CUMMINS ENGINES FOR RAIL APPLICATIONS kw

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1 CUMMINS ENGINES FOR RAIL APPLICATIONS kw

2 Meeting Every Need of the Rail Industry Railcar and locomotive design is rapidly evolving to meet ever growing requirements for higher running speeds, increased passenger capacity, lower operational costs and maximum reliability. All of these factors are placing exceptional demands on the performance of the diesel engine. That s why Cummins has developed a range of engines ideally suited to the rail industry, setting unrivalled standards of power density and durability, with low emissions and low life cycle costs. So from high speed DMUs (Diesel Multiple Units) to shunters and mainline locomotives, plus every type of track equipment, there is a Cummins engine available offering the most efficient power solution for your rail equipment. Experience with Expertise With over 13,000 rail engines in operation worldwide, Cummins has the experience to provide the right engine for each installation. Recognising the unique modes of operation of rail equipment, Cummins package is focused on providing the highest possible engine availability at the lowest possible running cost. High speed engine installations can provide major cost savings when replacing older low speed units. Fuel economy is significantly improved, with servicing and reliability concerns minimised for equipment owners. Cummins offers the rail user significant benefits whether specifying new equipment or re-powering older equipment. Specialised expertise and support is offered from Cummins dedicated team of engineers to provide an individual solution for each application. With a level of experience no other engine company can match, you can rely on Cummins every time. Enhanced Durability for Every Application Fundamental to the design of all Cummins rail engines is the need for exceptional durability. Ferrous cast ductile iron pistons, micro-finished camshafts, charge air cooling and the other advanced engineering features ensure the outstanding levels of durability you expect from Cummins. But this commitment to durability goes beyond extending first engine life, as every Cummins rail engine has been designed with a capability for multiple rebuilds with as new performance guaranteed. This is a major benefit in prolonging equipment life without making costly changes to the installation. No Compromise for Stricter Emissions Stringent emissions rules are now coming into force for the rail industry. New regulations are planned for the USA and Europe, and it is expected that other regions will follow at a later date. This will have a major influence on future plans for new equipment and re-powers. Only those companies ready to meet these challenges with the latest emissionised engines will have the ability to provide the best all round package for your rail equipment. With over $200m invested each year on research and engineering, Cummins can provide customers with the most advanced and cost-effective diesel engines available. Particulate Matter Fuel-Rich Region NOx Liquid Fuel Engine Combustion Simulation

3 Global Emissions Standards U.S. EPA emissions limits have already come into effect for rail equipment kw ( hp) at Tier 3 MOH (Mobile Off-Highway) levels. These will move to Tier 4 levels on January 1st Locomotives above 560 kw (750 hp) will remain at Tier 2 and move straight to Tier 4 in For Europe, railcar engine emissions will come into effect on January 1st 2006, with locomotives following in 2007 and 2009 depending on power output. All European legislation will be at the Stage IIIA levels. The UIC (Union Internationale des Chemins de Fer) will bring new limits into effect in 2008 for non EU or EPA installations which will be in line with the European Stage IIIA requirements. US EPA 225 to 560 kw US EPA >560 kw EU Railcars Tier 3 Tier 2 Stage IIIA Tier 4 Tier 4 the rail industry. Today and in the future Cummins will continue to deliver power uniquely matched and integrated into every rail application. Cummins, as a pioneer in emissions research and development, offer a complete range of diesel engines. All engineered to meet the current Tier 2/ Stage II and Tier 3/Stage IIIA emissions regulations using the latest in-cylinder advanced combustion technology. Cummins In-Cylinder Advanced Combustion Solution for Tier 3/Stage IIIA Using analysis-led design, Cummins engineers can model chemical reactions anywhere in the cylinder at any time and optimise the results by controlling or modifying critical design parameters. Thousands of combinations can be analysed before Cummins commits to a design. Temperatures EU Locomotives 130 to 560 kw Stage IIIA 350K 950K 825K ~1600K 2700K EU Locomotives > 560 kw Stage IIIA Injector UIC UIC2 The Right Technology Matters UIC3 Cold Fuel Warm Air Rich Fuel/Air Mix =4 Products of Rich Combustion CO, UHC & Particles Chemistry NOx CO 2 & H 2 O Cummins leadership in combustion research, fuel, air-handling, aftertreatment and controls systems allows Cummins to achieve the goal of maximizing customer value by providing the most appropriate emissions control technology integrated into each equipment type and market. Cummins component technology companies, subsidiaries, alliances and our relationships with universities and national laboratories uniquely position us to design, manufacture and implement the best solutions for Characteristics of Diesel Combustion This process has allowed Cummins to optimise the combustion system to meet the Tier 3/Stage IIIA NOx levels without the need for emissions control devices such as EGR or oxidation catalysts. This advanced combustion solution provides a stable product architecture through 2015 and beyond, resulting in long-term engine installation stability.

