QSV Diesel Engines

Module 11 - Marine Supplement

Cummins Corporate Training

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D / Marine / BMG / 01-01 / Rev. 03

 QSV Diesel Marine Engines

Learning Objective
To identify key build changes between QSV Industrial Diesel
Power Plant and Marine engines. Participants will be able to
identify the additional Marine components and and compare the
design changes.
Agenda
• Marine Engine Ratings
• Marine versus DPP Engine Layout
• Marine Cooling System
• Marine Fuel System
• Turbo Waste-gate - Propulsion Engines
• Marine Features and Options
• In-line Marine Genset Layout
• Marine Maintenance Schedule

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 Marine Engine Rating

POWER OUTPUT

• 115Kw / Cylinder continuos rating, or

• 130Kw / Cylinder Intermittent rating.

ENGINE SPEED

• 1500 / 1800 rpm for marine Genset 50/60 Hz.

• 1600 / 1650 rpm for propulsion engines (Cont / Int).

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 Marine V’s DPP Layout
• Only Marine versions of L6 and L8 will be sold by Cummins. The
industrial DPP market at this rating will be met by Cummins
QST30 and the KV 38/50 Litre engines. Only one In-line
configuration is therefore required, covering Marine Propulsion
and Marine Power Generation.
• The ‘V’ engine range exists in both Industrial DPP and Marine
configuration:
• DPP: Charge Air Cooler mounted at free-end, Lube Oil Module
mounted at flywheel-end as standard QSV Diesel.
• Marine: Sea Water Cooler (optional) mounted at the free-end of
the engine in addition to the Lube Oil Module and Sea Water
Pump. The Charge Air Cooler is located at flywheel-end. This
configuration is necessary due to the reduction in free-end area
with the fitment of the Sea Water Pump / Cooler.
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 Marine Free-End Layout - 6 L & 8L

10

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 ‘L’ Marine Simplified Cooling System Block Diagram

Cooling Water Control Unit High Temp Water Circuit

88 -100º C
ENGINE
HT Pump
BLOCK

LT Pump CAC
52 - 64º C
LOC

FW / SW
TC : Turbocharger Low Temp Water Circuit
LOC : Lube Oil Cooler Dual Circuit Water Pump
CAC : Charge Air Cooler
SWP CC : Central Cooler Thermostatic Valve
FW/SW : Heat exchanger
SWP : Sea Water Pump Communicating Circuit Plug

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 ‘V’ Engine Marine Layout

IN

OUT

Free-End Flywheel-End

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 ‘V’ Marine Simplified Cooling System Block Diagram

Cooling Water Control Unit High Temp Water Circuit

88 -100º C
ENGINE
HT Pump * TC BLOCK

* ‘ V ’ engines only

LT Pump
52 - 64º C
CAC LOC

FW / SW
Low Temp Water Circuit
TC : Turbocharger
LOC : Lube Oil Cooler Dual Circuit Water Pump
CAC : Charge Air Cooler
SWP
CC : Central Cooler
Thermostatic Valve

FW/SW : Heat exchanger

Communicating Circuit Plug
SWP : Sea Water Pump

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 Cooling System Flow Marine “V” Engines

FLYWHEEL-END
MOUNTED
AIR FLOW FIVE CHARGE AIR
PASS LT COOLER
SECTION
Water Flow ONLY

LT Feed Pipe LT Return Pipe

LT from LOM, LT Return, via

via block and flywheel housing
flywheel housing and block to
pump

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 Marine Fuel System Schematic

‘Dirty ’
Hot Box Clean
Drain - A Leakage

Fuel Inlet

Clean
M Leakage

‘Dirty ’
Hot Box
Drain - B Pressure Regulating Injection
Valve - 5 Bar Pump
Return

KEY Indicates Optional

Filter HP Injection Pump Non-Return Valve Pump Combi Cooler (optional) Float Switch

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 Turbo Waste-gate - Propulsion Engines
• Waste-gate used to optimise boost
Boost pressure regulated to
pressure across operating range by 2.75Bar on L6 & L8 engines.
diverting exhaust gas away from
turbo.
• Simple pressure valve used to
regulate boost pressure supplied to
engine. Gate valve operated
directly from boost pressure sense
line.
• Waste-gate trials in conjunction
with Woodward 723 speed
controller which incorporates fuel
Exhaust Manifold
boost limiter (Programmable Gain).
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 QSV In-line MK1 Turbo Waste-gate Arrangement

Propulsion Engines All other applications

Exhaust outlet / Elbow changed, waste-gate Blanking plate fitted to exhaust
fitted to exhaust manifold as shown. manifold as shown.

The pressure adjustment screw is located on the top of the waste-gate. Always check air
inlet system for leaks, turbocharger compressor / turbine blades for damage, dirt or soot
deposits and condition of turbocharger bearings before attempting adjustment. Set to
2.75Bar at rated speed and load. Ensure all instrumentation is calibrated.

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 Marine Features and Options

Emergency Pump
Connections
• Non-return valves are fitted on
the water pump LT and HT Emergency
outlets. These valves allow pump
engine to be connected to an connections
external pump in case of HT LT
emergency.
• The valves have a 4.0mm hole
to allow air to vent on fill and
when engine stopped.
Position of LT & HT
Standard Feature non-return valves.

