QSV HHP Natural Gas Engines Qualification Course

QSV 81/91 Gas Engines

Module 4s
ROUTINE MAINTENANCE

Cummins, Inc Corporate Training

 Routine Maintenance Module
Learning Objectives
To further develop the knowledge obtained from the Cummins, Inc. Virtual College ‘self-study’
CD-ROM. After completing this module you will be familiar with the maintenance intervals on
the QSV Gas engine and will be competent to carry out recommended daily and weekly
checks in addition to performing the specific routine maintenance tasks to the QSV 81 / 91
Natural Gas engine. We will also briefly look at the Air Start Compressor Maintenance. You
will demonstrate your knowledge by carrying out some engine unique routine maintenance
practical tasks.
Agenda ƒ Charge Air Cooler Maintenance.
ƒ Virtual College CD-ROM. ƒ VPS Maintenance
ƒ Operation and Maintenance Records. ƒ Spark Plug Types, Cleaning and Specials
ƒ General Maintenance Schedule. Tools.
ƒ Lube Oil Make-up System. ƒ Valve Clearance -14/16 Bar Engines.
ƒ Used Lube Oil Analysis. ƒ Throttle Body Adjustment.
ƒ Crankcase Ventilation Filter Maintenance. ƒ Vibration Damper Fluid Sampling and
ƒ Lube Oil Cooler Maintenance. Special Tools.
ƒ Air Start Compressor Maintenance

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 Virtual Training CD-ROM

The following Routine Service Procedures have been extensively covered

in the Cummins, Inc Virtual College CD-ROM ‘self-study’ program for the
QSV 81 and 91 Natural Gas Engines:

• Gas filter replacement,

• Oil filter replacement,
• Centrifugal filter service procedure,
• Spark plug renewal,
• Valve set adjustment.

ANY QUESTIONS???
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 Questions

1. The main constituent of Natural Gas is? Methane

2. The oil filter change-over valve must be False

left in the central position. True or False?

3. What mix is Cummins standard heavy 50% de-ionised water, 50% anti-
duty coolant? freeze, plus DCA 4.

4. The pistons used on the Cummins QSV Articulated pistons with an

81/ 91 Gas Engine are? aluminium skirt and steel crown.

5. Is it safe to use an oil recommended for No. Serious engine damage will
Diesel Engines in the QSV 81 / 91 Gas result.
Engine?

Do you need to review your Self-Study CD-ROM before the end of this
course? You WILL be tested on topics covered in the CD-ROM.
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 Operation & Maintenance Record
CW180 Training
OPERATION DATAOnly
Sample RECORD
CUSTOMER
SERIAL NUMBER

ƒ Good record keeping is QSV Gas Operation Data Record

ENGINE TYPE CW180OC
APPLICATION
Date
Running hours

essential to identify trends and Engine speed

Power
Engine room temperature

spot potential problems early. Atmosphere pressure

Description Sensor Unit TYpe

ƒ Use O&M records to assist

HT coolant temperature (engine outlet) 3865346 °C PT100
LT coolant temperature (RAS outlet) 3865346 °C PT100
Temp. Lub oil temperature after cooler 3865346 °C PT100
Compressor inlet temperature (free end) 3865345 °C PT100

with troubleshooting. Compressor inlet temperature (flywheel)

Intake manifold temperature
HT coolant pressure
3865345
3865345
3865337
°C
°C
bar
PT100
PT100
4_20mA

ƒ Make entries daily or more

LT coolant pressure 3865337 bar 4_20mA
Pres. Lub oil pressure engine outlet 3865337 bar 4_20mA
Lub oil pressure drop through filter 3865337 bar 4_20mA
Intake restriction pressure (free end) 3865345 bar 4_20mA

frequently dependant on hours Intake restriction pressure (flywheel)

Manifold absolute pressure
Crankcase pressure
3865345
3160404
?
bar
bar
bar
4_20mA
4_20mA
4_20mA

run. Exhaust gas temperature

Exhaust gas temperature
Exhaust gas temperature
3330147
3330147
3330147
°C
°C
°C
Thermocouple K
Thermocouple K
Thermocouple K

ƒ Log separately details in date Exhaust gas temperature

Exhaust gas temperature
Exhaust gas temperature
3330147
3330147
3330147
°C
°C
°C
Thermocouple K
Thermocouple K
Thermocouple K

order of any work carried out, Exhaust Exhaust gas temperature

Exhaust gas temperature
Exhaust gas temperature
3330147
3330147
3330147
°C
°C
°C
Thermocouple K
Thermocouple K
Thermocouple K

parts replaced or changes in temp.

