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 Learning Objectives
Understand Cummins engine operation
and parts, including:
• Engine Nomenclature
• Identification and type
• Fundamental of diesel engine operation
• Major component of diesel engine
• The block group
• The head group
• The end and pan group
• The accessories group
• Engine systems
• Lubrication
• Cooling
• Air
• Fuel
CUMMINS PRODUCT LINE
Cummins classifies its engines into
three groups according to displacement:

Midrange (below 9L)

Heavy Duty (10-15L)

High Horse Power (19L and above)

Each grouping serves designated

markets. however; there tends to be
overlap. For example; the majority of
engines used in power generation are the
High Horsepower group. Some smaller
power gen engines fall into the MidRange
and Heavy Duty categories as well.

•Engine Nomenclature
 Engine Families
A Series B Series/ ISB/ QSB
C8.3/ ISC/ QSC L10/ ISL/ QSL
M11/ ISM/ QSM N Series
ISX/ QSX K Series/ QSK
QST30 QSV
Natural Gas Engines

Engine Nomenclature
QS = Quantum System. Industrial engine
Operates electrically; “off-highway.”
Examples: QSB, QSC, QSL, QSM, QSX, QSK, QSV

IS = Interact System. Automotive, operates

electrically; “on-highway.”
Example: ISB, ISC, ISL, ISM, ISX

•Engine Nomenclature
What engines do we sell?

•Engine Nomenclature
Engine Identification

•Engine Nomenclature
 Identify Cummins® nomenclature & data
plates location
The Cummins® engine nomenclature provides the data as
illustrated in the graphics.
NOTE: The following letters designate some of the different
market applications for a Cummins® engine.

•Engine Nomenclature
Cummins Applications in Thailand Example:

•Engine Nomenclature
 Engine Identification
(view from TOP side of Engine)

Flywheel
Right Side / Bank (for V-type)

Rear

Left Side / Bank (for V-type)

D.O.R. Vibration
Damper
Front
•Engine Nomenclature
 What is an Engine ?
A mechanism for converting HEAT ENERGY (e.g.. fuel) into
useful MECHANICAL WORK.

What are the Elements for Combustion ?

ELEMENTS + STROKES = COMBUSTION
IN AIR INTAKE HEAT
PROPER
RATIO FUEL COMBUSTION WORK
HEAT POWER
EXHAUST
Engine Introduction

Fundamental of diesel engine operation

The Four- Stroke Engine Cycle

Fundamental of diesel engine operation

The Four- Stroke Engine Cycle

Fundamental of diesel engine operation

The Four- Stroke Engine Cycle

Fundamental of diesel engine operation

Engine Introduction

Horsepower
• A unit of measure of
engine performance.

Fundamental of diesel engine operation

 Engine Introduction

Torque
• A measure of the
force of rotation of
a driven shaft.

Fundamental of diesel engine operation

Engine Introduction

Fundamental of diesel engine operation

Major component of diesel engine

•The block group

•The head group
•The end and pan group
•The accessories group

Major component of diesel engine

The Block Group
Structural foundation of the
engine.
The cylinder block consists of 2
basic sections:
The cylinder and the crankcase.
• The cylinder section contains
cylinder bores, top deck, lower deck
and an outer wall.
• The crankcase section contains
skirts which enclose the crankcase.
The bottom edge of skirts provide
pan rails which connect the oil pan
to the engine.

Major component of diesel engine

The Block Group

The cylinder is a round, straight-

sided cavity in the engine block in
which the piston ride.

Multiple cylinders are arranged

side by side in the engine block and
lined with a hard metal. They are
housed in the outer wall of the cylinder
block between the top desk and the
lower deck. In heavy-duty machined
and pressed into the block

Major component of diesel engine

The Block Group

Cylinder Liner
Holds the cylinder inside the cylinder block.
A cylinder liner is typically cast
from gray iron, and can be either
wet or dry.
 The majority are wet liners,
which have grooves on the outside
surface to provide a coolant seal.
Thy have better cooling and a more
even temperature distribution.
 Dry liners press against the
metal surface of the cylinder block
itself, and do not come in contact
with coolant.

Major component of diesel engine

 The Block Group
Piston
Lubricated sliding shaft that fits tightly inside the
opening of a cylinder
The piston changes the volume
enclosed by the cylinder, exerts a force
on a fluid inside the cylinder and
covers and uncovers ports.
It is manufactured mostly from
aluminum, but sometimes iron or steel,
and is mounted to the connecting rod
with a wrist pin.

Major component of diesel engine

The Block Group
Piston Rings
Provide a combustion chamber seal
and adequate lubrication as the piston
moves up and down in the cylinder.
The piston rings, made of steel,
are located in grooves in the piston.
In most engines the rings include two
compression rings and one oil
control ring.

