1 MAREN 2012 ODRŽAVANJE MOTORA CUMMINS Simo Kolundžija
2 Cummins snaga Najveći nezavisni proizvođač dizel motora na svetuGlobalno rasprostranjena proizvodnja, prodaja i podrška Preko proizvođača opreme - prva ugradnja Cummins je zastupljeniji od drugih (prisutan u više tipova opreme) - ogromna prilagodljivost Poruka uz slajd 3: Cummins je u smislu primene najrasprostranjeniji dizel motor na svetu. Snaga Cummins brenda i sposobnost da uvek pruži pouzdan radni učinak predstavljaju prednost za sve OEM - oni danas sa ponosom mogu da ponude svoje mašine sa Cummins motorima krajnjim kupcima bez straha da li će se motor pokazati kao trajan i pouzdan. 12/8/2017 Cummins Confidential
3 Engine Range 12/8/2017 Cummins Confidential
4 Cummins Podrška 063 104 15 13 00-24 h Cummins internacionalna podrškaPreko servisnih centara Preko originalnih Cummins novih i ReCon rezervnih delova Cummins Serbomonte podrška Radionica i Terenski Servis 12 servis mehaničara ( QS) 24 časa/7 dana u nedelji Kompletan alat i oprema Lager ORIGINALNIH ® rezervnih delova Podrška korisnicima opreme Instruktori Servisa - Cummins Iskustvo Trening centar Literatura REMONTOVANI motori do 1600 KS za industrijsku zamenu 00-24 h 12/8/2017 Cummins Confidential
5 SERVICE CENTRES 12/8/2017 Cummins Confidential
6 Opšti troškovi rada dizel motoraMotor: KTA 38 - Period od sati, Faktor opterećenja: 40% Prema CUMMINS podacima 12/8/2017 Cummins Confidential
7 Očekivani radni vek motoraK50 – Gal K38 – Gal K19 – Gal N14 – Gal QSK78 QSK60 QSK50 QSK45 1,300,000 QSK38 QST30 1,000,000 QSK23 875,000 QSK19 750,000 Message: Cummins Tier 2 engines will achieve the longest time to overhaul in the industry as their Tier 2 predecessor - as they use the same proven platforms Supporting Details: Mid- life inspections will be required as part of maintenance procedure QSK78 – moves 1,262 to 1.300 QSK60 – same QSK50 – moves to 875 from 750 K2000E QSK38 – moves to 625 from 560 K1500E QSK45 – same QST30 - same QSK23 – minor move to 385 from 380 QSK19 – moves to 300 from 250 10% reduction if one of below ( 15% if two or all three) Throttle at 100% for 30 minutes or above Above 4,000 ft Temp over 105 F 625,000 500,000 385,000 300,000 12/8/2017 Cummins Confidential Design average life-to-overhaul (duty cycle dependent) - US gallons fuel burned
8 Održavanje mehaničkih motora Cummins12/8/2017 Cummins Confidential
9 Tipovi elektronskih motora CumminsTipovi Elektronskih motori u rudarskoj mehanizaciji QSB6.7 QSC/QSL9 QSM QSX15 QSK19 QST30 QSK45 QSK60 12/8/2017 Cummins Confidential
10 Cummins dizel motori QSX15hp 15 liter In-line 6 QSX15 Buldozer Dressta TD25M Dvostepeno filtriranje (primarno i sekundarno) Sekundarni filteri se nikada ne pune gorivom (samo prazni se zavrću), vrši se primiranje (filtrirano gorivo iz primarnog filtera ulazi u njih preko elektro pumpe). Uprimarni se sipa gorivo kao na klasičnim. Čisto gorivo Nano tehnologija injektora i pumpe za gorivo. Ceo motor konttrolisan ECM-om. 12/8/2017 Cummins Confidential
11 Cummins dizel motori QSK19 MCRShp 19 liter In-line 6 FCD pistons MCRS – Modular Common Rail System Poboljšan paket senzora Buldozer Dressta TD40E QSK19 Imaju najviše senzora na sebi oko 15. Isto kao i QSX 15 veoma osetljiv na gorivo.Pripada generaciji TIER3 emisiji izduvnih gasova. ECM je poboljšan motorolin model CM2150. Bosch je mnogo osetljiviji a Motorola je otpornija na teške uslove eksploatacije Fizički i komponente su trajnije. Može da se kači Road relay (bežični sistem praćenja rada motora) i praćenje svih parametara motora. 12/8/2017 Cummins Confidential
12 Cummins Dizel motori QST30hp 30 liter V12 FCD pistons Pump line nozzle fuel system Belaz 75570 QST30 Surface Miner 2500 SM V12 motori sa dve pumpe u paralelnom radu. Dve pumpe = dva ECM-a. Jedan master (glavni) koji upravlja drugim i sinhronizuje rad motora. 12/8/2017 Cummins Confidential