Exhaust gas temperature
Exhaust gas temperature
Exhaust gas temperature
3330147
3330147
3330147
°C
°C
°C
Thermocouple K
Thermocouple K
Thermocouple K

consumables, i.e. oil used. Exhaust gas temperature

Exhaust gas temperature
Exhaust gas temperature
3330147
3330147
3330147
°C
°C
°C
Thermocouple K
Thermocouple K
Thermocouple K
Exhaust gas temperature 3330147 °C Thermocouple K
Exhaust gas temperature 3330147 °C Thermocouple K
Exhaust gas temperature 3330147 °C Thermocouple K

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QSV Natural Gas Maintenance Schedule

O&M: 4021313 T&R: 4021314

Always refer to the latest O&M and T&R manuals for latest
maintenance schedules and repair procedures.
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 QSV Gas Maintenance Schedules

There are four different maintenance schedules published that cover ALL
the HHP lean burn gas products.
Always check that the maintenance chart used matches the engine type,
BMEP rating and speed. Refer to the operation and maintenance manual or
QuickServe Online for full listings.
Cummins operate a service code system of Maintenance and Overhaul
Intervals dependent on the number of hours run. When undertaking
maintenance always carry out all operations listed up to and including the
code required.
A major overhaul is recommended at 60,000 hours or 10 years for QSV 81
and 91 Natural Gas Engines.

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 Maintenance Schedules – x4
Engine Model Generator Set Model
QSV81G 1100GQMA (14 bar - 60Hz,1200rpm)
Schedule 1 QSV81G 1370GQMA (14 bar - 50Hz,1500rpm)
14 Bar - NG Sets QSV91G 1250GQNA (14 bar - 60Hz,1200 rpm)
QSV91G 1540GQNA (14 bar - 50Hz,1500 rpm)

Engine Model Generator Set Model

Schedule 2 QSV81G 1570GQMB (16 bar - 50Hz, 1500 rpm)
16 Bar - NG Sets QSV91G 1750GQNB (16 bar - 50Hz, 1500 rpm)
QSV91G 1750GQPB (16 bar - 60Hz,1200 rpm/g .box)

Schedule 3 Engine Model Generator Set Model

QSV91G 2000GQNC (18 bar – 50Hz, 1500 rpm)
18 Bar - NG Sets QSV91G 2000GQPC (18 bar – 60Hz, 1200 rpm/g.box)

Schedule 4 Engine Model Generator Set Model

QSV81G 1570GQMB(16 bar - 50Hz , 1500rpm)
Low BTU Sets QSV91G 1750GQNB (16 bar - 50Hz, 1500 rpm)
(Cummins Fuel class ‘C’)
QSV91G 1750GQPB (16 bar – 60n Hz, 1200 rpm/g.box)

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Example shown for QSV 14bar Gas 1200 & 1500rpm engines.

Maintenance - Key Aspects Only (1 of 4 )

The following maintenance schedule example covers engines which are rated at 14Bar for continuous
power (COP) 1200/1500 rpm.
Maintenance Procedures for Schedule 1: Manual
Procedures at Daily Maintenance Interval………………………………………………………Section 3
Air Cleaner Restriction – Check
Control Panel Assembly – Check
Coolant Level – Check
Lubricating Oil Level – Check
Procedures at Early Life Inspection – (250 Hours)……………………………………..………Section 4
Emissions Testing - Check
Lubricating Oil and Filters – Change Cartridge Filters + Clean Centrifugal Filter.
Overhead Set - Adjust
Procedures at Maintenance Interval 1 - (250 Hours or 14 Days)……..…..……………………Section 5
Batteries – Check
Lubricating Oil Analysis - Test
Waste Oil Reservoir - Check
Procedures at Maintenance Interval 2 - (2,000 Hours or 4 Months)…………………...………Section 6
Air Cleaner Element – Replace ( Panel type or Industrial Primary, inner filter ONLY)
Air Filter Dust Collector - Check
Bearing, Generator - Lubricate
Emissions Testing - Check
Lubricating Oil and Filters – Change Filter ONLY
Lubricating Oil Filter (Centrifugal) – Clean Rotor and Replace Element
Overhead Set - Adjust Table shown for training purposes only.
Spark Plugs (Non-Shielded) – Replace
Example shown for QSV 14bar Gas 1200 & 1500rpm engines.