Major component of diesel engine

The Block Group

Connecting Rod
Links the piston to the crankshaft. As
the crankshaft turns, the offset of the
connecting rod journal relative to the axis
of the crankshaft causes the piston to move
up and down in the cylinder

Major component of diesel engine

The Block Group

The connecting rod consists of a

small end through which the piston pin is
mounted, and a big end which is split and
bolted around the rod journal bearing of the
crankshaft. The design goal of the
connecting rod may be simple stated as to
provide maximum rigidity with minimum
weight. Weight must be minimal as the
connecting rod is a significant source of
inertia force.

Major component of diesel engine

The Block Group

Crankshaft
Translates reciprocating linear
piston motion into rotation.
The crankshaft is usually made
from steel and is responsible for
moving the piston up and down
inside the cylinder via the
connecting rod. It spins in main
bearing mounted in the block
within the crankcase.

Major component of diesel engine

The Block Group

Camshaft
Translates circular movement
to reciprocating movement which
is used to operate intake and
exhaust valves.

Major component of diesel engine

The Block Group

Bearings and Bushings

Permit constrained relative
motion between two mechanical
parts.

Major component of diesel engine

The Head Group

Cylinder head
Seals the tops of the cylinders,
closing off the combustion chambers.

Major component of diesel engine

The Head Group
The cylinder head consists of
three flat, parallel plates(or decks).
The bottom deck, called the firedeck,
sits on the top of the block, sealing the
combustion chamber. The middle
deck sits somewhere between the
firedeck and the top deck, and is
sliced to accommodate the ports. The
top deck forms the upper surface of the
head and serves as the mounting
surface for the valve train and fuel
injectors. The three decks are encased
in a side wall running around the
perimeter of the head.

Major component of diesel engine

The Head Group

Valves, Valve Guides and Valve Seats

Valves open and close the intake
and exhaust ports in the cylinder head.

Major component of diesel engine

The Head Group

Rocker Lever
Translates motion from the cam lobe
to the intake valve to open the valve.
One end of the rocker lever is raised
and lowered by the rotating lobes of the
camshaft (via the tappet and push tube),
while the other and acts on the valve
stem. When the cam lobes raises the
outside of the lever, the inside presses
down on the valve stem, opening the
valve. When the outside of the lever is
lowered by the camshaft, the inside rises,
allowing the valve spring to close.

Major component of diesel engine

The Head Group

Fuel Injector
Pump-like device that
converts the pressure energy
of a motive fluid (diesel
fuel) to velocity energy.

Major component of diesel engine

The Head Group

Near the end of the compression

stroke, diesel fuel is introduced into the
combustion chamber through an injector.
The fuel ignites from contact with the air
that , due to compression, has been
heated to an excessively high
temperature.
When the injector is energized an
electromagnet moves a plunger that open
the valve, allowing the pressurized fuel
to squirt out through a tiny nozzle. The
nozzle is designed to atomize the fuel to
make a fine mist so it burns easily.

Major component of diesel engine

 The Head Group

Intake Manifold
Supplies air/fuel mixture to the cylinders.

Exhaust Manifold
Collects the exhaust gases from multiple cylinders
into one pipe.
Major component of diesel engine
The End and The Pan Group
Flywheel
Reduces variation in engine speed. The
flywheel is housed in the bell housing, which
is bolted to the engine block. The housing
also contains the torque convertor or clutch
of the transmission, and serves as a structural
member in mating the engine to the
transmission (or other driven device).

Major component of diesel engine

The End and The Pan Group

Vibration Damper
Absorbs the firing pulses
of the crankshaft to avoid
transferring them to the
geartrain.

Major component of diesel engine

The End and The Pan Group
Gasket
Provides a seal between parts.

A gasket is a seal that fills the

space between two mechanical objects
in order to prevent leakage between
the two objects while under
compression. It must also have the
capability to maintain that seal for a
prolonged period, to provide
resistance to the medium being sealed,
and to withstand the temperature and
pressure of the application.

Major component of diesel engine

The End and The Pan Group

Oil Pan
Lower section of crankcase used
as lubricating oil reservoir.
Oil is drawn from the oil pan by
the suction tube assembly, then
circulates throughout the engine. Once
the oil has cooled and lubricated all
metal-contacting surfaces, it gravity-
flows back into the oil pan.

Major component of diesel engine

The Accessories Group

Components in the accessories

group include:

Turbocharger

Water Pump

Fan Hub

Air Compressor

Oil Pump

Fuel Pump

Gear Train

Major component of diesel engine

The Accessories Group

Turbocharger
Uses exhaust energy to
compress the incoming air prior
to introduce it to the cylinder.
A turbocharger compresses
the air flowing into the engine,
allowing more air into the
cylinder. More air allows for
the addition of more fuel,
increasing power from each
explosion in each cylinder.

