling System

1. Clean Radiator / Charge Air Cooler Externally.

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



D-Check ( Every 6000 hrs or 24 Months)


1. Check Turbocharger Bearing Clearance.

2. Clean Turbo. Compressor Wheel & Diffuser, if

required.

3. Check Air Compressor.




Fuel System

1. Check Fuel Pump Calibration.

2. Clean & Calibrate Injectors, if required.

3. Replace Fuel Pump Filter Screen.




Cooling System

1. Change Coolant.

2. Descale Cooling System



Lubrication System


None

D-Check ( Every 5000 hrs or 24 Months

None



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

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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

Cummins PoweGen Product Range - … Engine... · Marine Railway Agriculture Defence ... Cummins Diesel Engines B-Check ( Every 300 hrs or 6 Months) ... Check Turbocharger Bearing

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