Maintenance - Key Aspects Only (2 of 4 )

Maintenance Procedures for Schedule 1 (Continued): Manual
Procedures at Maintenance Interval 3 – (4,000 Hours or 8 Months)………..………………Section 7
Flexible Hose – Inspect
Lubricating Oil and Filters – Change both
Supplemental Coolant Additives (SCA) - Check
Procedures at Maintenance Interval 4 – (6,000 Hours or 1 Year)………….………….……Section 8
Air Cleaner Element – Replace ( Industrial Secondary (outer) filter ONLY)
Coolant Plumbing – Check
Crankcase Ventilation Re-Circulator Element - Replace
Engine Mounts – Check
Fuel Filter, NG – Clean and Check
Tappet Assembly – Inspect
Turbocharger Axial /Radial Clearance – Measure
Procedures at Top End Overhaul Interval – (15,000 Hours or 30 Months)……………….…Section 9
Air Leaks, Air Intake and Exhaust Systems – Check
Back-up Batteries – Replace
Coil-On-Plug – Replace Extensions
Cooling System – Clean and Flush
Cylinder Head – Replace
Electrical Connection, Generator – Inspect
Flexible Coupling , Generator – Inspect
Fuel Filter, NG – Replace
Fuel Line Seals, NG – Replace
Throttle Shaft Bearings – Replace Table shown for training purposes only.
Example shown for QSV 14bar Gas 1200 & 1500rpm engines. Table shown for training purposes only.

Maintenance - Key Aspects Only (3 of 4 )

Maintenance Procedures for Schedule 1 (Continued): Manual
Procedures at Intermediate Overhaul Interval – (30,000 Hours or 5 Years)……………Section 10
After Cooler – Clean and Inspect
Batteries – Replace
Bearing, Generator - Replace
Bearings, Connecting Rod – Replace
Bearings, Main – Replace (Engines with serial numbers below 66300567 for QSV91 and 66300590 for QSV81)
Connecting Rod Cap Screws – Replace
Connecting Rod – Inspect
Coolant Thermostat - Replace
Cylinder Block Counter Bore – Inspect
Cylinder Liner – Replace
Exhaust Manifold Heat Shield – Replace (If Equipped) Push Rods or Tubes – Replace
Exhaust Manifold, Dry – Rebuild Tappet Assembly – Replace
Flexible Coupling, Generator – Replace Turbocharger - Replace
Fuel Regulator, NG Seals – Replace Turbocharger Oil Drain Line - Replace
Fuel Shutoff Valve (FSOV), NG Seals - Replace Turbocharger Oil Supply Line -Replace
Gear Train Backlash, Front – Check Vibration Damper, Viscous – Sample Fluid
Generator (Alternator) Windings – Clean Water Pump - Replace
Lubricating Oil Cooler – Clean and Inspect
Lubricating Oil Pump - Replace
Lubricating Oil Thermostat – Replace
Piston Rings - Replace
Piston – Replace (Engines with serial numbers lower than 66300664)
Example shown for QSV 14bar Gas 1200 & 1500rpm engines.

Maintenance - Key Aspects Only (4 of 4 )

Maintenance Procedures for Schedule 1 (Continued): Manual
Procedures at Major Overhaul Interval – (60,000 Hours or 10 Years)…..……….…… …Section 11
Bearings, Main – Replace (Engines with serial numbers higher than 666300567 for QSV91and 366300590 for
QSV81)
Bearings, Thrust – Replace
Camshaft Bushings – Replace
Camshaft Thrust Bearing – Replace
Camshaft Intermediate Gear Assembly - Inspect
Connecting Rod – Replace
Cooling System Hoses – Replace
Crankshaft Seal, Rear – Replace
Generator, Main – Inspect
Lubricating Oil Check Valve – Replace
Piston Cooling Nozzle – Replace O’rings
Piston – Replace (Engines with serial numbers higher than 66300664)
Piston – Replace Pins
Rocker Lever Assembly – Replace
Starting Motor – Replace
Vibration Damper, Viscous – Replace

Table shown for training purposes only.

 Lube Oil Make-up System
Compensation Breather Line Fill Line
(to equalise to crankcase
pressure). TEST INSTRUCTION
(Low switch only wired)
• Remove test cap.
• Rotate knob clockwise &
hold. WARNING: Feed valve must be
‘ON’ as shown when set running.
• Wait for PLC time delay
(approximately 1 minute).
Oil supply
from daily
• Check HMI for Low Oil service/bulk
tank.
Level Alarm shutdown.
• Replace test cap.

Sump and
Outlet to sump dirty oil
High / Low Test knob (acts on float) tank drain.
(sense line)
NOTE: Rubber cap fitted to brass nut,
unscrew, DO NOT PULL OFF! NOTE: A controlled engine shutdown will be instigated if
the Dirty Oil Tank is full - alarm will show on HMI.

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 Used Lube Oil Analysis
• Who? - Site operators and
• What to do with it? - service technicians.
Send to a reputable oil • Why? - Establish trends and
testing laboratory. Enter in

SA
indicate problems.

IS
engine maintenance record

M
• Where? - From hot engine

YS
that an oil sample has been

PL
taken and sent for analysis. at Lube Oil Module (before
AL

E
filter) or Mid-Sump via
AN

dipstick tube.
• When? - 1500 hours
(maximum) or before as
directed by Cummins.

REPORT

What to do when we have results? -

Dependant on results, laboratory will usually make
recommendations (see handouts). Make entry in engine
maintenance record and file report for future reference.