Major component of diesel engine

The Accessories Group

Water Pump
Circulates engine coolant
through the cooling system.
Coolant is supplied to the
engine through the lower hose
and the water pump. The water
pump is engine-driven and
moves the coolant to a high-
pressure water header typically
running the length of the engine.

Major component of diesel engine

The Accessories Group

Fan Hub
Mounts the fan to the front of
the engine.
The fan controls cooling
system temperature as it senses
when the cooling system needs to
be activated. The fan is controlled
by the fan clutch, which powers it
on and off (according to what
other systems are functioning and
producing heat) and prevents the
engine from overheating.

Major component of diesel engine

The Accessories Group

Air Compressor
Compresses air, which
activates breaks.
Diesel engine brakes are
activated by air (as opposed to
being hydraulically actuated),
and therefore need air pressure
to function. The air compressor
is engine driven, and a required
level of air pressure must be
achieved to allow proper
functioning.

Major component of diesel engine

The Accessories Group

Oil Pump
Part of the lubrication system;
transports oil to various moving
parts inside the engine.
The oil pump draws the oil out
of the engine’s oil pan through a
wire mesh strainer and pumps the
oil through an oil filter before it
circulates throughout the engine to
all metal-contacting surfaces.

Major component of diesel engine

The Accessories Group
Fuel Pump
Regulates engine speed
by injecting a specific amount
of fuel at a specific time.
The fuel pump controls
how much fuel is pumped; if
less fuel is pumped into the
cylinders, this reduces engine
speed. If more fuel is pumped
this increases the speed of the
engine.

Major component of diesel engine

The Accessories Group

Gear Train
A system of gears arranged to
transfer rotational torque from one
part of a mechanical system to
another.
The gear train drives various
engine support systems which are
not powered by any other source.
These systems can include
lubrication and fuel systems, air
and freon compressors, cooling
and power steering pumps.

Major component of diesel engine

Engine systems
Basic Flow Systems
required to maintain the engine
operational are:-

 Air
 Fuel
 Lubrication
 Cooling

Engine Systems
 Air System
1. Intake Air Inlet to Turbocharger
2. Air Crossover
3. Aftercooler
4. Intake Manifold
5. Intake Valve Ports

Uses exhaust gas energy to

compress the incoming air prior to
introducing it into the cylinder.

AIR SYSTEM (INTAKE)

Engine Systems
Air System

AIR SYSTEM (EXHAUST)

1. Exhaust Valve Ports

2. Exhaust Manifold
3. Turbo Exhaust Outlet

Engine Systems
 Air System
KEY POINTS

Air Filtration - sufficient capacity required to provide full protection

(depends on Light, Medium or Heavy Dust environment)
Inlet/Exhaust Restriction - must be within limits when operating at rated load.
(air requirements listed in Engine Data Sheet)
Inlet Location - have to avoid the ingestion of rain, exhaust gases &
hot air (special consideration required for high ambient
temp.)
Clamping and Plumbing - loose clamps or other components will operate and
cause no apparent damage for long time! (check for
rust, dirt and rubbing brackets/cables)
Exhaust Location - located to minimize noise and contamination of air
(with regards to all codes, standards and regulations)

Engine Systems
 Air System
FUNCTION : To provide the engine with an adequate supply of clean,
dry and moderate temperature air for combustion

It does this by :-
AIR HEAT
Air Flow - must be sufficient with proper ventilation
(consume about 71 L/min of free air per HP output)
FUEL
Air Cleaner - require efficiency of 99.7% throughout its flow range
(efficiency based on the SAE J726 test code)
Air Temperature - moderate air temp. for adequate oxygen for combustion
(Nat. Asp. engines in temperate climates rarely > 24ºC
but Turbocharged engines may exceed 160ºC)

A well-designed air system is a vital part of every successful engine installation.

The reward of a good air system design is enhanced durability and reliability of the
engine, thus the equipment..

Engine Systems
Fuel System High Pressure Common Rail
CYL
Head

Fuel Rail
Pressure Injectors
ISB CM2150 Engine Relief Valve

High Pressure Fuel

Line to Rail
High Pressure
Connectors

Secondary
Filter Fuel
Return Fuel
Return

Fuel
Return
Fuel
Hand Primer Pump Return
Fuel Out

Primary
Filter
Fuel Tank
Fuel Gear
Pump
H.P. Fuel Pump
 Fuel System
KEY POINTS

Fuel Specifications - poor quality fuel can affect engine life (check for Cetane
#40, Sulphur (1.0% Max.) & Water
Fuel Filter - check daily for water & drain as needed. Change as
required.(high filter restriction causes low power output
without smoke)
Fuel Tank & Plumbing - subjected to regulation on design, size & location
Inspect / Clean - from fuel tank, supply & return line, pump & injectors
(need to service/calibrate at recommended intervals)
Fuel Temperature - high temp. may lead to power loss & governor instability
(fuel system component wear due to lower lubricity)
Fuel Consumption - depends on rating, load factor, duty cycle, etc...

Engine Systems
 Fuel System
FUNCTION : To keep the engine in proper operation, the fuel must be of
correct quality, quantity, timing and condition for combustion

It does this by :-

Fuel Quality - recommended Grade No.2 (as per ASTM D975) & Cetane 40

Fuel Quantity - dependent on metering time by fuel pump or injector

Injection Timing - accurate setting required on fuel pump or engine
Condition - dependant on size and number of cup/nozzle spray holes

Governor - control the engine speed range from low idle to rated/high idle.

Lack of maintenance on the Fuel System will result in difficult starting,

low power output, unstable operating speed, smoke, etc..
Over-fuelled (resulting in over-load/speed) operation is not warrantable.

Engine Systems
Lubricating System

Lubricates bearing
surface and cools
bearings by absorbing
friction-generated
heat.

Engine Systems
 Lubricating System
L
R
E
I
F
G
T
H
T

1. Oil Pump
2. To Oil Cooler
3. From Oil Cooler 1. From Oil Pump
4. Piston Cooling Nozzle 2. Oil Cooler Bypass Valve
5. Main Oil Rifle 3. Oil Cooler
6. Cam Bushings 4. Full Flow Oil Filter
7. To Overhead 5. To Main Oil Rifle
8. Main Bearing 6. Bypass Oil Filter
9. Con-Rod Drilling 7. Turbocharger Supply
10. Rifle Pressure Signal Line 8. Turbocharger Drain
Engine Systems
 Lubricating System
KEY POINTS

Oil Quality - all oil is not created equally

Oil Specifications - 15W40; CE or C/CD or CD/SF or better
Oil Change Interval - is in direct proportion to Life to Rebuild
Oil Filters - must be filled during oil change to prevent bearing damage
Oil Handling - Tank, Hoses, Nozzles are to kept CLEAN
Oil Consumption - is usually a good yardstick of engine useful life

Fast or Cold Start - the delay of oil flow to the main bearings
and high bearing loads can cause permanent bearing damage.

Engine Systems
 Lubricating System
FUNCTIONS of Lubricating Oil :-
Lubrication - by providing a film between moving parts to reduce wear
and friction.
Cooling - by serving as a heat transfer media to carry heat away from
critical areas (temp. controlled by oil cooler)
Sealing - by filling in the uneven surfaces in the cylinder wall, valve
stems and turbocharger oil seals
Cleaning - by holding contaminants in suspension to prevent a build up of
deposits on the engine surfaces
In addition, it must also provide :
•Dampening & Cushioning of components
•Protection from oxidation and corrosion
•Hydraulic action for components

Engine Lube Oil must be changed when it can no longer perform its functions. Oil
does not wear out, but it becomes contaminated to the point that it can no longer
satisfactorily protect the engine. Contamination of the oil is a normal result of
engine operation.

Engine Systems
 Cooling System

Uses a liquid coolant to transfer waste heat out of

The block and the internals of the engine.

Engine Systems
Cooling System

1. Water Pump
2. Oil Cooler
3. Water Manifold
4. Aftercooler Inlet
5. Aftercooler Outlet
6. Thermostat
7. Bypass
8. To Radiator
9. Water Pump Inlet

Engine Systems
 Cooling System
FUNCTION : To keep the engine temperatures within acceptable limits
(same function for all internal combustion engines)

Power Exhaust
It does this by :-

Absorption - absorbing heat from the engine components Cooling

Circulation - circulate the coolant in the engine

Dissipation - dissipate the heat through a heat exchanger (e.g. Radiator)
Control - control coolant temperature by the thermostat

The cooling system has a critical task to perform. If cooling is

reduced or interrupted even for an instant, it can result in serious
damage to the engine.

Engine Systems
 Cooling System
KEY POINTS

Coolant - tap water has always been the basis for cooling liquid
(cheap and available but contains variety of minerals/chemicals)
Chemical Balance - check and add coolant additive as recommended
(protect against Corrosion and Scale Formation)
Cooling System Pressure - slight leaks can allow pressure drop to zero
(allows pump cavitation, lowers boiling
temperature of coolant, etc...)
Air Flow Through Radiator - can be reduced by debris, fan slippage and
recirculation between the fan and shroud.

Engine Systems
 Conclusion
Having a basic understanding of Cummins diesel engines
and how they operate is important not only to engineers, but to
all employees and distributors of Cummins products.
By breaking down the engine into different engine groups
and systems it is easier to understand how each individual
component contributes to unleashing the Power of Cummins.
Not only in our engines, but our employees and distributors.