QSV 81/91 Series Gas Engines
Module 8 - Maintenance
Cummins Corporate Training
QSV Gas CUMMINS CORPORATION
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Maintenance Module
Learning Objectives
After completing this module you will be familiar with the maintenance
intervals on the QSV Gas engine and will be competent to carry out
specific maintenance tasks which are additional to QSV Diesel
maintenance.
Agenda
☛ Maintenance Records.
☛ General Maintenance Schedule.
☛ Spark Plug Maintenance.
☛ Spark Plug Replacement.
☛ Valve & Ignition Timing.
☛ Gas Filter Maintenance.
☛ Locate & Identify key Maintenance points.
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QSV Gas
Integrated, easy to maintain design
Coil on Plug Integrated
Design Lube - Oil
Module
Driven Pumps
Module Crank and
Camshaft
Inspection
covers
Nodular Cast Control /
Iron Ignition
Construction System
Access Panel
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Operation & Maintenance Record
- Refer to handout example - CW180 OPERATION DATA RECORD
CUSTOMER
• Good record keeping is SERIAL NUMBER
ENGINE TYPE
APPLICATION
CW180OC QSV Gas Operation Data Record
Date
essential to identify trends and Running hours
Engine speed
Power
spot potential problems early. Engine room temperature
Atmosphere pressure
Description Sensor Unit TYpe
HT coolant temperature (engine outlet) 3865346 °C PT100
• Use O & M records to assist LT coolant temperature (RAS outlet)
Temp. Lub oil temperature after cooler
Compressor inlet temperature (free end)
3865346
3865346
3865345
°C
°C
°C
PT100
PT100
PT100
with trouble-shooting.
Compressor inlet temperature (flywheel) 3865345 °C PT100
Intake manifold temperature 3865345 °C PT100
HT coolant pressure 3865337 bar 4_20mA
LT coolant pressure 3865337 bar 4_20mA
• Make entries daily or more
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
Intake restriction pressure (flywheel) 3865345 bar 4_20mA
frequently dependant on hours Manifold absolute pressure
Crankcase pressure
Exhaust gas temperature
3160404
?
3330147
bar
bar
°C
4_20mA
4_20mA
Thermocouple K
run. 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
• Log separately details in date Exhaust gas temperature
Exhaust 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 gas temperature 3330147 °C Thermocouple K
Exhaust gas temperature 3330147 °C Thermocouple K
Exhaust gas temperature 3330147 °C Thermocouple K
temp. Exhaust gas temperature 3330147 °C Thermocouple K
parts replaced or changes in 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
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QSV Gas Maintenance Schedule
FOR TRAINING USE ONLY
Engine type 1200 rpm 1500 rpm
QSV Gas
COP : Continuous Power rating, No overload available
Unlimited number of hour per year V16 1136 kWm 1424 kWm
Time between overhaul : 32000 hours V18 1278 kWm 1602 kWm
Code 0 5 10 20 60 120 240
Group Controls and maintenance operations Every Every Every Every Every Every Every Every Every
day week month 500 h 1000 h 2000 h 8000 h 16000 h 32000 h
Typical Schedule Header- Refer to Handout
The following maintenance schedule example covers engines which are rated for
continuous power (COP) 1200/1500 rpm.
Always check that the maintenance chart used matches the engine type, duty rating and
speed. Refer to the operation and maintenance manual for full listings.
Cummins operate a service code system 5, 10 , 20 dependant on the number of hours run
as shown. When undertaking maintenance always carry out all operations listed up to and
including the code required.
A major overhaul is estimated at 60,000 hrs for QSV Gas Engines.
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Maintenance Schedule (1 of 3)
Example shown for QSV Gas 1200 & 1500rpm engines.
Code 0 5 10 20 60 120 240
Group Controls and maintenance operations Every Every Every Every Every Every Every Every Every
day week month 500 h 1000 h 2000 h 8000 h 16000 h 32000 h
Clean the engine
Find out leakages and defects
Replace flexible coupling rubbers
Check camshaft, push rods and timing gears
Replace valve tappet assy
Replace push rod
Check and adjust valve clearance
Overhaul of cylinder head
Check turbochargers bearing clearances
Engine Turbochargers minor overhaul
Turbochargers major overhaul
Overhaul of exhaust manifold
Check cylinders (with an endoscop)
Replace cylinder liners
Replace pistons
Replace pistons rings
Replace con rod bearings (big end)
Replace con rod bushing (small end)
Replace crankshaft gaskets
Replace crankshaft bearings and thrust bearings
Replace camshaft bearings and thrust bearings
Replace intermediate gears bearings & thrust bearings
Replace free end intermediate gear bearing
Check all gears and replace if necessary
Replace all seals
Maintenance Schedule (2 of 3)
Example shown for QSV Gas 1200 & 1500rpm engines.
