QSK78 G-Drive Mechanical Product

Customer
Engineering
Bulletin
Title: This CEB is for the following applications:
QSK78 G-Drive Mechanical Product
Information Automotive Industrial Marine
G-Drive
Date: 10 July 2019 Refer to CEB00044 for Safety Practices, CEB Number: 00092
Guidelines and Procedures
Engine models included: QSK78 (D773002GX03)
Owner: Jonathan Cox Approver: per Procedure GCE-AS-1 Page 1 of 24
This CEB supersedes CEB00092 dated July 6, 2016.
Introduction
This CEB introduces the QSK78 engine for use in G-Drive and Power Generation applications.
The QSK78 has been developed to provide a cost competitive, emissions compliant engine model up to 3,778 bhp
with 6 turbos and 4,060 bhp with 4 turbos (number of turbos is dependent on the selected rating). The QSK78 is
designed to meet present and future competitive pressures and worldwide emissions regulations.
Several advanced engine technologies are used to meet legislative and customer requirements regarding
emissions. These include: a high-pressure (HPI-PT) full-authority electronic fuel system, cast iron pistons, and
employing low temperature after-cooling (LTA) systems. Figure 1 shows the QSK78 G-Drive Engine.
Figure 1. QSK78 4-Turbo G-Drive Engine (left) and 6-Turbo G-Drive Engine (right)
Internal Use Only - For business use only by employees and authorized non-Cummins entities with a need to know basis per
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Revision 06, 10 July 2019 Page 1 of 24 © Copyright 2019 Cummins Inc.

QSK78 G-Drive Mechanical Product Information CEB 00092
Table of Contents
Introduction .................................................................................................................................................................1
Table of Contents .......................................................................................................................................................2
List of Tables ...........................................................................................................................................................3
List of Figures ..........................................................................................................................................................3
Fuel Rating .................................................................................................................................................................4
Base Engine Features ................................................................................................................................................4
16 Cylinder Configuration ...........................................................................................................................................4
Cylinder Block .........................................................................................................................................................4
Crankshaft/Dampers ...............................................................................................................................................5
Cylinder Head .........................................................................................................................................................5
Gear Housing/Geartrain ..........................................................................................................................................6
Fuel System ............................................................................................................................................................6
Fuel Cooling ............................................................................................................................................................7
Fuel Pump and Connections ...................................................................................................................................7
Fuel Filters ..............................................................................................................................................................7
Fuel Flow and Restriction .......................................................................................................................................8
Cooling System .......................................................................................................................................................9
Surge Tank and Filling ............................................................................................................................................9
Coolant Treatment and Filtration ............................................................................................................................9
Venting ................................................................................................................................................................. 11
Cooling System Connections ............................................................................................................................... 11
Lubrication System............................................................................................................................................... 12
Eliminator.......................................................................................................................................................... 12
Venturi Combination Spin-on Filters................................................................................................................. 12
Centinel™ Continuous Oil Replacement System............................................................................................. 13
Oil Pan .............................................................................................................................................................. 13
Oil Types .......................................................................................................................................................... 14
Air Handling and Exhaust System ....................................................................................................................... 14
Air Intake System ................................................................................................................................................. 14
Engine Mounting .................................................................................................................................................. 15
Breather ............................................................................................................................................................... 15
Electronic Control System .................................................................................................................................... 15
Starters ................................................................................................................................................................. 17
Flywheel Housing ................................................................................................................................................. 17
Accessory Drive ................................................................................................................................................... 18
Alternator .............................................................................................................................................................. 18
Fan Drive .............................................................................................................................................................. 19
Service Accessibility ................................................................................................................................................ 19
Definitions ............................................................................................................................................................ 21
Reference Documentation ................................................................................................................................... 21
Change Log ............................................................................................................................................................. 22
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List of Tables
Table 1. Engine Comparison ......................................................................................................................................4

Table 2. Approximate Engine Envelope .....................................................................................................................4
Table 3. Geartrain Information ....................................................................................................................................6
Table 4. Fuel System Values ......................................................................................................................................8
Table 5. Oil Services Options .................................................................................................................................. 14
Table 6: Service Accessibility – Components and Clearance Guidelines ............................................................... 19
Table 7: Acronym Definitions ................................................................................................................................... 21
Table 8: Reference Documentation ......................................................................................................................... 21
List of Figures
Figure 1. QSK78 4-Turbo G-Drive Engine (left) and 6-Turbo G-Drive Engine (right) ................................................1
Figure 2. QSK78 Cylinder Block .................................................................................................................................5
Figure 3. Damper for the QSK78 ................................................................................................................................5
Figure 4. Cylinder Head ..............................................................................................................................................6
Figure 5. Geartrain as viewed from the front of the engine. .......................................................................................6
Figure 6. Fuel Pump and Filter canisters being used in Parallel ................................................................................7
Figure 7. Fuel System Flow ........................................................................................................................................8
Figure 8: QSK78 Single Stage Cooling System Flow Diagram ............................................................................... 10
Figure 9. LTC Connection Definition ....................................................................................................................... 11
Figure 10. HTC Connection Definition ..................................................................................................................... 11
Figure 11: Cummins EliminatorTM Oil Flow Diagram ............................................................................................... 12
Figure 12. Centinel Flow Diagram ........................................................................................................................... 13
Figure 13. Double deep oil pan used on the QSK78 engine ................................................................................... 14
Figure 14: QSK78 Lifting Brackets .......................................................................................................................... 15
Figure 15. Cummins Breather for the QSK78 Engine ............................................................................................. 15
Figure 16. GCS Controls System ............................................................................................................................ 16
Figure 17. PGI Controls System .............................................................................................................................. 17
Figure 18: QSK78 Flywheel Housing ...................................................................................................................... 18
Figure 19: Difference between EE, PU, EH Selectable, and EH Dependent Options Graphic............................... 19
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Fuel Rating
Table 1 shows comparisons between the QSK78 4-Turbo and 6-Turbo engines with other Cummins and non-
Cummins engines. For the latest Fuel Ratings and altitude capability and for information about the QSK78L G-Drive
and Power Generation ratings visit the Global Customer Engineering (GCE) G-Drive QSK78 webpage.
Table 1. Engine Comparison
QSK78 4-Turbo [6-Turbo] QSK60 KTA50 DDC4000 CAT C175-16
No. Cylinders 18 [18] 16 16 16 16
Bore x Stroke (mm) 170 x 190 [170 x 190] 159 x 190 159 x 159 165 x 190 175 x 220
Displacement (L) 77.6 [77.6] 60.2 50.3 65.0 84.6
Mean Piston Speed @ 37.4 [37.4] 37.4 31.3 37.4 36.1
Rated (ft/sec)
Engine Weight-Dry (lb) 20,327 [20,238] 15,835 11,820 14,841 30,000 (est.)
Base Engine Features