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 Marine Features and Options

Self Priming Sea Water Pump Optional

OUTLET
• Construction, centrifugal type with Non-Return
self-priming impeller. Valve
Priming Plug
• Impeller material: Aluminium
Bronze, Housing: leaded gunmetal. INLET
• Shaft bearings roller and double Oil
roller to take thrust Connection

• Water seal - mechanical

(carbon & ceramic).
• Oil seal - Lip seal running on
stainless steel collar.
• No routine maintenance.
• Prime with water via inlet plug
before first use and after draining. Main Priming
Drain
Impeller Plugs Impeller

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 Marine Features and Options

Sea Water Cooler

Plate construction consisting
of between 30 and 52 plates
or sections dependant on
engine type. Fitted on the
free-end .

• Plate material; Titanium.

• Zinc anode fitted in sea water pipework. Optional
• Dual function combi-cooler option available;
Plates used as heat exchanger for engine cooling circuits plus a
separated section of six plates used as heat exchanger for fuel
cooling. Maximum fuel inlet temp 50º C.
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 Marine Features and Options

Sea Water
Engine Coolant
Snap-on gaskets are
used to seal between
the plates. This
feature simplifies
renewing gaskets on
site.

Principle of
operation

Sea Water Cooler

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 Marine Features and Options

Engine Heater - Optional

‘L’ Engine Layout

NOTE: ‘V’ engine Marine layout
changes from Industrial layout as no
‘V’ Engine Layout HT water supply to charge air cooler

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 Marine Features and Options

Crankcase Explosion Valves

2 off -
Marine Standard Feature
(open @ 100Mb differential)

Safety Wall High Pressure

Injection Lines
All cylinders -
Marine Standard Feature

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 In-line Marine Generator Set Layout

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 Using of the engine: Unlimited
MARINE
APPLICATION (N = 1650 Cont) Major Overhaul : 32000 h
Controls & Maintenance Code 5 10 20 60 120 240

Marine Application Continuos Duty

Group Every Every Every Every Every Every Every Every
day week 500 1000 2000 8000 16000 32000
Operations
hours hours hours hours hours hours

1 Clean the engine

Maintenance at a Glance
2 Find out leakages and defects



3 Read all motors parameters



4 Check crankshaft alignment





5 Check Camshafts, Push Rods and
Gears



Engine 6 Check and Adjust valve Clearances





7 Overhaul of cylinder Heads




8 Check Turbochargers bearing
Clearances


9 Replace Turbochargers bearing




10 Check Cylinders (with an endoscope)





11 Check Connecting Rods, connecting
rods Bearing, (1 Piston and Cylinder


liner)
12 Replace Liners



13 Replace Pistons


14 Replace Pistons Rings

1650 RPM
15 Replace connecting rod bearings



16 Replace crankshaft bearings and
thrust bearings

17 Replace rubber coupling elements


18 Replace rings and thrust bearing for
intermediate shafts

19 Replace crankshaft gaskets .


20 Replace rings and thrust bearing for

Only for the FIRST
Camshafts
specified period
 APPLICATION Using of the engine: Unlimited
MARINE Major Overhaul : 32000 h
Controls & Maintenance Code 5 10 20 60 120 240

Marine Application Continuos Duty

Group Every Every Every Every Every Every Every Every
day week 500 1000 2000 8000 16000 32000
Operations
hours hours hours hours hours hours

21 Check lube-oil Level

Maintenance at a Glance
22 Take Oil sample for analysis







Lubrication 23 Replace Lube-oil cartridges, Check leaf
valve colmation





24 Replace Lube Oil






25 Inspect hoses and flexibles



26 Replace hoses and flexibles




27 Replace Oil nozzles


28 Replace Lube Oil thermostatic Valves




29 Replace Lube Oil thermostat Holders


30 Clean centrifugal filter








31 Check Oil Pump




32 Replace Oil Pump


33 Overhaul injection pumps



34 Check daily tank level

1650 RPM
35 Replace pre-filter






36 Replace fuel cartridge






Fuel Oil 37 Empty leakage tanks



and Injection 38 Check injectors



39 Replace injectors




.
40 Check Fuel pump






Only for the FIRST
41 Replace Fuel pump specified period


 Marine Application Continuos Duty
MAINTENANCE SCHEDULE CW170
APPLICATION Using of the engine: Unlimited
MARINE Major Overhaul : 32000 h
Controls & Maintenance Code 5 10 20 60 120 240

Maintenance at a Glance
Group Every Every Every Every Every Every Every Every
day week 500 1000 2000 8000 16000 32000
Operations
hours hours hours hours hours hours

42 Check cooling water level

43 Check Water treatment



44 Replace thermostatic Valves and
cooling Water



Cooling 45 Replace water thermostat holder
System

46 Clean Lube oil Cooler




47 Check Water pump




48 Replace Water pump


49 Check flexible Pipes





50 Check Cleanness of air filters



Air 51 Clean Air Filters As soon as colmation signal appears or every 1000 h.

Cooling 52 Replace Air Filters Depending on the number of cleaning or every 4000 h.

1650 RPM
53 Clean Charge Air Cooler




Starting 54 Check Starting system



55 Check batteries



Device 56 Check electric Connections



.

Only for the FIRST
specified period
 Module 11 - Marine

End

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QSV Diesel
Cummins Corporate Training
CUMMINS CORPORATION
D / Marine / BMG / 01-01 / Rev. 03