QSK 45G/60G Series Gas Engines QSK 45G/60G Series Gas Engines

Cummins Corporate Training Cummins Corporate Training

Module 4 - Base Engine Module 4 - Base Engine

CUMMINS CORPORATE TRAINING 45-60G/ Intro / BMG / 12 - 02 / REV 01.

CUMMINS inc.

2 CUMMINS CORPORATE TRAINING 45-60G/ Base Engine / BMG / 12 - 02 / REV 01.

CUMMINS ENGINE COMPANY

QSK Gas
QSK Gas Engines
Learning Objective To identify Key differences between the Industrial QSK45/60 diesel and gas engine and to identify components unique to the gas range. Participants will also understand QSK Gas engine terminology, layout and configuration. Agenda Gas Engine data. Gas Engine Layout. Engine Configuration. Differences between QSK Gas and QSK diesel engines

 Gas Component Familiarisation.

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CUMMINS ENGINE COMPANY

QSK Gas
QSK - Gas Engine Data
METHANE INDEX METHANE INDEX

Operates on Natural Gas with a Methane Index Greater than 70.

COMPRESSION COMPRESSION

12 : 1 = All 1200 and 1500 rpm engines. 11.4 : 1 = All 1800 rpm engines Low compression option for low methane index not released
IDLE SPEED IDLE SPEED

900 rpm for all engine models.

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CUMMINS ENGINE COMPANY

QSK Gas
Diesel / Gas Design Change Details
Piston: Change to deep bowl Ferrious Cast Ductile Iron (FCD) piston. Combination of Q60 (Keystone type top ring) and Q19G ( Rectangular type 2nd) rings. Cylinder head: Valve cover modifications for coil, Add coil Remove injector hardware and design to accept spark plug. Remove injector rocker arm, replace with spacer ring Stellite exhaust valves & seats with 20 deg seating angle.(exhaust valve seat modified for increased seat area due to increased temp). Triballoy intake valves & seats with 30 deg seating angle. Modified valve stem seals ( wetter, more oil flow) Modified valve guides (Hardening specification) Provision for Knock sensor location Different machining of cylinder head casting, for optimum cooling and to add intake swirl. Free end: Left bank cam gear ( l only) with 24+1 pattern for engine position sensing (EPS) Access to cam gear for EPS sensor through gear housing Diesel Fuel system: Remove diesel fuel system components (fuel lines, filters, housings), CM550 and housing. Gas system: Add inlet gas injection on each turbo Add Cummins type gas metering system Add gas line connections, Add regulator (off engine)

Add FSO (off engine), Add filter (off engine) Add manual shutoff valve (off engine) Air handling: Two HX82, HX82 mounting, water cooled bearing connection. Turbine out elbow Exhaust manifold sections (re-design for log manifold) Single aftercooler, two stage ( LTA & HT) Aftercooler coolant and air connections Add throttle & throttle driver Compressor inlet connections, Air filter, Air filter header box. Cast iron intake manifolds (Log type) Controls: Same as QSV: CENSE monitoring 16 exhaust thermocouples, One MCM700/harness/sensors Two SSM558/harness/sensors Lambda sensor & KW transducer for closed loop fuel control Simplified interface box and OEM connector as QSV.

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CUMMINS ENGINE COMPANY

QSK Gas
QSK60 V Engine

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CUMMINS ENGINE COMPANY

QSK Gas
Bank and Cylinder Identification
Bank designation always refers to engine when viewed from the Rear. Cylinder numbering from the Front

Front Front REAR REAR

RIGHT - Bank LEFT- Bank L1 L2 L3 L4 L5 L6

R1 R2 R3 R4 R5 R6

QSK 45/60 G - Front View

1. Compressor outlet Pressure (Boost) 2 . LT Coolant Temperature 3. LT Coolant Pressure 4. Throttle Position Actuator/ Sensor.
1 4 2 3

QSK 45/60 G - Left Bank View

1 .Compressor Inlet Temp, 2. Oxygen Sensor (when fitted), 3. Oil Rifle Pressure, 4. CM700 Speed Sensor, 5. DC Terminal Box, 6. Engine Harness Interface Connections ( X -Power Y -Auxiliary Z User Interface ), 7. Throttle Driver, 8. Crankcase Blowby Pressure (x2), 9. Oil Temperature Sensor,

10. CM558, 11. Oil Level Switch , 12. Ignition Module, 13. HT Coolant Temperature.
13 11 9 3 4 12 10 8 1 6 5 7
XYZ

QSK 45/60 G - Right Bank View

1. Gas Control Assembly (Fuel Inlet Pressure, Gas Mass Flow sensor, Fuel Control Valve, Fuel Outlet Temperature & Pressure) 2. HT Coolant Pressure, 3. Intake Manifold Pressure, 4. Intake Manifold Temperature, 5. Ignition Module, 6. Oil Pressure Pre-Filter, 7. Oil Pressure Post-Filter, 8. CM558, 9. Cense, 10. AC Terminal Box, 11. PCS Speed Sensor.
9 10

8 7 6 5 3 4 2 11 1

QSK 45/60 G - Top View

1. Fuel Inlet Pressure (FIP), 2. Fuel Outlet Temperature (FOT) , 3. Fuel Outlet Pressure (FOP), 4. Exhaust Back Pressure Sensor, 5. Coil On Plug (on each cylinder), 6. Knock Sensor (on each cylinder, refer to knock sensor position diagram), 7. Exhaust Port Temperature Sensor (on each cylinder).
7 5 6 2 3 1 4