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 Used Lube Oil Analysis
A Used Lube Oil Sample must be taken at every 1500 hours (maximum),
or earlier as recommended by Cummins, Inc. This is dependant on
environmental conditions, such as:

• High or low ambient air temperatures,

• Air condition (dust levels, etc.),
• Engine application and duty cycle.

In summary, a used Lube Oil Analysis can be used to:

• Help diagnose internal engine damage,
• Monitor engine lube oil condition - Premature oil change may be
required if oils protective properties have deteriorated.
(3000 hours recommended maximum oil change interval).
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 Used Lube Oil Analysis
Lube Oil • Ensure that the area that the sample is to be taken
Module
from is clean.
• With the engine running - at normal operating
temperature and using a suitable container, take a
sample of lube oil of at least 0.125 litres.
• Label the sample as described on next slide and
submit to a reputable local oil analysis laboratory.

Fit Suitable Drain Tap Here.

IMPORTANT NOTE:
Do NOT disassemble an engine for repair based only on the results of an oil
analysis. Inspect the oil filters also. If the oil filters show evidence of internal
engine damage, find the source problem and repair the damage.

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 Used Lube Oil Analysis
LUBE OIL ANALYSIS - WORK RULES:

• Always sample from a hot engine, pre-filter, before adding oil to

compensate for consumption or before oil change.
• Use a sterile, air tight, container (minimum 0.125litre). Attach a label!
• Sample from the Lube Oil Module - before the filters - using a suitable tap
(customer supplied) fitted to the Lube Oil Thermostat Housing.
Alternatively, draw oil through the dipstick tube using a syringe and tube
of suitable length to take oil sample from middle of sump.
• Supply the following identification and information:
Engine Make - Type - Serial No - Type of use & engine hours - Fuel type.
Sample Date - Sample conditions (at oil change / intermediate)
Engine Hours - Oil hours - Oil brand & name - Oil Viscosity (SAE)
Oil top-up quantities since last oil change - Recent maintenance.
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 Crankcase Breather & Ventilation Filter

Crankcase Ventilation Filter

Crankcase
Breather
connection on
A & B-Bank

Filter Outlet

The purpose of the ventilation filter is to remove oil mist and air
borne particles from the crankcase breather outlet. Efficiency up
to 99%. It is mandatory to pipe the crankcase breather outlet Filter Drain Line
outside the container or building. to Dirty Oil Tank
NOTE: Change the filter element in accordance with
recommendations in the Genset O&M Manual.
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Crankcase Ventilation Filter - Service

NOTE: It is recommended that this procedure

is performed prior to oil changes.

• With the engine shut down, remove the band

clamp.
• Remove the end cover (1) and filter element
(2) from the housing.
• Use a rag dampened with a suitable de-
greasing agent to clean the inside of the filter
2 housing and dry with compressed air.
1
• Install a new filter element and refit end
cover.
• Install the band clamp and Torque as
specified in O&M manual.

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 Lube Oil Cooler Maintenance
The Lube Oil Cooler requires cleaning every 15,000 hours. Failure to perform this
service could result in excessive scale forming and a decrease in the Lube Oil
Cooler cooling efficiency.

Location
of Top
• Carry out engine isolation procedures.
Aluminium • Remove Lube Oil Cooler End Covers as
Gasket per T&R manual procedure - section 7.
Note: This assembly will contain a
considerable amount of oil - even when
Location of engine oil has been drained
exposed (approximately 80ltrs.).
O-ring
• Remove both exposed O-rings from
Location each end of the tube element and top
of Bottom and bottom aluminium gaskets from the
Aluminium housing.
Gasket
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 Lube Oil Cooler Maintenance
• Push the tube element in one direction
until the inner O-ring is exposed. Remove
the O-ring. Push the element back through
the housing to expose and remove the
remaining inner O-ring.
• Carefully remove the tube element from
the housing, taking care not to damage the
cooling element.
Location of Lube Oil
inner O-ring Cooler Element

• Only lift the element by the element ends,

serious damage will occur if the element is
lifted by the element tubes.
X
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 Lube Oil Cooler Maintenance

• Wash the internal and external surfaces of the element with a solvent that will not
harm copper. If necessary, only use a nylon brush to aid cleaning.
• Check the interior of the tubes for scaling. If scale is present, use a cooling scale
removing chemical, or send to a specialist company for chemical cleaning.
• Rinse element with clean water and dry with compressed air.
• Clean the housing and end covers with solvent and lint-free cloths.
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Lube Oil Cooler Maintenance
• If the unit is suspected of having leaks, attach
pressure test tooling and a source of
compressed air to the fixture.
• Submerge the element in water, supply 8Bar
(116psi) air pressure and check for leaks.
Obey local pressure testing regulations.
NOTE: If the element leaks, it MUST be
replaced. Do NOT attempt to repair a
damaged element.