Table 2 gives the QSK78 engine envelope and compares it to the KTA50 and QSK60 Cummins engines.
Table 2. Approximate Engine Envelope
18 Cylinder Configuration 16 Cylinder Configuration
QSK78 4-Turbo [6-Turbo] KTA50 QSK60
Height above Centerline of Crankshaft 1,233 mm [1,233 mm] 1,127 mm 1,354 mm
Overall Engine Height 2,031 mm [2,031 mm] 1,765 mm 2,140 mm
Overall Length from rear face of FW
3,062 mm [3,062 mm] 2,657 mm 2,780 mm
Hsg to front face of the crank pulley
Overall Width at widest point 1,591 mm [1,570 mm] 1,438 mm 1,794 mm
Engine Weight Dry 9,220 kg [9,180 kg] 5,360 kg 7,185 kg
(Standard pricing configuration) (20,327 lb) [(20,238 lb)] (11,820 lb) (15,835 lb)
Cylinder Block
The QSK78 cylinder block, shown in Figure 2 below, is a robust design that is made of a one-piece iron casting.
It has a durable design to absorb internal forces and to enable resilient mounting. The bore of the QSK78 is 170
mm, the stroke is 190 mm, and the angle between the two banks is 60 degrees. The engine uses pressed-in
removable cylinder liners that incorporate a top-stop liner design. The design incorporates special honing for oil
control and related piston ring wear. This design also provides improved top ring cooling, improved resistance to
liner cavitation, and improvements to cylinder head attachment joint due to lower bending stress.
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Figure 2. QSK78 Cylinder Block
Crankshaft/Dampers
The crankshaft is made of forged high tensile steel. The 520-mm diameter dual viscous dampers are mounted on
the front crankshaft nose. This dampens the crankshaft torsional vibration and reduces gear train wear. The
damper is shown in Figure 3.
Figure 3. Damper for the QSK78
Cylinder Head
The cylinder head, shown in Figure 4, is made of cast iron and features two intake valves and two exhaust valves
per cylinder. The head incorporates high efficiency coolant jackets for improved cooling of the thermally loaded
combustion deck.
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Figure 4. Cylinder Head
Gear Housing/Geartrain
The cast iron front gear housing encloses the heavy-duty front gear train, which has low gear loading and robust
fatigue strength. The QSK78 gear train differs from that of the QSK60 gear train, the major items including a split
crank gear, larger 6-bolt idler shaft, and larger gear teeth. Figure 5 and Table 3 show and give Geartrain
information.
Table 3. Geartrain Information
Item
Gear Description Rotation
Number
1 Crankshaft (rear) CW
2 Crankshaft (front) CW
8 7 3 Lube Pump Idler CCW
6 4 Lube Pump Drive CW
5 Accessory Comp Idler CCW
9 6 Cam Comp Idler CCW
12
1 7 Left Bank Cam CW
5
2 8 Right Bank Cam Idler CW
9 Right Bank Cam CCW
11 10
13 10 Water Pump Idler CCW
3 11 Water Pump CW
12 Fuel Pump Drive CW
4 13 LTA Pump Drive CW
Figure 5. Geartrain as viewed from the front of the engine.
Fuel System
The QSK78 uses the Cummins High Pressure Injection PT (HPI-PT) full-authority electronic fuel system for G-
Drive engines. The HPI-PT fuel system boasts reduced emissions, improved fuel economy and power. The HPI-
PT fuel system is managed by a G-Drive Governor Control System (GCS) controller, which is provided in a kit for
off engine mounting in the genset control panel. In addition to the GCS controller, the HPI-PT fuel system is also
managed by the Power Generation Interface (PGI) which includes an on engine CM2250.
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The HPI fuel injection is characterized as an open nozzle system that provides a “soft” start of injection, and thus
lower combustion noise. Injection timing is infinitely variable which allows optimization for emissions, fuel economy,
and operating environment.
The QSK78 fuel rail flow is fed to each bank from each end of the engine to help reduce start of injection (SOI)
variation. The fuel manifolds are located outside the air intake manifolds and have five drillings running the length
of the manifold. The top two drillings are for timing, the middle is the drain, and the bottom two are for the fueling
rail. The left bank fuel for the rail and timing is fed to the fuel manifold by tubes routed from the left bank fuel block
located behind the Electronic Control Valve Assembly (ECVA). The right bank fuel for the rail and timing is fed
across the block to the right bank fuel block located behind the Eliminator and then to the fuel manifold by tubes.
Fuel Cooling
All QSK78 engine applications are required to adhere to the 71 °C (160 °F) maximum fuel supply temperature
specification. Due to the increased fuel heat rejection, ∼45 kWm (2500 BTU/min), the use of a fuel cooler in the
fuel return line is required. See the rating data sheet for the specific fuel heat rejection requirement.
For further information refer to CEB00598 “Installation Requirements – Fuel Temperature”.
Fuel Pump and Connections
The QSK78 has an electronically controlled variable pressure gear pump designed to meet the performance
characteristics for the HPI-PT system. The fuel pump is located at the left bank towards the front of the engine.
The fuel inlet connection is a 2 in. -12 O-Ring face seal (ORFS) located at the rear of the double fuel filter
housing. The fuel drain connection is a 1 7/8 in. -12 37-degree flare located on the top left bank side of the gear
housing with the fitting orientation downward. The drain fitting has a built-in check valve to prevent reverse flow of
fuel into the engine.
Fuel Filters
The engine uses a double fuel filter housing system with six 10-micron spin-on fuel filters located on the left bank
of the engine. Service filters will be Cummins Filtration FS 1006. Figure 6 shows the fuel pump and filter canisters
and Figure 7 is the Fuel System flow diagram.
Fuel Inlet
Figure 6. Fuel Pump and Filter canisters being used in Parallel
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HPI-PT Fuel System Typical Flow Diagram
Figure 7. Fuel System Flow
1 - ECVA 7 - Timing Fuel 13 - Fuel Filters