13 Cummins Dizel motori QSK45hp 45 liter V12 FCD pistons HPI - High Pressure Injection CENSE monitoring option QSK45 Komatsu HD1500-7 Jednodelni klipovi poboljšani ubačeni od marta 2008 godine i u Boru i MPk-u su već u motorima. TIER 2 varijanta sa mehaničkim injektorima – dugotrajniji zbog lošeg kvalieteta goriva na našem tržištu. Zupčasta pumpa. ECM500 model Motorolin. 12/8/2017 Cummins Confidential
14 Cummins dizel motori QSK60Belaz 75306 hp 60 liter V16 FCD pistons Mehanički injektori ECM – model CM500 QSK60 Isto Tier 2 sa mehaničkim injektorima. Opremljen sa 4 turboa. Do 2500 HP je sa 4 turboa (single stage), a iznad 2500 HP je sa 6 (two stage). 12/8/2017 Cummins Confidential
15 Šema održavanja motora serije QSK19 MCRS12/8/2017 Cummins Confidential
16 QSKV- Extended Service TechnologySection 3 : Extended Service Technology 6 SLIDES Message: Our Tier 2 engines will offer the best capability in the industry for extended oil service Note: Each slide contains speaker support - to access, click on ‘View – Notes Pages’ 12/8/2017 Cummins Confidential
17 Extended Service: OptionsDramatically reduce downtime and can lower lube service costs by up to 90% Enhance equipment capability for 24/7 operations Ensure best possible engine lubrication Major reduction in used oil & filter disposal System: Oil Drain Filter Service Fleetguard® ES hrs hrs Spin-on disposable filters Eliminator™ * Centrifugal filtration system Centinel™ indefinite* Oil replacement system Centinel™ & Eliminator™ indefinite* * oil analysis required at 250 hour intervals for all extended oil drain operations Message Cummins extended service technology enables you to specify the ideal oil service option to meet your operational needs Eliminator and Centinel – only available with a Cummins engine Based on field data – we are now able to extend Centinel oil change to indefinite hours with oil analysis sampling undertaken Supporting Detail: For Centinel & Eliminator extended service - oil sample must be taken (i.e. from engine oil rifle) every 250 hours and can be sent to Fleetguard for analysis. Oil analysis must include (total base number) & soot measurements 12/8/2017 Cummins Confidential
18 Extended Service: Eliminator™ FiltrationEngine mounted oil filter which cleans itself as it cleans the oil Two-stage filtration system with a permanent core: First Stage: full-flow filter Second Stage: back-flush centrifuge Extends oil change intervals up to ,000 hours based on oil analysis Eliminates the need for disposable spin-on filters Ensures cleaner engine oil Message Breakeven cost typical at months by eliminating over 50% of lube related downtime (compared to 250 hour standard interval) Proven success - 80% of QSK45/60 industrial engines specified with Eliminator Supporting Detail: Oil interval extended up to 1,000 hours. Sample must be taken (i.e. from engine oil rifle) every 250 hours and can be sent to Fleetguard for analysis. Oil analysis must include (total base number) & soot measurements Requires minimal servicing - full-flow filter at engine overhaul requires inspection, cleaning, replace O rings on filter & hydraulic motor - back-flush flow centrifuge service at hrs depending engine load, application, oil quality. - remove bowl liner with sludge, inspect bowl & spindle and reinstall – less than 15 mins 12/8/2017 Cummins Confidential
19 Extended Service: Eliminator™ FiltrationFirst Stage: full-flow stainless steel filter screen removes particles down to 20 microns. Sends 95% of clean oil to engine Second Stage: remaining 5% backflushes the filter every 90 seconds Backflushed oil is routed to a 2 micron centrifugal separator Message Virtually maintenance free system Eliminates the need (and disposal) of spin-on filters Supporting Detail: Oil change extended up to 1,000 hours. Oil sample must be taken (i.e. from engine oil rifle) every 250 hours and can be sent to Fleetguard for analysis. Oil analysis must include (total base number) & soot measurements Requires minimal servicing: - back-flush flow centrifuge service at hrs depending engine load, application, oil quality - full-flow filter at engine overhaul requires inspection, cleaning, replace O rings on filter & hydraulic motor - remove bowl liner with sludge, inspect bowl & spindle and reinstall – less than 15 mins 12/8/2017 Cummins Confidential