• To reassemble, push the element through

the housing until the inner O-ring groove is
exposed on the opposite end. Lubricate and
install a new O-ring. Repeat for other end. Fit
new outer O-rings to each element end.
• Complete the re-assembly of the cooler as
detail in the T&R manual - section 7.

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 Charge Air Cooler Maintenance

Clean the Charge Air Cooler as specified in the O&M manual (currently every
15,000 hours). Failure to perform this service could result in excessive scale
forming and a decrease in the Charge Air Cooler cooling efficiency.

• Carry out engine isolation procedures.

• Remove Charge Air Cooler as per T&R
manual procedure - section 10.
WARNING: This assembly must be removed
using suitable lifting equipment to avoid
personal injury.
• Remove both end covers and top cover from
the Charge Air Cooler.

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 Charge Air Cooler Maintenance

• If there is a lot of scale present, clean through the water channels using a suitable
stiff nylon brush.
• Apply a detergent and wash through with a pressure washer - 120Bar (1740psi)
is recommended. Only direct spray parallel to fins and keep nozzle a distance of
2 metres (6.5 feet) from fin surface. If necessary, remove any oil residue from air
circuit (closed crankcase breathing only) using a lower pressure.
• Allow excess water to drain and dry cooler with compressed air.
• Reassemble according to procedure in T&R manual - section 10.
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Charge Air Cooler Maintenance
• If this service procedure is neglected,
or coolant additives are not correctly
monitored and maintained, scaling
may be so severe that the cooler may
require chemical cleaning by dipping -
takes 24 hours. This is more costly and
results in increased engine down-time.

• If the unit is suspected of having a leak, the

assembly should be pressure tested. Block
either the inlet or outlet with a blanking plate.
Cover the other top face with a blanking
plate containing a quick-connect air fitting.
Submerge unit in water and apply 4.1Bar
(60psi) and check for leaks. NOTE: If unit
leaks it MUST be replaced. DO NOT attempt
to repair a damaged cooler.

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Valve Proving System – VPS504 maintenance

Valve Proving VPS Outlet The VPS requires regular

System Filter & O-Ring inspection and service.
ƒ Carry out a yearly inspection. If
operating in a harsh environment
carry out every six months.
ƒ Inspect gas connections and VPS
fittings. Test for leaks.
ƒ Replace Inlet and Outlet filters and
O-rings.
ƒ Filter servicing is vital as blocked
filters will cause the VPS to pass
the test, regardless of condition of
the DSSV valves.

VPS Inlet Filter

ƒ Filter replacement Kit Cummins
& O-Ring Part No. TBA
NOTE: In some countries VPS servicing MUST be undertaken by a gas registered
technician. Follow local legislation & codes

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 ‘V’ Engine - SEM COP Assembly (from May ‘03)
Easily identified by its
integral harness and 3-
pin Deutsch Connector.
Removable HT
Insulator Section

Coil Housing

A - (–) Vdc.
A B - (+) Vdc - 330v to
Primary Winding.
C B
C - Not Used.

ƒRemovable injection molded Insulator section with rubber boot. (Cummins Pt No. 4917686).
IMPORTANT! The coil has a liquid polymer insulation. Do NOT energise the coil in a horizontal position
as it is possible to get an internal flash-over between the LV and HV circuits.

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 ‘V’ Engine - Altronic COP Field Service
(QSV to May ‘03)
Cummins manufacturing discontinued fitment of Altronic COP’s in May 2003
(PT No. 3608008). Now Service Use Only, until replace and go to SEM COP
(PT No. 4011615).
For complete list of parts and instruction for field conversion to SEM COP Refer
to service parts Topic 05-TO-27. (Harness pigtail required (4014052) plus new
Rocker Cover, Spacer, Insulator, Seals, etc).

Altronic
COP PIN LAYOUT

A = (+) V dc (300v).
B = (–) V dc.
E
C = HV sensor (–).
D A
D = HV sensor (+).
B E = Not Used.
C

Synergy Update REV 3.0 BMG 06/06

Spark Plugs - Special Tools
Cummins Part #: WARNING: USE OF RUBBER
3162231 BOOT TYPES ARE PROHIBITED

NOTE: No rubber
6” extension insert
NOT supplied
as part of tool.
This is
required in
Wire Clip
order to reach
spark plug.

22mm Clip Type Shown

Socket only Cummins Part No. 3162231

An 18mm spark plug thread and seat chaser tool is also

recommended (Plug - 18mm thread / 22mm Hex)
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 Spark Plug Maintenance
Cleanliness is vital (EHT)
Never Handle Porcelain Part of
the Plug!
4010981 PLUG GAP = 0.2mm
( 0.008 ins)
4098162 PLUG GAP = 0.25mm
( 0.010 - 031 ins).