2 - Timing Actuators 8 - Metering Fuel 14 - Fuel Pump (Compact Pump)
3 - FSOV 9 - Injector 15 - Fuel Pump Pressure Sensor
4 - Metering Actuator 10 - Injector 16 - Gear Pump
5 - Metering Press Sensor 11 - Drain Fuel 17 - Bleed Line
6 - Timing Press Sensor 12 - Fuel Tank 18 - Fuel Pump Actuator
Fuel Flow and Restriction
The QSK78 uses the HPI-PT fuel system. The maximum fuel return flows will be at rated speed, with no load.
Care must be taken to not exceed the maximum inlet and return restrictions. The fuel lines must be sized for the
flows given in Table 4:
Table 4. Fuel System Values

Supply Return
Fuel Flow 2,225 L/hr (590 gph) 2,100 L/hr (555 gph)
Minimum Fuel Line sizes (2.0 in.) (1 7/8 in.)
Maximum Fuel Line Restriction Clean Filter Dirty Filter
To Fuel Pump 16.9 kPa (5.0 in Hg) 30 kPa (9.0 in Hg)
To Injector Return Line 34 kPa (10.0 in Hg) 34 kPa (10.0 in Hg)
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Cooling System
The QSK78 will be using a Two Pump-Two Loop (2P2L) cooling circuit with an engine loop and a Low
Temperature After cooling (LTA) loop. The engine loop operates at relatively higher temperatures and is
therefore referred to as the High Temperature Circuit (HTC). The LTA loop operates at lower temperatures and is
therefore often referred to as the Low Temperature Circuit (LTC).
The two circuits make use of two separate coolant pumps. The high output LTA coolant pump is used to circulate
coolant to the aftercoolers and is located at the front left bank side of the engine. The main engine coolant pump
is used to circulate coolant through the engine, oil coolers, etc. and is located at the front right bank side of the
engine. Two separate radiators are required, one for the engine heat rejection (engine radiator) and the other
radiator for aftercooler heat rejection (LTA radiator). Separate thermostats control the LTC and the HTC. There are
eight thermostats (four per side) used for the HTC, with the thermostats located in the thermostat housing at the
front center of the engine. There are four thermostats used for the LTC, with the thermostats located inside the box
at the front left bank.
Surge Tank and Filling
A common surge tank or individual surge tanks can be used for both cooling circuits. If a common tank is used
the LTC and HTC circuits can be filled simultaneously. As a common reservoir, the surge tank allows a small
quantity of coolant from both circuits to be mixed during engine operation, increasing the LTC heat rejection.
OEM’s need to make provisions for make up lines and venting.
The surge tank(s) should be designed to reduce the turbulence in the tank so that acceptable deaeration and draw
down are achieved. Baffles may need to be incorporated into the surge tank to reduce turbulence. Petcocks on
water cooled bearing housing turbos need to be kept open at the time of initial filling of the system.
Coolant Treatment and Filtration
A mixture of 50/50 water and antifreeze is recommended with Cummins Filtration Fleetguard Fully Formulated
Coolant. Supplemental Coolant Additive (SCA) must always be used, and the Fleetguard SCA is known
specifically as “DCA4” in the marketplace. The two spin-on coolant filters contain 46 units of SCA (23 units each).
Additional SCA must be added to the system. The quantity of DCA4 coolant additive needs to be calculated
based upon total system capacity (HTC circuit + LTC circuit + radiators + plumbing). It is recommended that 3.0
units of DCA4 per gallon be used for initial coolant precharge. Minimum level of DCA4 should never be below 1.2
units per gallon of coolant.
Reference - Service Bulletin # 3666132, Cummins Coolant Requirements and Maintenance
- O&M Manual Bulletin # 3666714, QSK78 Operation and Maintenance Manual
Coolant Filters are not required for the LTC. If separate surge tanks are used, both systems should be filled with
the proper level of SCAs. However, it is not required to provide filters to maintain the SCAs for the LTC. There is
no need for separate filters for the LTC, since the coolant gets mixed in a common surge tank. Figure 8 shows the
Cooling System Flow Diagram for the QSK78 single-stage configuration.
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Figure 8: QSK78 Single Stage Cooling System Flow Diagram
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Venting
The venting of the QSK78 engine is similar to the QSK45/60 engines. Venting for both the aftercoolers LTC and
the jacket water HTC is done at thermostat housing. Open all turbo petcocks when filling the cooling system, and
close after a steady stream of coolant flows from each. Please see installation drawing for vent locations.
Cooling System Connections
The HTC loop connection points are two 75-mm diameter openings with three-bolt flange, using M10x1.5-6H
threads. The LTC loop connection point is a 65-mm diameter opening with three-bolt flange, using M10x1.5-6H
threads. See Figures 9 and 10 for interface details.
Figure 9. LTC Connection Definition
Figure 10. HTC Connection Definition
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Lubrication System
Eliminator
The Cummins Eliminator™ lube oil filter, shown in Figure 8, is standard equipment and is the only option available
for the QSK78 engine. This allows for increased productivity and reduced cost over the life of the engine, with
reduced downtime. The Eliminator™ filter is a combination of an automatic, self-cleaning full flow filter and a
centrifugal bypass filter housed within a single unit, which is engine mounted.
Cummins Filtration has introduced a replacement drop-in disposable rotor solution for centrifuges in EliminatorsTM
and remote centrifuge units used in High Horsepower applications. For the QSK78 engine, the CS41019 replaces
84 pieces with a single, disposable assembly. The new disposable rotor using Cummins Filtration patented SpiraTec
technology offers easier maintenance and considerable cost savings without any compromise in filtration
performance. The full flow automatic, self-cleaning portion is a filter that screens particles as small as 20 microns
from the oil flow. Ninety-five percent of the oil that passes through the automatic stage 1 filter goes directly into
lubricating the engine. The remaining five percent is used to backflush the filter, keeping it clean. The oil that is
used to backflush the filter is then sent to a centrifugal separator. The spinning action of the disk-stack centrifuge
removes solid particles less than 2 microns in size, depositing the heaviest particles on a replaceable liner inside
the centrifuge bowl. The benefits of the new disposable centrifuge are:
- Minimum service life of 1,000 hours

