The document discusses the installation of a Cummins ISX15 diesel engine into a Volvo VNL 780 heavy duty truck. It begins with background on Cummins and describes the objectives of exploring proper installation methods and ensuring smooth engine functionality for the client. It then discusses selecting the ISX15 engine due to its fuel efficiency, reliability, and performance ratings being well-suited for the truck. The summary describes several key factors for properly installing the engine, including the mounting system, drivetrain, cooling and fuel systems, electrical wiring, and documentation of testing.
Cummins Power Generation is a world leader in the design and manufacture of power generation equipment, including PowerCommand standby and prime power systems. We also provide single–source warranty, planned maintenance, and round–the–clock emergency service 24 hours a day, seven days a week including back–up power rental through our network of distributors.
Valeo presents its alternative solution to replace the Dual-Mass Flywheel (DMF) technology: the clutch KIT4P conversion kit.
In this valeoscope product focus, you will discover from a technical perspective:
• the genesis of this solution
• the components
• the design
• the main advantages
• specific technical support
• detailed FAQ
Learn about Valeo KIT4P technology & benefits: https://youtu.be/4lwZ0ocAzfc
Discover our KIT4P fitting guide movie: https://youtu.be/mPRiVierHtc
Today’s modern engines produce higher torques and can be driven at low engine speeds. The resulting higher maximum engine torque to be transmitted leads to increased vibration and noise. One of the key reasons why diesel cars and light commercial vehicles
have become much quieter over recent years and less prone to rattling is the development of the Dual Mass Flywheel (D.M.F.) technology.
In order to meet consumer needs, Valeo introduced in 2002 the Clutch KIT4P, manufactured under Valeo’s highest quality standards, an efficient and reliable alternative solution ensuring full customer satisfaction. Efficient because Valeo’s expertise in research and development allows the reduction of clutch noise and vibrations, along with enhanced driver comfort through better gear changes, giving consumers a smoother and comfortable ride. Reliable because Valeo clutches are able to perform in the most hostile operating environments. Valeo’s Aftermarket customers benefit from this Original Equipment expertise, rigor and quality.
It is important to remember that Valeo is an increasingly important O.E. Dual Mass Flywheel supplier for several car makers. Valeo’s powertrain technology roadmap clearly identifies D.M.F. as a future solution for different powertrain structures. It is important to note that within technological constraints, both D.M.F. and rigid flywheel solutions are possible according to the car maker’s choice.
• Find Valeo clutch offer on spare parts on http://www.valeoservice.com
Discover other valeoscope brochures:
• Dual-Mass flywheel technology: http://www.slideshare.net/ValeoService/valeo-transmission-systems-dualmass-flywheel-valeoscope-product-focus-998120
• Seft-Adjusting Technology & High-Efficiency Clutches: http://www.slideshare.net/ValeoService/valeo-transmission-systems-clutch-sathec-valeoscope-product-focus-998121
• Clutch hydraulics CSC, CMC & CRC: http://slideshare.net/ValeoService/valeo-transmission-systems-clutch-hydraulics-valeoscope-product-focus-998123
• Air Conditioning: http://www.slideshare.net/ValeoService/valeo-air-conditioning-valeoscope-technical-brochure-ac-handbook-part-1-998321
• Lighting Systems: http://www.slideshare.net/ValeoService/valeo-lighting-systems-from-light-to-advanced-vision-technologies-valeoscope-technical-handbook-998542
• Truck brake pad diag & fit: http://www.slideshare.net/ValeoService/truck-brake-pad-fault-assessment-valeoscope-diagfit-brochure-957100
Valeo, automotive technology, naturally.
Cummins Power Generation is a world leader in the design and manufacture of power generation equipment, including PowerCommand standby and prime power systems. We also provide single–source warranty, planned maintenance, and round–the–clock emergency service 24 hours a day, seven days a week including back–up power rental through our network of distributors.
Valeo presents its alternative solution to replace the Dual-Mass Flywheel (DMF) technology: the clutch KIT4P conversion kit.
