Understanding Cummins HPI to MCRS fuel system upgrades for mining

As mining companies worldwide formulate strategies to transition to more sustainable operations without impacting cost of production, a key place to start is with their existing asset base. Upgrading mining engines to the latest technology leads to operational, environmental and even financial improvements.

Cummins has developed upgrade kits for QSK60 and QSK78 engines with HPI fuel systems. These kits convert the engines to Cummins’ newer Modular Common Rail Fuel System (MCRS). 

The MCRS’ increased injection pressure and larger injector accumulator volume allows for a variety of improvements over older fuel systems:

Improved fuel efficiency:

Precise fuel injection at high pressure leads to better combustion and reduced fuel consumption. Our customers report fuel savings in the field between 3-5%.

Lower emissions:

Optimized fuel injection minimizes emissions by ensuring complete combustion. Particulate Matter (PM) emission is up to 63% lower vs Tier 1.

Enhanced engine performance:

Consistent fuel delivery across the engine power range results in smoother operation and increased power.

Extended engine life:

Precise control of fuel injection reduces wear and tear on engine components, extending life to overhaul by up to 10%.

Quick start capability:

The high-pressure system enables fast engine starts even in cold conditions.

Smooth and quiet performance:

Consistent and precise fuel delivery results in a more smooth and quiet performance, reducing driver fatigue and increasing safety.

Engine upgrades are performed as part of the rebuild process at one of Cummins state-of-the-art High-Horsepower Master Rebuild Centers, where a highly trained rebuild team works through a rigorous six-step process, from tear-down through testing.