- Designed to allow for quick filter changes without any special tools. Reduces service time from 1.5 – 2.0 hours
to approximately 15 – 20 minutes.
- Reduced total cost of ownership due to quick and clean service
- Less risk of injury during rotor service
Figure 11: Cummins EliminatorTM Oil Flow Diagram
Refer to CEB00201, “Eliminator™ Lubricating Oil Filtration System”, for additional information on Eliminator™.
The Eliminator is only mounted on the right bank (water pump side) of the engine.
Venturi Combination Spin-on Filters
A standard spin-on lube filter head uses the same filters as the QSK60. The QSK78 uses 6 spin-on Venturi
combination filters. The Venturi filter design provides for both full flow and bypass lube oil filtration in the same
canister thus eliminating the requirement for bypass filters in Prime Power applications. The Venturi filter utilizes a
synthetic Stratapore™ media with a wire mesh backing for long life. It has a filtration capability of 30 micron.
These Venturi filters will only be mounted on the right bank (water pump side) of the engine.
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Centinel™ Continuous Oil Replacement System
The Centinel™ Continuous Oil Replacement System is optional equipment for the QSK78 Power Generation
engine, and is a means of disposing of used engine oil in a productive manner as engine fuel. The Centinel™
system significantly reduces maintenance costs while maximizing uptime and productivity. This is done through
optimized oil management and enhanced engine protection with a system, which ensures that oil quality remains
stable and thus gives greater protection over the long run. The Centinel™ Flow Diagram is given in Figure 12.
This patented system utilizes the concept of burning used engine oil at a rate dependent upon load factor.
Centinel™ can be purchased in a “burn-only” or “burn and make-up” configurations. Both systems pull oil from the
engine rifle and meter it into the fuel inlet. With the “burn and make-up” system the burned oil is replaced by the
addition of oil from a remote auxiliary oil tank. The Centinel system does not make up for the normal oil burned by
the engine. Therefore, the operator will still need to do the routine oil level checks.
Reference - CEB00610, “Industrial HHP Products for Oil Service Interval Extension”
- CEB00610 Attachment A, “Chart Method for Oil Drain Interval Estimation”
MAIN OIL RIFLE CENTINEL UNIT

PORT
LOW OIL
LEVEL
SENSOR FUEL INJECTOR / FUEL FILTER
CYLINDER HEAD
Figure 12. Centinel Flow Diagram
Oil Pan
The QSK78 engine utilizes an oil pan adapter and a bolt-on sump. Sumps can be added to four locations on the
pan adapter. The addition of the sump will provide increased capacity for meeting oil change requirements. The
QSK78 double-deep and full sump pans have oil capacities of 287.7 liters (76 gallons) and 412.6 liters
(109 gallons), respectively. Figure 13 shows the double deep sump / cast aluminum oil pan.
Angularity for the QSK78 engine is 15 degrees in all directions. In addition, breather angularity is also available at
9 degrees (Front Up Engine Angularity), 9 degrees (Front Down Engine Angularity) and 8 degrees (Side to side
Engine Angularity).
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Figure 13. Double deep oil pan used on the QSK78 engine
Oil Types
Standard oils are the oils meeting the requirements of American Petroleum Institute (API) and CF4. Premium oils
are the oil meeting the requirements of API CH4 or greater.
Extended Oil & Filter Service Intervals Summary - Prediction Only