In this valeoscope product focus, you will discover from a technical perspective:
• the genesis of this solution
• the components
• the design
• the main advantages
• specific technical support
• detailed FAQ
Learn about Valeo KIT4P technology & benefits: https://youtu.be/4lwZ0ocAzfc
Discover our KIT4P fitting guide movie: https://youtu.be/mPRiVierHtc
Today’s modern engines produce higher torques and can be driven at low engine speeds. The resulting higher maximum engine torque to be transmitted leads to increased vibration and noise. One of the key reasons why diesel cars and light commercial vehicles
have become much quieter over recent years and less prone to rattling is the development of the Dual Mass Flywheel (D.M.F.) technology.
In order to meet consumer needs, Valeo introduced in 2002 the Clutch KIT4P, manufactured under Valeo’s highest quality standards, an efficient and reliable alternative solution ensuring full customer satisfaction. Efficient because Valeo’s expertise in research and development allows the reduction of clutch noise and vibrations, along with enhanced driver comfort through better gear changes, giving consumers a smoother and comfortable ride. Reliable because Valeo clutches are able to perform in the most hostile operating environments. Valeo’s Aftermarket customers benefit from this Original Equipment expertise, rigor and quality.
It is important to remember that Valeo is an increasingly important O.E. Dual Mass Flywheel supplier for several car makers. Valeo’s powertrain technology roadmap clearly identifies D.M.F. as a future solution for different powertrain structures. It is important to note that within technological constraints, both D.M.F. and rigid flywheel solutions are possible according to the car maker’s choice.
• Find Valeo clutch offer on spare parts on http://www.valeoservice.com
Discover other valeoscope brochures:
• Dual-Mass flywheel technology: http://www.slideshare.net/ValeoService/valeo-transmission-systems-dualmass-flywheel-valeoscope-product-focus-998120
• Seft-Adjusting Technology & High-Efficiency Clutches: http://www.slideshare.net/ValeoService/valeo-transmission-systems-clutch-sathec-valeoscope-product-focus-998121
• Clutch hydraulics CSC, CMC & CRC: http://slideshare.net/ValeoService/valeo-transmission-systems-clutch-hydraulics-valeoscope-product-focus-998123
• Air Conditioning: http://www.slideshare.net/ValeoService/valeo-air-conditioning-valeoscope-technical-brochure-ac-handbook-part-1-998321
• Lighting Systems: http://www.slideshare.net/ValeoService/valeo-lighting-systems-from-light-to-advanced-vision-technologies-valeoscope-technical-handbook-998542
• Truck brake pad diag & fit: http://www.slideshare.net/ValeoService/truck-brake-pad-fault-assessment-valeoscope-diagfit-brochure-957100
Valeo, automotive technology, naturally.
A Report on 2 week "In-Plant Training" done in FACT Ltd,Udyogmandal Rajesh Gangireddy
This is a 18- page Report on In-plant training done in "The Fertilizers and Chemicals Travancore Ltd",Udyogmandal ,Ernakulam,kerala. I went through a 2 week in-plant training with the Instrumentation Department .
The report consists of information regarding various instruments,sensors and functioning of various chemicals plants in both UD and PD sections. It also covers the Distributive Control Systems used in the plants.
PS: Please take this doc as a sample/example and dont copy paste the same matter as a whole .
BEV ( Battery Operated Electric Vehicles) PPTPranav Mistry
Presentation done on subject of BEV ( Battery Operated Electrical Vehicles) at ARAI ( Automobile Research Association Of India ,Pune) on 4 Th December .2019
A Report on 2 week "In-Plant Training" done in FACT Ltd,Udyogmandal Rajesh Gangireddy
This is a 18- page Report on In-plant training done in "The Fertilizers and Chemicals Travancore Ltd",Udyogmandal ,Ernakulam,kerala. I went through a 2 week in-plant training with the Instrumentation Department .
The report consists of information regarding various instruments,sensors and functioning of various chemicals plants in both UD and PD sections. It also covers the Distributive Control Systems used in the plants.
PS: Please take this doc as a sample/example and dont copy paste the same matter as a whole .
BEV ( Battery Operated Electric Vehicles) PPTPranav Mistry
Presentation done on subject of BEV ( Battery Operated Electrical Vehicles) at ARAI ( Automobile Research Association Of India ,Pune) on 4 Th December .2019
Designing paper straw bridge (lightest at ARU - 2.1g). Designing in inventor, Finite Element Modelling and Analysis - ANSYS , Stiffness matrix and constructing a final product.
Finite element analysis of engine mounting bracket by considering pretension ...eSAT Journals
Abstract Bracket is one of the important components of an engine mount assembly, heavy performance truck has their engine supported by bracket and this engine mounting brackets assembly is used in chassis front frame which has been designed as a framework to support engine along with transmission member. The main function of the engine mount bracket is to properly balance the engine and transmission on the vehicle chassis, engine mount is an important part of the vehicle to reduce the vibration and noise, by which smooth ride of the vehicle can be achieved. Vibration and strength of engine bracket has been continuously a concern which may lead to structural failure if the resulting vibration and stresses are severe and excessive. The present work focuses on the FEA analysis of engine mount bracket for three materials by using meshing and analysis software which are HYPERMESH and ABACUS, the materials used are cast iron, wrought iron and mild steel, modal analysis and static analysis carried out by which maximum von-misses stress and natural frequency are computed. The main objective is to select the best material from the obtained result under prescribed conditions. Key Words: Engine mount bracket, Vehicle chassis, Modal & Static analysis, pretension load, & Service load.
A car engine mount holds the engine in certain position with less noise and vibration, and stabilizes the engine in the engine bay. It may be a small part of your vehicle, but its importance is very high. Once it wears out or malfunctions means, several problems will arise which will turn your journey unsafe from the start to end. Go through the slides to know what these problems are and how it affects the engine.
The Baja SAE Series is an annual competition organized by the Society of Automotive Engineers and has the objective to encourage undergraduate students to design, manufacture and test and All-Terrain vehicle prototype. There are almost 100 participants and it was a good opportunity to put in practice the knowledge acquired in class. In 2010 we achieved the 1st place in design, it has been the highest achievement in the whole team’s history, and it was of course a consequence of our hard work. As Powertrain head I led several tests in order to characterize the dynamical behavior of the vehicle, these developments settles a good base for future generations.
The Company manufactures and supplies Engine & Chassis Dynamometerswith all Accessories and undertakes turnkey projects for the complete set-up of Engine Test Facility which includes Acoustic Enclosures, Water Circulation System with Cooling Tower, Engine Flue Gas Extraction System, Air Handling System and fully automated Engine Test System with match-plates, engine mounting pallets/trolleys with auto docking and Computer controlled Engine Performance Monitor.
The Company provides Engine Test Facility for carrying out endurance testing of engines. Two numbers of engine test beds with EDA&CSS have been erected in a separate premises of about 4000 sq. ft. area in the factory premises.
Here are the presentations from Productiv's 4th Meet the Engineer event, supported by the Automotive Council and the UK's Advanced Propulsion Centre.
The event included 21 'pecha kucha' style technology pitches from SME Technology Developers representing a range of early stage through to production ready Automotive innovations.
The event was host to an audience of OEMs and Tier 1s, including Jaguar Land Rover, Ford, Tevva Motors, Alexander Dennis, Optare, Caterpillar, Schaefller and many more.
Thank you to all the Technology Developers for delivering high quality and engaging pitches. Thank you to the audience for listening and engaging with the presenters in the networking and exhibition sessions.
If you'd like to learn more about the event, connect with one of the speakers, or talk about your technology industrialisation and proving production challenges then please get in touch with us.
The Proving Factory, Gielgud Way, Coventry CV2 2SA
enquiries@productivgroup.co.uk | +442476 309 291
www.productivgroup.co.uk
Quality defects in TMT Bars, Possible causes and Potential Solutions.PrashantGoswami42
Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
Event Management System Vb Net Project Report.pdfKamal Acharya
In present era, the scopes of information technology growing with a very fast .We do not see any are untouched from this industry. The scope of information technology has become wider includes: Business and industry. Household Business, Communication, Education, Entertainment, Science, Medicine, Engineering, Distance Learning, Weather Forecasting. Carrier Searching and so on.
My project named “Event Management System” is software that store and maintained all events coordinated in college. It also helpful to print related reports. My project will help to record the events coordinated by faculties with their Name, Event subject, date & details in an efficient & effective ways.
In my system we have to make a system by which a user can record all events coordinated by a particular faculty. In our proposed system some more featured are added which differs it from the existing system such as security.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
2. Cummins Preface
• Cummins Inc. is the designer, manufacturer, distributor of engines, filtration and power generation products.
Cummins is Fortune 500 company.
• Dates back to the 1919, Cummins was founded by Clessie Cummins.
• The biggest manufacturer for the diesel engines for the
trucking company by 1937.
• Based with its headquarters at Columbia, Indiana, U.S. Cummins Inc.
is a massive international organization with operating overseas in more
than 190 countries along its subsidiaries and strong network of 6000
dealers worldwide resulting in the net revenue of income nearly $17 billion.
• Global clients include: Komatsu, Volvo, DAF, MAN, IVECO, Tata.
You name it !
• Much of its major business segments involve
– 1. Engine Power Generation
– 2. Component Business and
Distribution.
3. Presentation
Objective !
• Finding a Cummins designed diesel engine
• To pick an on highway application of the Cummins selected diesel
engine.
• To explore the proper installation methods for the engine onto the
vehicle using customer engineering prospects.
• Relatively, consideration for the smooth functionality of the engine for
the client.
• To conclude the whole research of the customer engineering application
for the engine to the client in 8 minutes.
4. Customer Engineering
• The part of the engineering group which is responsible for providing the solutions and the services to their client / customer who
has signed a contract.
• Customer
Engineering Group
INSTALLATION TEST & AFTER
SALES SERVICE
Cylinder head torque
Drive pulley (harmonic
balancer/dampener)
Intake manifold must be cleaned
Rocker arm assemblies
Fuel system
Radiator/cooling system
Heat riser or exhaust thermostat
control
Oil system
Thrust bearing
Preventing the causes of thrust
bearing failure is the responsibility of
the installer
Flywheel
Accessories
Rubber goods
ENGINE ANALYSIS
Oil Pressure.
Define the Customer and Vessel
Requirements
Installation profile
major features and options
required by the customer
Select engine(s)
Finalize machinery layout.
Document the design and layout
issues
Communication with builder and
designer
Initiate preliminary engine
option list for engine shop order.
Design review with the
customer/ Client
Confirm Design Compliance
Conduct the Trial test
Document the Installation
Design Specification
Prototype design
Commissioning, Auditing, Statistics &
Process Quality & Client Delivery /
Shipping & Service
Commissionaire the final model with the
internal audits and external audits (clients or
the customer)
Keep hold of the manufacturing unit
using 6sigma strategies and use of
Statistical Process Quality.
The finished engines with the proper
Documentation and installation to the
client.
5. Selection
Phase
• Concept phase is before the selection and installation of the engine to the client’s vehicle.
• Comparison of the requirements to the range of the engines
& their features.
• Use of Pugh Chart for features.
• Referring PDS for exact engine selection.
• Going through Conceptual phase and evaluating.
• Value analysis.
• Referring Gantt Chart for the installation project.
• Reviewing and finalizing the engine.
(Figure right: Shows the steps from customer engineering selection of engine to selling and installing it to the client.)
6. On Highway Application
Engine requirements for Volvo VNL 780 – Heavy Duty Truck
• Volvo VNL 780American is an American highway heavy duty truck.
• Use of Cummins heavy duty diesel engines
to meet its need.
• Designed for demanding professional drivers.
• Optimized fuel efficiency.
(Figure Right: Volvo VNL 780, advertised, Volvo Website)
• Responsive yet fuel efficient.
• Strong braking systems
• Harsh environment engine operations. Long run.
• Ease of start and long term service free engines.
• Maintaining the brand identity.
(Figure on right below: Showing the calibration and dashboard of
Volvo VNL Series 780 )
7. Diesel Engine Preface
How a diesel engine works ?
• Turn key is used for ignition.
• Fuel pumps deliver the fuel from the fuel tank to the engine.
• The fuel injection pump pressurizes fuel into a delivery tube.
• The fuel, air, and “fire” meet in the cylinders.
• Combustion spreads from the smaller amount of fuel that’s
placed under pressure in the precombustion chamber to the
fuel and air in the combustion chamber itself.
Figure 1
Figure 2
Figure 3
Figure 4
8. Cummins Diesel Engines
Ranges for On Highway heavy duty applications
• Wide range of the diesel engines from Cummins for oh highway heavy duty applications.
ISX15 for Heavy-Duty Truck (2013) SmartAdvantage™ Powertrain for HD Truck (2013) ISX12 for Heavy-Duty Truck (2013)
ISX12 G ISG11/12 ISX15 for Heavy-Duty Truck (EPA 2010) ISX for Heavy-Duty Truck (EPA 07)
and counting on ISX & ISG series.
9. Why Cummins ISX15 (2013) ?
• Better Fuel Economy.
Certified to meet 2014 Environmental Protection Agency (EPA). The Cummins ISX15 is the industry leader in fuel economy with 2% better fuel economy
• Better Reliability and Durability.
Total integration of everything from the air handling to the exhaust after treatment allows us to optimize every function to a degree no other engine
manufacturer can match
• Better Performance.
Ratings range from 400-600 hp (298-447 kW) with up to 2050 lb-ft (2779 N•m) of peak torque
• Better Coverage For Better Confidence.
Ratings range from 400-600 hp (298-447 kW) with up to 2050 lb-ft (2779 N•m) of peak torque
• Engine Specifications (Cummins Website, accessed online)
Advertised Horsepower 400-600 hp 298-447 kW
Peak Torque 1450-2050 lb-ft 1966-2779 Nm
Governed Speed 1800-2000 rpm
Clutch Engagement Torque 1000 lb-ft 1356 Nm
Number of Cylinders 6
System Weight 3204 lb 1453 kg
Engine (Dry) 2964 lb 1344 kg
Aftertreatment System* 240 lb 109 kg
10. ISX15 – Volvo VNL 780
Steps Installation Quality Assurance Process
• Volvo as client vehicle requirements.
• Reason for selecting ISX15 (2013) & Rating
• Heavy duty
• Fuel efficiency
• Lesser NOx
• Drive Cycles; Duty Cycles
• Comparison with other series of engine and determining the factors.
• Packaging the engine into the vehicle
• Defining critical components
• Defining mounting scheme
• Major vehicle connection point zones
• Fuel Water Air Exhaust.
• Documentation of design and layout issues
•
• Engine Sub-Systems design
• Construct Engine Order
• Design Compliance with the vehicle confirmation
• Test trail
• Installation, Service and Documentation
11. Installation Factors
For ISX15 (2013) On Volvo VNL 780
• Engine mounting system
• Drivetrain
• Engine driven accessories
• Exhaust system
• Cooling system
• Air intake system
• Fuel system
• Electrical system
• Starting system
• Electronic control system
• Controls, gauges, and alarms
• Lubrication system
• Documentation
• Test trail/ test run
For a successful installation of the engine on to the Volvo VNL 780 the above factors play an
important role apart from certain considerations mentioned at the end of presentation.
12. Factor 1 -
Engine mounting system
• The mounting system must be constructed so the supporting
structure deflections do not overstress the engine castings.
(Figure right shows typical Engine mounting bed )
• The engine must have sufficient clearance to prevent damage
from physical contact between the engine components and adjoining vessel structures.
• Vibration Isolators must be installed so their horizontal centreline is parallel to the
crankshaft centreline and their vertical centreline is parallel to both the engine vertical
centreline and to the rear face of the block. (Vibration Isolators llal to the horizontal central line , figure on right)
• Vibration isolators must be free to deflect and not be fully compressed under static load.
• The engine must be installed so the static bending moment at the point where the flywheel housing is
attached to the engine does not exceed the maximum value on the General Engine Data Sheet.
• Static installation angle should not exceed the General
Engine Data sheet value.
(Figure left to Right : engine installation
angles; shows a maximum installation
angle)
13. Factor 2-
Drivetrain
• The angular alignment of the torsional coupling must be within the coupling and gear Cummins's
specified limits.
• The engine crankshaft end clearance must be within specifications after
installation of the gear or any accessories that imposes an axial load on the
crankshaft.
(Figure in right (top) – Crankshaft; right – Crankshaft clearance end)
• The calculated axial load on the crankshaft must not exceed the
values specified on the General Engine Data Sheet.
• A Torsional Vibration Analysis must be performed on all new engine installations with remote mounted
reduction gears.
• The results from a Torsional Vibration Analysis (TVA), performed, must be within acceptable limits of
General Engine Data Sheet.
• Proper test of the crankcase pressure before installation.
14. Factor 3-
Engine Driven Accessories
• The total power taken off the front of the crankshaft must not exceed the value listed in the Engine
Performance Curve and Data Sheet.
Torque (N•m) = HP x 7120 / n
Torque (lb-ft.) = HP x 5252 / n
where HP (Horse Power = (Flow rate (L/m) x Pressure (kPa) x Design Service Factor) / n x Efficiency
• Brackets used to mount accessories must provide adequate strength to hold the static and dynamic load of
the accessory and avoid resonant vibration within the normal
operating range of the engine.
• All exposed rotating components must have a protective guard.
• The calculated radial load on the crankshaft must not exceed the
values specified in the Engine General Data Sheet.
(Figure in right shows the values of the radial load in relation to angle of the engine.)
• Belt driven accessories must be mounted on the engine when
a flexible mounting system is used.
• Belt driven equipment must be held in alignment to a tolerance of
1 mm in 200mm (1/16 inch in 12 inches)(Figure in right)
15. Factor 4 -
Exhaust Systems
• The exhaust back pressure must not exceed the value specified in the General Engine Data Sheet.
• The exhaust system components must not impose excessive load or bending moment on the
exhaust manifold or turbocharger due to weight, inertia, relative motion of the components, or
dimensional change due to thermal growth.
• The exhaust system must prevent the entrance of water into the engine.
• Exhaust system surfaces that persons or gear may come in contact with must not exceed 93 C
(200 F).
• Dispersion of Exhaust gases.
• Piping must not be installed near combustible
material.
(figure in the right shows the first generation of
Cummins ISX series exhaust manifolds.)
16. Factor 5 –
Cooling Systems
• All joints, components, piping, and connections must be leak free.
• The engine must have a closed cooling system that will maintain the system pressure.
• Remote mounted expansion tanks must be mounted with the low
coolant alarm level above the highest point in the cooling system.
• The coolant level sensor must be installed in the expansion tank.
• All cooling system accessories must have a minimum pressure rating.
(Figure right: Use of Cummins Coolant)
• Heat Exchanger needs to be cooled.
• The system must vent during initial fill to allow filling of the total
cooling system volume to 95 percent of its full capacity.
• The cooling system must remove entrained air at
engine start-up, and must continuously remove air
that enters the cooling system during normal operation.
(Figure right: Heat Exchanger, combined manifold analysis)
Type
A B C D E F G H
End Cover Front Tubestack Body tube Filler Cap
Filler Neck
Assembly
Body Large hose clip Small Hose Clip
17. Factor 6 –
Air Intake System
• The air intake system restriction must not exceed the value specified in the Engine GeneralData Sheet.
• All ducts, components, and connections must be free from leaks.
(Figure below: Air filter in diesel engine; Figure right below: Cummins ISX Air filter )
• All ducts, components, and connections must be capable of operating continuously in a maximum
ambient temperature of 92° C (200° F).
• The air cleaner must have an initial efficiency of 99.5%, an overall efficiency of 99.9%, and a dirt holding
capacity as per test specifications
18. Factor 7 –
Fuel Systems
• The fuel used in Cummins engines must meet the requirements
specified by Cummins service bulletin.
• The fuel supply line must be routed to prevent pressure
surges and must be free from vertical loops.
• All joints, components, and connections must be leak free.
• The fuel tank must be equipped with a vent; the vent must
be designed and installed to prevent the entry of water
and/or dirt.
(Figure right: showing the fuel System in standard diesel engine)
• Flexible lines must be installed between the engine and vessel
plumbing to allow for relative motion.
• All hoses must be adequately protected from chafing and clipped
to appropriate pieces on the engine/vessel structure such that there
is not overhanging load on connections.
(Figure in right: Showing the Cummins Diesel engine filter)
19. Factor 8 –
Electrical System
• The battery bank cranking ampere rating must be greater than the value specified in the Engine General
Data Sheet.
• The battery bank reserve capacity must not be less than the value
specified in the Engine General Data Sheet.
(Figure right: Proper use of the metals for the batteries.)
• The voltage at the battery must exceed the minimum voltage
specified in the General Engine Data Sheet.
• Cummins supplied wiring harnesses must be installed without
modifications or splices.
• All ground connections to the engine must be to a common point.
• The wiring must use protective grommets at clamp points.
(Figure right: Proper cover of the wiring)
• All powered circuits must include wiring and overcurrent protection that complies with governing
standards of the intended application.
• Cummins provided alternators must be used.
20. Factor 9-
Starting System
• Starter(s) must be connected directly to the battery or to a common connection point (bus), which is
connected directly to the battery.
• A battery disconnect switch must be installed.
• The engine must achieve a minimum cranking speed
• The engine must be prevented from
starting when in gear.
(Figure Right: Use of ECM Cooling plates and connectors)
• The ECM determines the fuelling and timing
quantities within a given bank and commands the
corresponding fuel pulse widths from the actuators.
(Figure right: Showing the actuator flows)
21. Factor 10 –
Electronic Control System
• The ECM power cable must be a dedicated power supply to the ECM. No additional loads may be
connected to the ECM power cable.
• The ECM power cable must have proper overcurrent protection.
• The ECM power cable circuit resistance must not exceed 50 milli ohm
• The ECM positive and negative power cables must be connected to the engine battery so that the power
to the ECM will not be interrupted during operation.
• The data link diagnostic connector must be installed in a technician accessible location
(Figure Right: Showing the ECM and the cable length)
22. Factor 11 –
Controls, Gauges & Alarms
• Instrument panels and wiring must be installed according to Cummins installation instructions.
• There must be no additional electrical devices connected to the instrument panels.
• All audible and visual alarms must have test and acknowledge/reset capability
• Wiring harnesses and hoses must be secured to the vessel where the harness will not be subjected to
physical damage or high temperatures, and will not interfere with normal vessel operating activities.
• Mechanical fuel pump throttle lever must be against the idle stop when the hand lever(s) is in the idle
position and against the wide open stop when the hand lever(s) is in the fuel throttle position
(both forward and reverse).
(Figure right: Showing the mechanical throttle pump of a
cummins onan engine)
23. Factor 12 –
Lubrication
• The lubricating oil used in the engine must meet the specifications listed in the Operation and
maintenance manual.
• Unmarked oil dipsticks must be engraved (not stamped or notched) with the high and low levels when
the vessel is in the water and at its normal trim.
• The primary lubricating oil filter that is supplied by Cummins Inc. with every engine must be used.
• All joints, components, and connections must be leak free.
• Fittings and threaded connections must be free from teflon tape or wrap style thread sealants.
(Figure Below left to Right: oil pan immersion heater; engraving dipstick; Use of flexible hoses)
24. Other Installation
Considerations
• Corrosion prevention for engine (galvanizing, painting) (cummins website, online)
• Understanding vehicle setup rear axle ratio.
• Determining the vehicle setup tire revolutions per distance.
• OEM ambient air temperature sensor working.
• Crankcase ventilator heater enable.
• Engine braking and engine oil working properly with the hydraulics.
• Powertrain protection switched torque limit with
miles.
• Powertrain protection axle torque limit.
• Powertrain protection gear ratios.
(Figure right: Engine being painted before final installation)
25. Test Trial / Run
• Trial tests must be completed according to the procedures specified within this document for all new
engine installations and following major engine repairs.
• All readings requiring manual measurements must be recorded at three speeds: Full throttle, max
speed, and peak torque in rpm.
• Trial measurements must be above the minimum value and below the maximum value listed in the
Engine General Data Sheet and the Engine Performance Curves and Data Sheet.
(Figure right to left : Shows the tested and properly documented engines ready for the clients, at Darlington Engine plant, UK)
(The testing of the manufactured diesel engines)
26. Other Factors
After Sales Service & Marketing
• Non-Cummins Inc. supplied hoses and fittings connected to the engine or gear must comply with the
standards of Cummins ISX15.
• Promotion of the engine by providing a service operation for 5 years.
• Free service of the engine up to 3 years or 100,000 miles.
• Cummins Care.
• Ease of servicing ports and service station locations within reachable access.
• Proper documentation of the product’s test and service to Volvo.
• Cummins ISX15 EPA certification 2013. Greener technology solution with negligible amount of NOx. &
diesel particulate emissions. Complying the EU laws.
• Engine security features & anti theft control features.
27. References
• Cummins Engine Website: http://cumminsengines.com/isx15-heavy-duty-truck-
2013?#specifications [Accessed online. 16th April 2014]
• Cummins Inc. – History
• Cummins On highway Application. Website : http://cumminsengines.com/powerspec-isx-
vehicle-setup [Accessed online. 20th April 2014]
• Volvo heavy duty trucks. Website: http://www.volvotrucks.com/trucks/na/en-
us/products/vnl/vnl780/Pages/vnl780.aspx [Accessed online. 20th April 2014]
• Cummins diesel engine understanding. Website:
http://www.cumminspowersouth.com/CPSU/ [Accessed online 21st April 2014]