Power with purpose: How the QSK95 is redefining ultra-class mining productivity
Why engine power matters
For miners, the performance of ultra-class haul trucks is critical to overall productivity. These machines do the heavy lifting, moving hundreds of tons of material every hour, often in harsh environments and at high altitude. At the heart of this performance is the engine.
While many operations rely on proven mid-range horsepower platforms to power vehicles, there comes a point when pressure to optimize cost per ton, improve uptime, and simplify fleet logistics leads to a decision on whether to upgrade engine power.
To better understand this moment and the myriad factors at play, Cummins has put a spotlight on the comparative performance differences between products within its engine range, to assess where and when miners might make the jump up in size.
Putting theory to the test
To test when a larger engine can create value within mining, Cummins conducted a detailed, controlled simulation study. The analysis compared the Cummins QSK95 with the smaller, 3,500-horsepower QSK78 in both 320-ton and 400-ton trucks across eight real mine haul routes.
The routes reflected actual operating conditions, including varied distances, steep grades, and high-altitude terrain, with variations in load, engine condition and driver behavior all factored into calculations.
Most of the sites simulated were located more than 3,100 meters above sea level and the study was based on single equipment condition. The goal was to evaluate cycle time, fuel efficiency, performance, productivity and total cost of ownership.
The results are in
Producing up to 4,400-horsepower, the QSK95 is Cummins’ most powerful engine. It is also the most powerful available in the ultra-class haul truck category. Engineered as a clean sheet design with mining requirements in mind, the QSK95 delivers performance, reliability, and durability in ways that directly impacts total cost of ownership and mining productivity.
The results from the extensive Cummins simulation study showed that a 400-ton haul truck powered by the QSK95 was 11 percent more productive than the same truck with a 3,500-horsepower engine.
Compared to a 320-ton truck with a 3,500-horsepower engine, the QSK95-powered 400-ton truck delivered a 24 percent boost in productivity.
Compared to a 3,500-horsepower engine, the QSK95 is expected to deliver up to 29 per cent longer life to overhaul. That means more operating hours, fewer interventions, and lower total lifecycle costs.
While the larger engine was found to use more fuel, the overall cost of production per ton remained similar. The QSK95 moved more material, faster, helping to offset increased fuel costs with greater efficiency.
Smarter fleet strategy, same production
The biggest opportunity from the study came into focus at the fleet scalability level. With faster haul rates, miners are able to reduce the number of trucks in operation while maintaining output. This creates the potential for major savings in areas such as labor, maintenance, and parts.
This smaller-fleets-with-bigger-engines approach can simplify operations for miners and increase productivity, especially at remote or high-altitude sites where uptime is critical, and available staffing is limited.
However, it’s important that miners consider the risk of fewer trucks and potential productivity lost when trucks come out of operation for maintenance or unexpected downtime. The QSK78 remains a strong engine for many applications where more flexibility is required and site profile is better suited.
Proven platform
The QSK95 was built to meet mining demands. It is a clean-sheet design, developed to meet the toughest mining conditions — from extreme temperatures and high altitudes, to heavy duty cycles and long service intervals.
Cummins’ biggest engine features single stage turbocharging that delivers full power at high altitude, external oil coolers for easier service access and four turbos instead of six, reducing overall complexity. A V16 layout and reinforced block minimizes noise and vibration for miners, with fewer moving parts and stronger bearings helping to extend engine life.
More than 1,200 QSK95 engines are already in service across different sectors in 36 countries, working in some of the toughest conditions an engine can perform in. In mining, the QSK95 is also supported by Cummins’ service network and digital monitoring tools like PrevenTech. These tools provide real time, over the air insight into engine performance, helping operators identify issues early, reduce unplanned downtime, and make data-informed decisions on variables like driver behavior and downrating that can improve fleet productivity.
Looking ahead
As the mining sector adapts to challenges, decisions about haul fleet strategy are becoming more data driven and critical to overall site efficiency. Engine choice is no longer just about horsepower, it is about total uptime value, serviceability, and cost per ton.
The QSK95 offers miners a powerful option that can boost productivity, simplify operations, and provide long-term value in some of the most demanding conditions on earth.
For miners ready to move more, faster, and with fewer interruptions, the QSK95 is ready to power a change.
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