How to use the matrix given in Table 5:
Find the row on the matrix that has your options marked with an “x”. Follow the row across to the last two columns
to determine your filter change interval and oil change interval. Please note that the filter change interval and oil
change interval can be different.
Table 5. Oil Services Options
Various Filtration and Extended Service Interval Options
LF 9050 Fleetguard Eliminator Centinel Filter Change Oil Change Interval
Combo Filters Centrifuge Interval
(CH44100)
X 250 hrs or at oil change 250 hrs or chart method
X X 1000 hrs 4000 hrs
X c-fuge 1000 hrs** 250 hrs or chart method
X X c-fuge 1500 hrs** 4000 hrs
NOTES:
* Combo Filter change intervals may be extended based on the pressure drop across the filters. Filters must
be changed at a pressure drop of 12 psi.
** The interval is dependent on engine application, duty cycle (load factor), fuel quality, and oil quality. It is
recommended that the first service interval on the centrifuge be performed at 1000 hours. The interval can
be extended in increments of 250 hours if the centrifuge dirt level is acceptable. It is not recommended to
exceed 2000 hours between service intervals.
Air Handling and Exhaust System
The QSK78 uses six HX83 high efficiency CTT turbochargers for the G-6 rating and four HX83, HX82, HE851, or
HE800FG turbochargers for all other ratings. The turbocharger model is dependent on the selected fuel rating.
Air Intake System
The turbocharger inlet air connection provides 139-mm O.D. with a 142-mm raised bead for hose connections.
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Engine Mounting
The standard lifting arrangement for the QSK78 utilizes four lifting hooks located on rocker housings shown in
Figure 14. Each lifting bracket is mounted to the engine block using four M14x2.0 cap screws.
Figure 14: QSK78 Lifting Brackets
Breather
A single open crankcase breather, shown in Figure 15, is incorporated into the left bank of the QSK78 engine.
Figure 15. Cummins Breather for the QSK78 Engine
Electronic Control System

The G-Drive Controls System (GCS) System Description and the Power Generation Interface (PGI) System
Description are shown in Figures 16 and 17 respectively. For more information on the GCS and the PGI please see
the following Manuals:
CEB00199 – GCS Control Manual

CEB00381 – Electronic Features Technical Interface Package for CM850 PGI (Power Generation Interface)
Engines.
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Generator-Drive Control System for Quantum System Description
Electronic
Service
Tool
Service Tool
Interface
GOEM
Controls
GOEM
Interface
GCS
Controller
Engine Fuel System

Interface Interface
Engine Alternator
Figure 16. GCS Controls System
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Figure 17. PGI Controls System
Starters
The present available starter arrangement requires: Three 24V Delco Remy 50MT-400 starters, locating two on
the left bank and one on the right bank. The QSK78 Power Generation engine has a starter option (ST option)
that doesn’t include pre-lube systems and other ST options that include remote or on engine pre-lube systems.
The option with no pre-lube device fitted is for StandBy applications that require immediate startup for power
generation and cannot take the time to pre-lube the engine.
Flywheel Housing
The flywheel housing offered for the QSK78 is a SAE “00” housing that has three magnetic pickup (speed sensor)
locations, at 10, 11, and 1 o-clock positions as viewed from the rear. Two magnetic pickup holes are currently
dedicated for use by OEM/customers. One location is currently used for the engine GCS/PGI system. All
magnetic pickup holes available are M22 STOR threads. Figure 18 shows the QSK78 flywheel housing.
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Figure 18: QSK78 Flywheel Housing

Accessory Drive
The clockwise rotation (as viewed facing the front of the engine) of the drives is the same as the QSKV engines.
The ratio is as follows:
DRIVE GEAR RATIO SPEED (at 1800 engine speed)
Alternator Drive 1.73:1 3,114 RPM
Alternator
The alternator drive pulley is available on the right bank of the engine. The QSK78 alternator drive can provide
power to a 240 Amp alternator. A 5-groove poly-vee pulley and belt are utilized for alternator drives at or below
100 Amp. Above 100 Amp, a 10-groove poly-vee pulley and belt are used. The 240 Amp alternator drive option
incorporates a backside automatic idler arrangement. The alternator drive is a dependent option (EH) that is driven
out when the customer selects the alternator (EE) and alternator mounting (EH) options. Figure 19 shows each of
these separate options.
The overall ratio for the alternator drive arrangement is as follows:
OVERALL RATIO MULTI-VEE PULLEY CONFIGURATION
2.62:1 5 groove pulleys
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Alternator Mounting
(EH option)
Alternator
(EE option) Alternator Drive Pulley
(EH dependent option)
Accessory Drive Pulley

(PU option)
Figure 19: Difference between EE, PU, EH Selectable, and EH Dependent Options Graphic
Fan Drive
Currently the only Fan Drive option available on the QSK78 configuration is a no content option. Fan Drive is a
responsibility of the OEM. Please contact your Application Engineer if further assistance is required.
Service Accessibility
Check QuickServe Online (https://quickserve.cummins.com/) for maintenance and inspection requirements and
intervals. The clearance guidelines in the table below can be used to assess service accessibility for engine
components during the installation review.
Table 6: Service Accessibility – Components and Clearance Guidelines