20 Extended Service: Centinel™ Oil ManagementElectronically controlled continuous oil replacement system Automatically replaces lube oil at load factor dependent intervals Burns the used oil with the fuel during combustion as an additional energy source Enables oil change intervals to be dramatically extended based on oil analysis 1:1 removal / replacement based on fuel consumption ensures a consistently high level of oil quality Major reduction in used oil & filter disposal cost Message: Proprietary to Cummins This is a fuel consumption based system – unlike time based systems It is able to exchange more oil when the engine is working hard and less oil when it is not – our research shows that oil quality is more directly related to fuel consumption than on time factors Supporting Detail: EPA certified for use (i.e. burning oil with fuel) – but Centinel cannot be used on equipment domiciled in California because CARB does not allow burning of used oil Designed to be maintained free – though generally worth the investment to change the control valve at engine overhaul Not available for QSK23 12/8/2017 Cummins Confidential
21 Extended Service: Centinel™ Oil ManagementSelf-monitoring, continuous oil replacement system for QSK controlled by engine ECM Message: QSK50 diagram shows a typical system for HHP engines (nbQSK19 has a different configuration & not available for QSK23) Everything is done in the engine ECM and normal fault lamps for the equipment are used (as for any other engine fault code) Self-monitoring system reverts engine to standard operation if make-up tank requires refill or a system fault recognized. Once low oil tank or other fault is cleared, the system operates in faster mode to compensate for shut-down time Supporting Detail Maintenance free system to engine overhaul – when control valve is usually replaced System will shut down, send an alert to the cab and return engine to standard lube filtration mode if makeup tank level is too low Oil sample must be taken (i.e. from engine oil rifle) every 250 hours and can be sent to Fleetguard for analysis Oil analysis must include (total base number) & soot measurements Burn-only system not available on hhp engines 12/8/2017 Cummins Confidential
22 Level of contaminationExtended Service: Centinel™ Oil Management Achieves lube oil stabilization within safe zone condition Proven to reduce wear in critical areas such as the engine overhead by limiting soot accumulation & minimizing oil thickening Typical oil change intervals Centinel oil replacement Level of contamination Danger Zone Caution Zone Safe Zone 1X 2X 3X 4X Message: Diagram shows how Centinel stabilizes oil quality better than with typical oil change intervals Improves engine lubrication & wear protection by maintaining lube oil TBN (Total Base Number) and reduced soot loading – both key indicators oil quality Additional Detail: Soot is a main contributor of wear in sliding areas such as overheads – as soot increases so does wear Results of an M11 test with high quality CH-4 lubricant show relative overhead wear at 80% lower using Centinel compared to standard operation (over 300 hours) – test is actually used by API to classify oil Not available for QSK23 12/8/2017 Cummins Confidential
23 VRHUNSKI PROIZVODI ZAHTEVAJU VRHUNSKI SERVIS I ODRŽAVANJEZaključak Motor održavati prema Cummins uputstvima Koristiti ®iginalne Cummins rezervne delove Koristiti preporučeno ulje i Fleetguard® filtere Koristiti preporučeno rashladno sredstvo Koristiti pogonsko gorivo zahtevanog kvaliteta VRHUNSKI PROIZVODI ZAHTEVAJU VRHUNSKI SERVIS I ODRŽAVANJE 12/8/2017 Cummins Confidential
24 Pitanja? 12/8/2017 Cummins Confidential