Plug Electrode Two Approved Plugs Available Plug Electrode

Part No. 4010981 Know the differences ! Part No. 4098162
ƒ 4010981 – Approved for all QSV engines. Clean and re-gap the spark plugs at
750 hrs, follow the Cummins recommended procedure. Replace at 1,500 hrs max.
ƒ 4098162 – Approved for all QSV engines. No re-gap necessary, replace only at
1,500 hrs max.
ƒ Important - Use only Cummins approved Spark Plugs. Always replace at the
recommended service interval, even if engine is running normally.
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 Spark Plug Cleaning
• ALWAYS replace the spark plug sealing washer when refitting any removed spark
plugs (Cummins Part #: 3072541). If necessary, clean the spark plug porcelain with
alcohol or a mineral spirit - REMEMBER: DO NOT touch the porcelain extension of
the spark plug during the cleaning process.
• Only use a good quality commercial spark plug gap adjusting tool. Adjust the gap to
specification by either tapping the spark plug ground electrode on a suitable
surface (to close the gap) or by using the tool to bend the ground electrode open.
Ensure that you check the gap with care so as not to damage the precious-
metal electrodes. Ensure feeler gauges are clean. Wire type
feeler gauges are preferred (if available).
• Refit the spark plugs. DO NOT use any lubricant, etc. on the
spark plug threads. Torque as specified in O&M manual.
• After cleaning, make an entry in the engine maintenance log
showing that a cleaning and re-gapping procedure has been
performed.
IMPORTANT NOTE: Cummins, Inc. recommend that QSV spark plugs are only cleaned ONCE.

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 Consumable Items
Cleaning Fluid:
• General Purpose Alcohol based Contact Cleaner.
• Must be Non Silicone based.
• Suitable for cleaning spark plug bodies, electrical connectors & components.
Cummins Part No. 3824510 (16 oz. aerosol).
CONTACT
Dielectric Grease (Dupont Krytox 205) :
Must be Silicone based (increases temperature rating).
CLEANER
• Suitable for light smearing of spark plug boots before installation. 16 oz.
Cummins Part No. 3164956.
Pt.3824510
Lithium Grease (Lubriplate) :
•Suitable for smearing on electrical connections. Minimises terminal ‘Fretting’
due to vibration. Resists rust and corrosion. Apply to Female connector only.
Cummins Part No. 3822934 (1¾ oz. tube).

Anti-seize:
• Should be a copper compound and not lead based.
• Suitable for application to temperature sensors before installation.
Cummins Part No. 3824732 (4 oz. tube).

Synergy Update REV 3.0 BMG 06/06

 Valve Clearances – 14/16 bar Engines

KE
Y
– Floating Crosshead Design.

ST
E
ƒ Procedure as Virtual College CD ROM…..

PS
ƒ Carry out Isolation procedure.
ƒ Remove LT connector & rocker covers.
ƒ Engage barring device, turn engine to TDC - 0º mark of
any cylinder combination.
ƒ Cylinder with both levers free ready to adjust.
ƒ Back off rocker arm Lock nut then the adjusting screw
(1 & 2) four turns. * Use Special Wide Feeler gauges
ƒ Adjust rocker arm inlet & exhaust clearance (1), torque (2) Cummins Pt No. 4918217
to 40Nm / 30 ft-lbs. (inc. 0.4, 0.8, & 1.0 mm gauges).
ƒ CHECK SETTING : Attempt to insert a feeler gauge
0.03mm (0.001in) thicker, if it fits the setting is not correct.

Valve Clearance - 14 Bar Engines Valve Clearance - 16 Bar Engines

Intake 0.40 mm (0.016 in) Intake 0.40 mm (0.016 in)
Exhaust 0.80 mm (0.032 in) Exhaust 1.0 mm (0.040 in)

Note : 3164393 – 14 Bar Feeler Gauge set includes only 0.4 & 0.8mm gauges.

Synergy Update REV 3.0 BMG 06/06

 Throttle Body Adjustment - Procedure

• Isolate Engine as per procedure.

• Before making any adjustments, mark
original position of the actuator by
making a mark on the actuator mounting
flange and an adjacent cooling fin.

• Loosen the four capscrews (1) and

nuts (2) holding the actuator to the
2 flange coupling.

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 Throttle Body Adjustment - Procedure
NOTE: The power to the actuator should be ‘ON’
so that the drive shaft is held on the actuator stop.
• Rotate the actuator counter-clockwise until
you feel the throttle plate close.
• Place a second alignment mark on the
actuator mounting flange to indicate the
throttle plate closed position.