Component Clearance Area
Engine and Major Major subsystems including engine removal and installation, flywheel housings, etc.
subsystems will need to be evaluated in each application. Listed below are guidelines for Service
accessibility evaluation for inspection and repair of components on the engine.
Accessory Drive 203 mm (8 in) clearance in front of the pulley is recommended to pull and replace
pulley with proper tool.
Air Cleaner Clearance equal to 1-1/4 times element length and 1-1/4 times element diameter.
Clearance for easy fastener release and tightening
Air Compressor 152 mm (6 in) spherical clearance of the head will provide the working space to
check the air lines, regulator valve and replace the head. 203 mm (8 in) radial
clearance to the forward mounting flange provides wrench clearance for
replacement.
Air Piping 152 mm (6 in) minimum adjacent to hose clamps, manifold and crossover cap
screws
Alternator 162 mm (6 in) clearance on the pulley side of the alternator and along the length of
the adjusting link for belt adjustment or replacement. End clearance equivalent to the
length of the pivot mounting bolt plus 51 mm (2 in) on at least one end of the
mounting bracket to allow removal.
Corrosion Resistor Spin On Provide 152 mm (6 in) minimum side clearance to the can for strap wrench and hand
clearance
Crankcase breather 152 mm (6 in) minimum on one side of breather for replacement and servicing
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Cylinder Head/Gasket Clearance over the cylinder head by the amount necessary to remove the rocker
lever assembly bolts (220 mm (8 in)) will permit replacement of cylinder heads and
gaskets
Dipstick and Tube 203 mm (8 in) minimum tunnel to the dipstick. Tube entrance visible for replacing
dipstick.
Engine Barring Fixture 19 mm (3/4 inch) drive ratchet wrench with minimum of 914 mm (36 in) long handle
and 90 degree swing
Ether injection system Access to the container mounting is necessary to replace the starting fluid supply
cylinder. 38 mm (1-1/2 in) added end clearance is sufficient for replacement of the
screw on pressure type container.
Freon Compressor 152 mm (6 in) clearance necessary adjacent to the belt adjusting bolts and the
mounting bolts for wrench working space.
Fuel Pump 356 mm (14 inch) spherical clearance adjacent to the fuel pump should be provided
to permit checking connections and replacement of pump. This clearance should be
over pump for the QST30 V engine.
Fuel Tank Drain Drains should be located for easy access so sediment and condensation can be kept
to a minimum.
Injectors 254 mm (10 in) space above the rocker housing is recommended to replace
injectors.
Lube Oil Filter 102 mm (4 in) minimum end clearance is recommended to change the element. 254
mm (10 in) radial clearance at bottom of filter can is recommended to afford end
wrench or strap wrench working space.
Oil Filler 203 mm (8 in) open area around filler cap is desirable for hand clearance. 305 mm
(12 in) diameter approach area is recommended to accommodate oil metering
nozzles or oil containers.
Oil Pan Drain plug 254 mm (10 in) clearance adjacent to the plug is recommended for wrench
clearance. Unobstructed area below drain plug.
Radiator Core 76 mm (3 in) on each side of the core will allow the cleaning by air or water jet. Fan
may be closer than 76 mm (3 in) without obstructing maintenance.
Radiator Fill spout Spout should have 305 mm (12 in) clearance for 1/3 the circumference around the
spout and be accessible from the top so a 7.57 or 11.36 Liter (2 or 3 gallon)
container can be used.
Rear Seal Sufficient clearance to remove transmissions, torque converters, wet flywheel
housings etc. is required to expose the rear seal for replacement
Starter 152 mm (6 in) radial clearance around the starter mounting flange for wrench
working space. 152 mm (6 in) end clearance and around the solenoid to provide axial
movement and working space.
Turbocharger 254 mm (10 in) clearance over mounting bolts for socket wrench or air impact
wrench.
Valve Cover 190.5 mm (7.5 in) clearance above valve cover to permit removal
Vibration Damper and front 102 mm (4 in) minimum in front of damper and or pulley.
seal
CORP-00-24-0-00.

Definitions
Table 7: Acronym Definitions

2P2L 2 Pump, 2 Loop
API American Petroleum Institute
CEB Customer Engineering Bulletin
ECVA Electronic Control Valve Assembly
EE Alternator
EH Alternator Mounting
GCE Global Customer Engineering
GCS Governor Control System
HHP High Horsepower
HPI High Pressure Injection
HTC High Temperature Circuit
LTA Low Temperature Aftercooler
LTC Low Temperature Circuit
OEM Original Equipment Manufacturer
ORFS O-Ring Face Seal
O&M Operation and Maintenance
PGI Power Generation Interface
PU Accessory Drive Pulley
SCA Supplemental Coolant Additive
SOI Start of Injection
STOR Straight Thread O-Ring
ST Starting Motor
Reference Documentation
For engine installation drawings and engine datasheets, visit the QSK78 G-Drive GCE webpage.
Table 8: Reference Documentation

CEB Document
Title
Number
CEB00199 GCS Control Manual
CEB00201 Eliminator™ Lubricating Oil Filtration System
Electronic Features Technical Interface Package for CM850 PGI (Power
CEB00381
Generation Interface) Engines
CEB00598 Installation Requirements – Fuel Temperature
CEB00610 Industrial HHP Products for Oil Service Interval Extension
CEB00610
Chart Method for Oil Drain Interval Estimation
Attachment A
CORP-00-24-0-00.

