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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
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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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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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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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
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
• 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
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
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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