Line up edge of fin

with 3.5mm mark
• Make a new alignment mark 3.5mm (0.14 in.)
clockwise from the closed alignment mark. NOTE: This
should coincide with the alignment mark made prior to
moving the actuator if the original position was correct.
• Rotate the actuator clockwise to open the throttle so
that the same actuator fin is aligned with the new
3.5mm (0.14 in.) mark.
• Torque the capscrews and nuts to specified value.
• Repeat procedure for second throttle - if fitted.
Synergy Update REV 3.0 BMG 06/06
 Throttle Body Adjustment - Principle
Rotate throttle body counter-clockwise
until throttle plate is closed, i.e. throttle
plate makes contact with housing.

Housing

The Throttle Actuators require replacement

at the 60,000 hour (M6) interval. This With power ‘ON’, throttle
shaft is held against the
procedure should be used to set the actuator stop.
throttle clearances, as well as when
experiencing hard start conditions.

Synergy Update REV 3.0 BMG 06/06

Throttle Body Adjustment - Principle

Rotate throttle body clockwise 3.5mm

(0.14 in.) to give desired throttle clearance.

Housing

Clearance

Synergy Update REV 3.0 BMG 06/06

 Vibration Damper - Special Tools

Ensure that
you supply
Damper serial
number is
ALL requested
stamped information!
adjacent to the
two sampling
holes and is
coded by year of
manufacture, i.e.
940750 is 1994
manufacture.

Vibration Damper Silicone Fluid Damper Plug Removal Tool - No

Test Kit: Cummins Part #: 4011475 Cummins Part Number, available
from Metaldyne - Part #: J30671

Synergy Update REV 3.0 BMG 06/06

 Torsional Vibration Damper
Sample Sample
Optional Crankshaft Plugs
adapter not shown Plugs
Ancillary
Drive Gear

Crankshaft
Free-End

Optional Power
take-off Crankshaft
Adapter

Crankshaft
Single Damper Arrangement Flange
Dual Damper Arrangement
V18 Engines V16 Engines

• Analyse Silicone Fluid at 15,000 hours, replace Vibration Damper at 30,000 hours (max).
Synergy Update REV 3.0 BMG 06/06
 Vibration Damper - Fluid Sampling
V16 Inboard Damper, V18 Single Damper

View of vibration damper through View of vibration damper plug

A9 crankshaft access aperture from inside engine

• Carry out engine isolation and lock-out procedures. Take sample whilst engine
oil is drained (part of 15,000 hour maintenance schedule) and engine warm.
• Remove A9 crankshaft access cover to gain access to vibration damper inner
plug. Bar engine so that damper plug is in the 6 o’clock position.
Synergy Update REV 3.0 BMG 06/06
 Vibration Damper - Fluid Sampling
V16 Inboard Damper, V18 Single Damper

Screw silicone
Remove damper
fluid sample tube
sample plug using
in place of the
special tool and
blanking plug.
extension.

• Using the special tool, remove the Vibration Damper blanking plug.
• Select the correct end of the sample tube and screw into the blanking plug hole.
• Remove the other cap nut. Allow fluid to flow from the open end and replace cap.
• Remove sample tube, fit new blanking plug and O-ring, torque as specified on O&M Manual.
Synergy Update REV 3.0 BMG 06/06
Vibration Damper - Fluid Sampling
V16 Outboard Damper
• To sample fluid from the front Vibration
Damper (V16 engines), remove the
crankshaft access cover from the free-end
of the engine.
Crankshaft
Cover
• Next, remove the gear, following procedure
in T&R manual - section 1. You can now
see the Vibration Damper. Bar engine until
blanking plug is visible and take sample of
fluid as previously detailed.
• Alternatively, the Vibration Damper can be
accessed by removing the Centrifugal Filter
assembly. The sample can then be taken
via the Centrifuge Oil Return aperture in the
engine block.
• After taking sample, reassemble as per
procedures in T&R manual - section 1.
Synergy Update REV 3.0 BMG 06/06
 Vibration Damper - Fluid Sampling
Taking Silicone Fluid Samples From The Viscous Torsional Vibration Damper:
Sample every 15,000 hours. At 30,000 hours vibration damper replacement required. Isolate The Engine!

1 2 3 4 5
Gain access to front Remove filling plug Allow fluid to Replace cap nut and Fit second cap nut
or rear damper plug. and screw container reach open end unscrew container. to container .
Rotate engine until into filling hole. of container. Immediately fit new Ensure container
one plug is visible, Remove the other May take 60 damper plug & seal. is at least 75% full.
wait 1hour. Sample cap nut. seconds or 1 Torque to value
Complete label and
container has two hour, dependant specified in O&M
attach to tube. Make
threads. Remove on conditions. Manual.
entry in engine
cap nut with thread
maintenance record.
to match filling plug.
Synergy Update REV 3.0 BMG 06/06
 Vibration Damper - Fluid Sampling
Normal Condition:
Original fluid is completely clear and free from
debris. Submit fluid for analysis - continue to
use engine.