4 Quantum System Engines Quantum System electronic controls are at the heart of Cummins emissions solutions. These manage everything from fuel delivery and power curve shaping to protection features and data management. All are designed to work with a common set of application and diagnostic software, to simplify engineering installation as well as servicing. These Quantum System engines deliver exceptional durability in the world s most demanding rail operations. Plus, they are designed to meet every applicable emissions standard from Tier 2 to Tier 3, and Stage II to Stage IIIA with "in-cylinder" technology. So, you can spec Cummins for years to come, with every assurance. QSX-L The Quantum System 15 litre QSX-L has a power output range from 261 to 448 kw (350 to 600 hp), especially suitable for switching and yard QSM-L The QSM-L is an 11 litre engine with a power range of 216 to 298 kw (290 to 400 hp). This proven heavy-duty performer utilises Cummins in-cylinder advanced combustion and is ideally suited to provide the responsive performance required in the shunting locomotive market. The electronic control module ensures the engine maintains an optimum balance between load demands and fuel efficiency ensuring high reliability and low running costs in arduous and intensive rail operations. locomotives. One of its key design features is the Dual Overhead Camshafts (DOHC). The first camshaft drives the high-pressure fuel injection system, capable of pressures up to 30,000 psi (2,068 bar) - giving even more power to the operator. The second cam operates the valves. This design gives the operator the benefit of up to 40% longer life to overhaul and low cost of operation. The high power to weight ratio and high torque allows movement of significant weights without the need for a larger locomotive engine.

5 QSK19-L QSK19-R The QSK19-R is the number one choice for high speed rail DMUs around the world. Available up to 560 kw (750 hp) it offers high acceleration and high speed capability. This reduces journey times with the renowned durability from Cummins. The horizontal configuration gives ease of access for maintenance at the side of the rail vehicle. It also reduces noise and vibration and increases passenger capacity. The new Tier 3/Stage IIIA QSK19-L is one of the latest additions to the Cummins locomotive engine range. By incorporating new combustion and fuel system technology, the well-proven Cummins 19 litre platform meets Tier 3/Stage IIIA emissions with ratings up to 522 kw (700 hp). The enhanced design incorporates the new high pressure common rail (HPCR) system achieving peak fuel injection pressure of up to 23,000 psi (1,586 bar). The engine has the ability to be installed in locomotives with single or multiple engine configurations. This gives increased flexibility for the operator to provide the lowest possible Tier 3/ Stage IIIA emissions whilst reducing The QSK19-R is a unique product in the underfloor railcar diesel market offering unparalleled power, advanced electronics, low emissions and durability which in turn gives the operator benefits of lower than ever life cycle cost, environmental advantages and faster journey times. running costs and maintaining a high level of rail equipment availability. Further benefits include an increase in durability up to 10% and reduction in oil consumption by approximately 20% - offering operators important cost savings.

6 QSK23-L QST30-L The QST30-L, rated at 787 kw (1050 hp) is built to withstand the toughest operating conditions in the rail environment. Ductile iron pistons allow higher power to handle high heat and heavy loads. With power output of up to 708 kw (950 hp), the 23 litre engine is the optimum choice to power branchline locomotives for passenger or freight operation. High pressure fuel injection and sophisticated air-handling systems give the QSK23-L excellent responsiveness with low fuel consumption. This means that the engine power is available, whatever the operating conditions of the locomotive, providing reliable low cost service. A swirl port cylinder head reduces emissions and increases low end torque. This gives the locomotive the power it needs to get moving quickly - whatever the task. Its durable design is ready to handle the thermal fatigue experienced in the rail industry. QSK45-L With power outputs of 940 to 1343 kw (1260 to 1800 hp), the QSK45-L has been specially configured for both new and re-power locomotive applications up to 80 tonnes requiring a compact engine envelope. With a 38% larger camshaft and

7 an extra-wide gear train, the 45 litre engine gives unrivalled durability for even higher load factors. The QSK45-L offers dramatically extended service intervals up to 4,000 hours using Cummins service extension options and it requires virtually no maintenance intervention between overhauls. The 45 litre engine incorporates the latest smart electronic system, CENSE faults such as sensor failure, low oil pressure or high coolant temperature are instantly recognised by this system. With CENSE, diagnostic and prognostic reports can be viewed on a cylinder-by-cylinder basis, taking QSK45-L productivity to a new level. K50 with the strength of single-piece ferrous cast ductile iron pistons that provide a 10% longer lifeto-overhaul. Its V16 configuration offers a power range from 1343 to 1492 kw (1800 to 2000 hp), capable of meeting Tier 2/Stage II emissions with in-cylinder technology. The Cummins modular common-rail fuel system maintains high injection pressures for exceptional performance at every rpm. This provides enhanced locomotive acceleration and maximum speed for effective train operation. Rail operators are able to quickly respond to issues and maintain a higher level of equipment uptime. QSK50-L QSK60-L The QSK60-L has the same design features as the QSK45-L, but with four additional cylinders. With an output range of 1492 to 1865 kw (2000 to 2500 hp), this engine is suitable for mainline freight and passenger locomotives. For high power rail applications, the QSK50-L combines the durability of the legendary Cummins The V-16 configuration of the QSK60-L, heavy duty components and extended maintenance features