Change Log
Revision Date Author Description Page(s)

06 10July19 Jonathan Cox Formatting and grammar changes throughout. Multiple
Added References to all tables and figures. Multiple
Updated GCE G-Drive Global Page link 4, 16
Deleted Specific Power row from Table 1: 4
Changed Lubrication Section from “The Cummins Eliminator™ lube 11

oil filter is standard equipment and is the only option available
for the QSK78 engine. This allows for increased productivity and
reduced cost over the life of the engine, with reduced downtime.
The Eliminator™ filter is a combination of an automatic, self-
cleaning full flow filter and a centrifugal bypass filter housed
within a single unit, which is engine mounted. The full flow
automatic, self-cleaning portion is a stainless steel filter that
screens particles as small as 20 microns from the oil flow.
Ninety-five percent of the oil that passes through the automatic
first-stage filter goes directly into lubricating the engine. The
remaining five percent is used to backflush the filter, keeping it
clean. The oil that is used to backflush the filter is then sent to a
centrifugal separator. The spinning action of the disk-stack
centrifuge removes solid particles less than 2 microns in size,
depositing the heaviest particles on a replaceable liner inside the
centrifuge bowl. The unique features of the Eliminator™ filter
include:
- Filter service at 1,000 hours or one year for the centrifuge
(hours dependent upon load factor, oil quality, local conditions –
see Service Procedure 102-002 Maintenance Schedule)
- Bolts directly to the engine block
- Totally sealed system to reduce the possibility of
contamination/dirt
- Full flow filter life equivalent to the life of the engine”
To “The Cummins Eliminator™ lube oil filter, shown in Figure 8,
is standard equipment and is the only option available for the
QSK78 engine. This allows for increased productivity and
reduced cost over the life of the engine, with reduced downtime.
The Eliminator™ filter is a combination of an automatic, self-
cleaning full flow filter and a centrifugal bypass filter housed
within a single unit, which is engine mounted.
Cummins Filtration has introduced a replacement drop-in
disposable rotor solution for centrifuges in EliminatorsTM and
remote centrifuge units used in High Horsepower applications.
For the QSK78 engine, the CS41019 replaces 84 pieces with a
single, disposable assembly. The new disposable rotor using
Cummins Filtration patented SpiraTec technology offers easier
maintenance and considerable cost savings without any
compromise in filtration performance. The full flow automatic,
self-cleaning portion is a filter that screens particles as small as
20 microns from the oil flow. Ninety-five percent of the oil that
passes through the automatic stage 1 filter goes directly into
lubricating the engine. The remaining five percent is used to
backflush the filter, keeping it clean. The oil that is used to
backflush the filter is then sent to a centrifugal separator. The
spinning action of the disk-stack centrifuge removes solid
particles less than 2 microns in size, depositing the heaviest
particles on a replaceable liner inside the centrifuge bowl. The
benefits of the new disposable centrifuge are:
- Minimum service life of 1,000 hours
CORP-00-24-0-00.

- Designed to allow for quick filter changes without any
special tools. Reduces service time from 1.5 – 2.0 hours to
approximately 15 – 20 minutes.
- Reduced total cost of ownership due to quick and clean
service
Updated / changed many figures and tables. Multiple
Changed, “If a common surge tank is used, the coolant from both 9
circuits will mix in the tank and provide some filtration and
maintenance to the LTC.” to “There is no need for separate filters for
the LTC, since the coolant gets mixed in a common surge tank. Figure
8 shows the Cooling System Flow Diagram for the QSK78 single-
stage configuration.”
Changed “Prelube™ is an option for the QSK78 Power Generation 17
engine” to “The QSK78 Power Generation engine has a starter option
(ST option) that doesn’t include pre-lube systems and other ST
options that include remote or on engine pre-lube systems. The
option with no pre-lube device fitted is for StandBy applications that
require immediate startup for power generation and cannot take the
time to pre-lube the engine.”
Added “Definitions” Table and “Reference Documentation” Table 19
05 6Jul16 Rafael Mestril Changed text from “101 mm HG” to “16.9 kPa”, from “203 mm HG” to 8
“30 kPa”, from “229 mm Hg” to “34 kPa”, and from “203 mm Hg”
to “34 kPa”.
Changed text from “AEB 41.12” to “CEB00201”. 10
Changed text from “AEB 150.06” to “CEB00199”. 14
04 13Oct15 Arine Hillery Initial creation of CEB from AEB 10.112 All
03 12Sep13 Ayman Hamid Added G-Drive in the header. 1
Revised Fuel Rating section. 4
Added text “In addition to the GCS controller, the HPI-PT fuel 7
system is also managed by the Power Generation Interface
which includes an on engine CM2250.”
Deleted text “-01” from Reference Service Bulletin. 9
Deleted text “at the initial PG launch” from Eliminator section. 11
Deleted text “LF9024” from Venturi Combination Spin-on Filter 12
section.
Deleted text “CG4” from Oil Types. 13
Added text “The HE851 Turbo is used for the G15 and G16 rating.” 13
Added text “In addition breather angularity is also available at
9 degrees (Front Up Engine Angularity), 9 degrees (Front 14
Down Engine Angularity) and 8 degrees (Side to side Engine
Angularity).”
16
Added Figure 15.
16
Added text “and the Power Generation Interface”.
16
Added AEB 15.74.
17
Changed text from “GCS module” to “GCS/PGI system”.
17
Changed text from “The fan drive offered for Power Generation on
the QSK78 is the same as the QSK45/60. It is a low cost drive
with a moderate horsepower drive capability to drive an engine
or radiator mounted fan. This fan drive is capable of up to 90 hp
and maximum fan inertia of 10 Kgm2. It will use a shock
absorber tensioning arrangement and a 31-rib imperial K-
section belt. Multiple crank pulley options are shown in the
Sales Handbook. Fan drive ratios of 0.4 and 0.5:1 will also be
available, other options will be made available depending on
customer demand.” to “Currently the only Fan Drive option
available on the QSK78 configuration is a no content option.
Fan Drive is a responsibility of the OEM. Please contact your
Application Engineer if further assistance is required.”
02 16Apr12 Liz McLean Updated AEB to most recent format – no content change. All
01 19Dec11 Gaurang Updated AEB to most recent format.
Kachhadiya Updated figure. 1
CORP-00-24-0-00.