Intermediate Condition:
Intermediate sample can be slightly
discoloured and may contain some particles.
Submit fluid for analysis - continue to use
engine.
Requires Immediate Service:
Dark brown to black and contaminated with
metallic debris. Stop using engine, renew
damper immediately.

NOTE: The vibration damper should also be replaced if no fluid is forthcoming

after a reasonable period, i.e. overnight.
Synergy Update REV 3.0 BMG 06/06
 Engine Maintenance Notes

NOTES:
• Used oil in a Natural Gas engine retains a new look, even
though the additives may be depleted and it contains
contaminates.
• Spark Plugs MUST only be cleaned once!
• ALWAYS tighten to specified Torque!
• Remember to take the various fluid samples for analysis at
the specified time!
• Maintain your engine maintenance record as well as your
engine!
Synergy Update REV 3.0 BMG 06/06
 Bladder Tanks ‘Schrader’ Valve
Function Pump to 12 – 15
ƒ Often used in place of the standard “Header Tank”. Serves PSI with Auto
the same functions but achieves system static pressure pump or similar.
without the need to be raised high above the engine like a
standard Header tank.
ƒ Acts as a “volume accumulator”. Bladder shrinks in Dust Cap.
volume on coolant contraction and expands in volume on
coolant expansion to maintain coolant pump “Static Head”.
ƒ Static ‘Head’ can be adjusted to suit the different system
requirements, improving performance. ‘EPDM’
ƒ Sized to suit the specific System coolant volume. Rubber
ƒ Often used with CHP systems. Membrane or
ƒ General use / Maintenance: ‘Bladder’.
ƒ Remove the dust cap and connect a hand pump to the
Schrader valve located on the top of tank.
ƒ Pressurise the tank to 12 – 15 psi (1 Bar), replace the dust
cap.
ƒ Fill the engine cooling system with coolant to achieve a
system pressure of 15 – 18 psi (cold) at engine water
pump input when all air has been ‘bled’ from the system.
(Check via HMI or as appropriate).
ƒ NOTE: Bladder tanks may be supplied pre-pressurised
with Air or Nitrogen. Check and adjust pressure before Water Connection at Bottom Of Tank,
use. Water / Coolant fills the inside of Bladder
ƒ Failure Mode:
ƒ Aggressive pressure swings between cold and hot.
Typically low when cold and high when hot.
Synergy Update REV 3.0 BMG 06/06
 ERVOR Air Start Compressor -
Typical Plant Layout
Air Supply Line - 40Bar regulated to
10Bar (maximum) to starter motor.

⊗
⊗
Compressor Inter-Connect
Isolation Valve -normally closed ⊗
Note: The system pressure, arrangement and equipment supplier my
vary upon location. Always follow the manufacturers instructions.
e.g. Ervor – European Supply , Ingersol Rand USA supply.
Synergy Update REV 3.0 BMG 06/06
ERVOR Air Start Compressor –
Key Daily Checks

It is important that the ERVOR Air

Start Compressor is correctly
maintained in accordance with the
Maintenance Guide (see handouts) . On
a daily basis the operator should:
1. Drain condensates from Collector
Box.
1
2. Check compressor motor oil
level.
3. Check Auto Drain Solenoid - test
and check settings.

2 3

Synergy Update REV 3.0 BMG 06/06

QSV 81/91 Gas Engines
Module 3 - Routine Engine
Maintenance
Team Tasks - Practical Exercises

Cummins, Inc Training

Synergy Update REV 3.0 BMG 06/06

 Practical Work Rules

Use safety shoes, the protective gloves and other protective clothing provided.
Lifting and handling equipment provided for large and heavy items.
When dismantling the engine always set out the work area first, working in an
orderly manner will assist in re-assembly:
1) Spread clean paper on the ground to layout the parts as removed.
2) Layout the components in sets; A1, A2, A3, etc. in the order of removal
starting furthest away from the engine. Replacement is then simplified by
starting with the parts closest to the engine and working outward.
3) Always replace bolts after parts have been removed, they are then at hand for
re-assembly!
Make reference to the O&M and T&R manuals for procedures and torque values.

Synergy Update REV 3.0 BMG 06/06

 Practical Team Tasks

Divide into groups and carry out the following Routine

Maintenance Team Tasks:

• Spark Plug Maintenance (One Cylinder).

• Oil Filter Change,
• Centrifugal Oil Filter Maintenance,
• Valve Set – Phase 1 and/OR Phase 2 cylinder heads,
• Throttle Valve Setting.

Synergy Update REV 3.0 BMG 06/06

 QSV HHP Natural Gas Engines Qualification Course

Module 4s
ROUTINE ENGINE
MAINTENANCE

End
Cummins, Inc. Corporate Training

Natural Gas CUMMINS, INC 2006 C

POWER QSV Engine / Routine Maintenance / BMG / 06 - 06 / REV 3.0
Synergy Update REV 3.0 BMG 06/06