8 help set the standard for high productivity at high rail load factors. Performance and durability are maintained even for intensively used locomotives operating a high number of hours. high maximum speeds. Using Cummins service extension technology it has the ability to run up to 4,000 hours between services providing significant cost reductions for the rail operator. The 78 litre, 2238 to 2611 kw (3000 to 3500 hp) engine gives operators of larger locomotives the ability to choose Cummins renowned levels of durability and reliability. QSK78-L It s one of the most powerful high speed diesel engines in the rail industry with 18 cylinders, and 78 litres displacement. With output range of up to 2611 kw (3500 hp), the V-18 configuration of the QSK78-L combines the proven durability of the Cummins K Series with an advanced electronic control system and enhanced durability. The 78 litre engine is specifically designed for the latest generation of low axle-weight rail vehicles with

9 Service Extension Technology Cummins has the ability to provide factory fitted options which will significantly increase your equipment reliability and availability whilst reducing engine servicing costs. problems. The system operates under its own hydraulic power with a self-cleaning full-flow filter and a centrifugal separator, which is capable of removing oil particles down to 2 microns or less. It extends oil change intervals to 1000 hours, and removes the need to dispose of old filters. Cummins PRELUB System Cummins PRELUB System helps to eliminate wear from cold and hot starts giving longer engine life. It automatically protects the engine by requiring full oil pressure to all major components prior to cranking. Fitted as standard on all Cummins high-horsepower (HHP) locomotive engines it can extend engine life by up to 25%. ELIMINATOR Filtration System CENTINEL CENTINEL is an advanced engine oil management system which dramatically increases oil changes intervals up to 4,000 hours, while ensuring even better engine lubrication in the process. Using advanced electronic control technology the system constantly monitors oil quality in relation to duty cycle and load factor demands. CENTINEL removes small amounts of used oil as required and replaces it with new oil from an auxiliary oil tank to maintain lubrication quality at a consistent level. The removed oil becomes a useful energy source as it is blended into the fuel and burned during combustion. This is a major factor in reducing servicing costs. ELIMINATOR is an engine mounted oil purification system, which eliminates the need for conventional oil filters, saving service time and disposal

10 Quantum Electronics for Rail Engines Cummins Quantum system concept is the use of electronic control systems and information technology to enable engine users to run their business more effectively. Service downtime can be reduced, faults can be rapidly identified and fuel efficiency can be analysed. All new Cummins electronic engines feature this system, by far the most advanced electronic management system yet seen on any rail diesel engine. The system continuously monitors engine performance, adjusting the fuel-to-air mixture to maximise engine response across the whole duty cycle while achieving fuel efficiency and lowest emissions. With over 60 programmable features, engine performance can be customised to specific operator requirements. Military-standard harnessing allows Cummins Quantum electronic systems to operate in the most severe rail environments with reliability in excess of engine overhaul life. And as smart electronics, they will readily integrate with power interface modules on rail vehicles with isolated electrical returns. INSITE and INFORM Rail vehicle productivity can be significantly improved by using Cummins Windows based INSITE and INFORM software tools for smart diagnostics, trip data and fleet management. Cummins INSITE software minimises downtime and operational costs by providing rapid diagnostics to instantly pinpoint faults and service needs. Features step-by- step repair directions with precise diagrams. INFORM is a highly effective full fleet management data retrieval tool that aids prediction of service requirements, compares fuel consumption to targets and translates data into easy to use graphs and charts. Optimum performance with POWERMATCH Quantum System electronics allow Cummins to customise the performance of your rail engine to a specific piece of equipment or application. We examine everything from load factors to ambient temperatures to different operating modes. Once we have that profile, we customise the torque curves and power ratings to get your engine and equipment working together for optimum performance.

11 Cummins Power for Rail Equipment Model Cylinders Capacity Max Power Max torque (litres) kw hp (Nm) QSM-L QSX-L QSK19-L QSK19-R QSK23-L QST30-L V QSK45-L V QSK50-L V QSK60-L V QSK78-L V Cummins is a pioneer in product development. Thus specifications may change without notice.

12 At Cummins, we recognise that it s not just about investing in the best engine technology. Equally important is the investment we make in our service support. With a network of over 5,000 dealer locations, few other engine companies come close to Cummins global support capability. And that support goes even further with QuickServe - our commitment to rapid response. Cummins customers can access on-line a complete portfolio of engine diagnostics, maintenance procedures, repair and parts information. Cummins Engine Company Ltd Global Rail Group, Royal Oak Way South, Daventry, Northants NN11 8NU, UK Tel: +44 (0) Fax: +44 (0) cabo.customerassistance@cummins.com Bulletin No Printed in UK 06/05

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