Updated information for 4 turbo and related options. 1, 3, 13, 14
Deleted information about 7-bolt cylinder heads. 5
Changed “Fleetguard” to “Cummins Filtration”. 7, 9
Changed the status of the Eliminator to “optional” from “standard”. 11
Corrected AEB title. 7, 11, 12, 15
Added AEB reference. 12
Deleted “QSKV Generator Drive Speed Governing System 16
Specification” section.
Deleted “Refrigerant Compressor”, “Hydraulic Pump Drive”, and “Air 16
Compressor” sections.
Deleted 3.56:1 ration and 10 groove pulleys. 16
00 26Nov03 Dave Initial Document All
VanValkenburg
CORP-00-24-0-00.

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Customer

Engine models included: QSK78 (D773002GX03)

Owner: Jonathan Cox Approver: per Procedure GCE-AS-1 Page 1 of 24

This CEB supersedes CEB00092 dated July 6, 2016.

Revision 06, 10 July 2019 Page 1 of 24 © Copyright 2019 Cummins Inc.

Revision 06, 10 July 2019 Page 2 of 24 © Copyright 2019 Cummins Inc.

Table 1. Engine Comparison ......................................................................................................................................4

Revision 06, 10 July 2019 Page 3 of 24 © Copyright 2019 Cummins Inc.

Base Engine Features

Revision 06, 10 July 2019 Page 4 of 24 © Copyright 2019 Cummins Inc.

Figure 2. QSK78 Cylinder Block

Figure 3. Damper for the QSK78

Revision 06, 10 July 2019 Page 5 of 24 © Copyright 2019 Cummins Inc.

Figure 4. Cylinder Head

Figure 5. Geartrain as viewed from the front of the engine.

Revision 06, 10 July 2019 Page 6 of 24 © Copyright 2019 Cummins Inc.

Fuel Pump and Connections

Figure 6. Fuel Pump and Filter canisters being used in Parallel

Revision 06, 10 July 2019 Page 7 of 24 © Copyright 2019 Cummins Inc.

HPI-PT Fuel System Typical Flow Diagram

Figure 7. Fuel System Flow

1 - ECVA 7 - Timing Fuel 13 - Fuel Filters

Fuel Flow and Restriction

Table 4. Fuel System Values

Revision 06, 10 July 2019 Page 8 of 24 © Copyright 2019 Cummins Inc.

Surge Tank and Filling

Coolant Treatment and Filtration

Revision 06, 10 July 2019 Page 9 of 24 © Copyright 2019 Cummins Inc.

Figure 8: QSK78 Single Stage Cooling System Flow Diagram

Revision 06, 10 July 2019 Page 10 of 24 © Copyright 2019 Cummins Inc.

Cooling System Connections

Figure 9. LTC Connection Definition

Figure 10. HTC Connection Definition

Revision 06, 10 July 2019 Page 11 of 24 © Copyright 2019 Cummins Inc.

- Minimum service life of 1,000 hours

Figure 11: Cummins EliminatorTM Oil Flow Diagram

Venturi Combination Spin-on Filters

Revision 06, 10 July 2019 Page 12 of 24 © Copyright 2019 Cummins Inc.

MAIN OIL RIFLE CENTINEL UNIT

Figure 12. Centinel Flow Diagram

Revision 06, 10 July 2019 Page 13 of 24 © Copyright 2019 Cummins Inc.

Extended Oil & Filter Service Intervals Summary - Prediction Only

Air Handling and Exhaust System

Air Intake System

Revision 06, 10 July 2019 Page 14 of 24 © Copyright 2019 Cummins Inc.

Figure 14: QSK78 Lifting Brackets

Figure 15. Cummins Breather for the QSK78 Engine

Electronic Control System

CEB00199 – GCS Control Manual

Revision 06, 10 July 2019 Page 15 of 24 © Copyright 2019 Cummins Inc.

Engine Fuel System

Figure 16. GCS Controls System

Revision 06, 10 July 2019 Page 16 of 24 © Copyright 2019 Cummins Inc.

Figure 17. PGI Controls System

Revision 06, 10 July 2019 Page 17 of 24 © Copyright 2019 Cummins Inc.

Figure 18: QSK78 Flywheel Housing

DRIVE GEAR RATIO SPEED (at 1800 engine speed)

Alternator Drive 1.73:1 3,114 RPM

The overall ratio for the alternator drive arrangement is as follows: