Reunión DFSE

HHP, Mineria,
MRC, Partes

Carlos Rosales, Deyvis Tasayco

16/02/2022
 Agenda

 Actualización Procedimientos de Servicio

Actualización Boletines, TSBs
• Boletin3666253 Eliminator Filter, del 10/02/22
• TSB 220018 New Eliminator Oil Filter assembly, del 10/02/22
• TSB 220022 ECM Will not communicate or will not accept ECM Calibration Code, 07/02/22
• TSB 220016 Leaking coolant from trurbocharger coolant retun line, 4/02/22

Top ten Enero 2022 HHP DCP

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Agenda
 Actualización PITS QSK60/78

• KE850-37603 Cylinder Head Gasket/ Coolant Grommet Degradation

with No Compression Seal Leak.
• OB823-36726 Camshaft Thrust Bearing Capscrews Backing Out (Issue
under investigation)
• SBAR-8WLD2X Cylinder Block Head Deck at 8RB - Crack
• Escalamiento 924 QSK78 CM2350 Crankcase pressure sensor PN
4954405 failure

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Procedimiento Actualizados
QSOL
Motores Cummins HHP

Mining Market
2022
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Procedimientos actualizados QSK45/60 HPI – QSOL

56-016-004 - Flexplate

• Procedimientos actualizados tanto en el idioma castellano e Ingles.

• Ultima Modificación: 01-DIC.-2021 – QSOL
• Procedimiento añadido a manual.

56-013-081 - Alternator Guard

• Procedimientos actualizados tanto en el idioma castellano e Ingles.

• Ultima Modificación: 01-DIC.-2021 – QSOL
• Procedimiento añadido a manual.

56-006-109 Fuel Leak Check

• Procedimientos actualizados tanto en el idioma castellano e Ingles.

• Ultima Modificación: 08-DIC.-2021 – QSOL
• Procedimiento añadido a manual. 5
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Procedimientos actualizados QSK78 HPI – QSOL
50-010-084 Intercooler Element

•Procedimientos actualizados tanto en el idioma castellano e Ingles. Ultima Modificación: 01-DIC.-2021 –

QSOL
• Se agregaron instrucciones para inspeccionar visualmente el elemento del intercooler en
busca de signos de grietas. Se agregó un gráfico que representa esta instrucción.

50-007-067 Eliminator™ Filter

•Procedimientos actualizados tanto en el idioma castellano e Ingles. Ultima Modificación: 01-DIC.-2021 –

QSOL
• Se agregó la lista Seleccionar herramientas de servicio, Información general y Pasos
preparatorios. Se agregó una referencia al procedimiento 007-066.

50- 006-013 Fuel Drain Lines

• Procedimientos actualizados tanto en el idioma castellano e Ingles. Ultima Modificación: 01-DIC.-2021 –

QSOL
• Procedimiento actualizado para manifold de combustible de gran capacidad

50-007-035 Lubricating Oil Suction Tube (Block-Mounted)

• Procedimientos actualizados tanto en el idioma castellano e Ingles. Ultima Modificación: 01-DIC.-2021 –

QSOL
• Información actualizada para los tubos de succión de aceite lubricante estándar y largos en
el procedimiento. 6
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Procedimientos actualizados QSK78 MCRS – QSOL

591-001-058 Cylinder Block Counterbore

• Procedimientos actualizados tanto en el idioma castellano e Ingles.

• Ultima Modificación: 01-DIC.-2021 – QSOL
• Se actualizo Tabla de especificaciones de Espesor del Shim,
Especificaciones de Sleeve para camisa del cilindro. Se corrigieron
los valores enumerados en Dimensiones del alojamiento del sleeve
para la reparación estándar y de sobremedida.

591-007-035 Lubricating Oil Suction Tube (Block-Mounted)

• Procedimientos actualizados tanto en el idioma castellano e Ingles.

• Ultima Modificación: 01-DIC.-2021 – QSOL
• Información actualizada para los tubos de succión de aceite lubricante
estándar y largos en el procedimiento.

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QSK78 MCRS Cylinder
Head Gasket Leak –
Thermal Damage to
Grommet
PITS #KE850-37603

Cummins Confidential
QSK78 MCRS Cylinder Head Gasket Leak – Thermal Damage
to Grommet
 Failure Mode
• Customer observes coolant leak originating from under the engine’s cylinder head. Upon further investigation it is
discovered that the cylinder head gaskets have been damaged; specifically thermal damage/ degradation at two
coolant grommet locations.

 Failure Mechanism – Understood

• Current grommet material HNBR is sustainable up to 132°C; however, from prior engine test data and
FEA analysis there are evidences which shows the temperature at gasket grommet rises to ~161°C. This aligns with
the field return parts analysis.

 Field Countermeasure
• Fix as fail.

 Root Cause and Preventative Action

• Coolant grommet material does not have the required higher temperature sustainability. Improved grommet material
being introduced.

 Corrective Action
• Production and Service: TBD.

Cummins Confidential 9
QSK78 CM500 Camshaft
Thrust Bearing
Capscrews Backing Out
PITS: OB823-36726

Cummins Confidential
QSK78 CM500 Camshaft Thrust Bearing Capscrews Backing Out

 Failure Mode
• Customers notice unusual loud noise; engine shuts down suddenly. Troubleshooting reveals FC222 related to the
Electronic Chip Detectors (ECD). Further inspections of both ECDs reveal metallic particles. The left bank Camshaft thrust
bearing capscrews are backed out and have fallen into the gear train.

 Failure Mechanism – Investigating

• Clamp load too low at assembly
• Clamp load too low
• Slip to high within the bolted joint
• Camshaft thrust bearing bolts loosening at left bank of engine in construction applications

 Field Countermeasure
• Use of old thrust bearing PN 5376260 (3082437)

 Root Cause and Preventative Action

• TBD

 Corrective Action
• Production: TBD
• Service: TBD

Cummins Confidential 11
Rocky Mountain QSK60 Cylinder Bolt Hole Crack Repair

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ESN 33174627
Crack Discovered
ESN 33174066

Wall thickness .308 in

Bolt hole depth 3.488
~25,000 hours

ESN 33174627

~25,000 hours
Wall thickness .305 in
Bolt hole depth 3.487

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Crack Drilled and Inserts
Installed

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Post Insert

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Thread Insert

In this picture-Cummins vs. One supplied by Lock in Stitch

Cummins
Service Part

One concern is the additional depth required to install this insert flush with
head deck (*Cummins insert must be installed below the head deck or there is
not adequate head bolt engagement depth)
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QSK60/78/95 MCRS
Erratic crankcase pressure
reading and trending
Incorrect CCPS installation on
Q78 / Q95
Escalation #924

Armin Henrich – TTM Latin America ABO

24th November 2021
Q60/78/Q95 MCRS crankcase pressure erratic reading
Model/Application Failure Hrs. Range :
Issue Reported from
IPS SCORE - 120
Segment: Fail Count :
QSK78CM2350 /
Mining 10 ( 13 ) From : 1 - 1461 2021 YTD RPH ( TSR ) - 14.9
QSK95CM2350

Issue description : Crankcase pressure sensor ( PN 4954405 ) shows erratic reading / trending causing FC without issue

List of reported TSR’s 4 sensors to be returned to the supplier Trafag in Switzerland, 2 on route via SSC
Investigation results pending
5th sensor available in Chile in case of need

As per CES 14609 as well as supplier specification sensors require a vertical installation.
QSK78CM2350 and QSK95CM2350 does have a horizontal installation, see slides 9 & 10

Unknown at this stage if the direction of installation has a direct impact on the reading,
but it is outside of engineering standard and re-design is highly recommended.
Alternative solution could be the addition of an 90 degree elbow where space permits and cable length is not
compromised, otherwise a different location needs to be specified, which may require a cable extension.

In comparison other HHP product is installed vertically, see slides 12, 13, 14 & 15

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TSR Summary

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New sensor installed

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 Findings so far :
1.) initial returns to Trafag during Infant care : NTF
2.) Sensor found painted on critical location ( membrane )
3.) Installation directions are not met, neither supplier nor CES
standard
4.) else, pending feedback from Trafag from sensors returned
( 2 x QSK60, 2 x QSK78 )

Sensor condition QSK78 MCRS QSK95 MCRS

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 Sensor
PN 4954405
Supplier
Trafag

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Sensor PN 4954405
Supplier Trafag

As Trafag requires “ vertical “, is

this meant to be electrical
connector on top or bottom,
or does it not matter ?

- Specification: Vertical (plug

upwards 12 o'clock pos) ±30° this
is also how we calibrate

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Excerpt from CES 14609

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QSK78 CM2350 – installed in Breather
box

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 QSK95 CM2350
Hand hole
Cover #5 LB
CCPS #1
Real crankcase pressure

QSK95 CM2350
CCPS #2
“Coalescer pressure“
Indicating a plugged
breather 28
 QSK38 CM2150
HHC located RB 1&2

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 QSK50 CM2150
Oil filler HHC located # ??

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 QSK60 CM2150
RB cylinder #1 head deck

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 QSK60 CM2350
RB cylinder #1 head deck

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QSK78 CM2350
Sprint project
solution / step 3

Exceeding angularity
- +/- 30 degrees ?

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 QSK78
CM2350
proposed
location,
HHC requires
modification
to adopt
elbow
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Q78MCRS HHC
installation port details
requires alternative elbow
or machining of HHC

Elbow PN
4967227(8
)

HHC port

Sensor
port
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 QSK95 CM2350
proposed
solution using
elbow PN 4967227(8)
Thread port in HHC does
match

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Q95 HHC installation
port details

Elbow PN
4967227(8
)

HHC port

Sensor
port
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 QSK95 en patio de armado Antamina
 Series 37285641 y 37285703

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Q and A

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