Code 0 5 10 20 60 120 240
Group Controls and maintenance operations Every Every Every Every Every Every Every Every Every
day week month 500 h 1000 h 2000 h 8000 h 16000 h 32000 h
Check lub oil level
Take oil sample for analysis
Replace lub oil cartridge
Replace lub oil
Inspect lub oil hoses and flexibles
Replace lub oil hoses and flexible
Lub oil Clean oil nozzles and jets
Circuit Clean centrifugal filter
Replace lub oil thermostatic valves
Replace thermostatic valve holders
Repace lub oil retaining valve assy
Clean lub oil cooler
Check lub oil pump
Replace lub oil pump
Check cooling water level
Check water treatment
Replace cooling water
cooling Inspect cooling water pipes
Water Replace water thermostatic valves
circuit Replace thermostatic valve holders
Clean water exchangers
Check water pump
Replace water pump
Only after the first period
Maintenance Schedule (3 of 3)
Example shown for QSV Gas 1200 & 1500rpm engines.
Code 0 5 10 20 60 120 240
Group Controls and maintenance operations Every Every Every Every Every Every Every Every Every
day week month 500 h 1000 h 2000 h 8000 h 16000 h 32000 h
Check air filters
Charge Clean air filters As soon as colmation signal appears
air Replace air filters Depending of the number of cleaning
Overhaul of air pipes
Clean charge air cooler
Check flexibles
Starting Check starter gear
device Overhaul of starting pressure regulator
Check and lubricate sun and planet gear with greasse
Damper Replace the damper
Clean gas filter
Replace gas filter
Gas line Replace gas line seals and flexibles
Replace safety devices for gas line
Overhaul of pressure regulator and discharge valve
Safety Check safety devices and electrical connections
Check all engine parameters
Check all control system parameters
Control Check all control system tables
system Calibration of lambda sensor
Replace lambda sensor
Replace wiring harness
Check spark plugs
Ignition Replace spark plugs
system Check static spark timing
Check ignition coil
Replace ignition coil
Spark Plug Care
• Ensure every spark plug is clean.
(Cummins Pt.No 4010981)
• Do NOT assume new plugs are clean or set
• Clean by rubbing porcelain with alcohol (mineral
spirits) on a soft cloth.
• Take care not to touch the porcelain extension of the Pt. No 4010981
spark plug.
• Never insert using a socket with a rubber insert, this Cleanliness is vital
will soil a clean plug. (EHT)
• Check plug with care using non-metallic, clean Never Handle
feeler gauges, to avoid damaging the special Porcelain Part of the
Plug !
(platinum) electrode coating.
• Always replace at the recommended service interval PLUG GAP = 0.2mm
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Changing Spark Plugs
• Remove valve cover single bolt fixing and
lift off cover and COP.
• Remove / Install using a magnetic or clip
type spark plug socket only.
• Install new plug and gasket, torque to
50Nm (38 ft-lbs.). COP/Valve cover ass’y
• Inspect coil boot for damage or signs of
tracking, replace if necessary
• Apply small amount of dielectric grease
inside COP boot (prevents plug body
sticking). Excess attracts dirt !
• Slide COP/Valve cover assembly into
spark plug well, tighten valve cover fixing.
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Valve timing
The valve timing procedure may be carried out as detailed for the QSV Diesel with
the following amendments:
• As no pump lobe exists on the gas camshaft, valve timing is referenced to the
exhaust lobe. In order to achieve the correct exhaust lobe position (rising) the
cylinder must be timed at BDC position. As a TDC tool will not track BDC position
we must determine TDC of another cylinder that corresponds to BDC of the
cylinder being set.
• Use 5.3 mm (+/- 0.08) exhaust cam lift at 14 degrees BBDC firing stroke. This
equals 84 or 93mm in DOR when measured on the largest 683 or 760mm flywheel
circumference (V16/18 data). OR, use inclinometer. Then check 7.44mm +/- 0.07 at
BDC.
• Remember to check timing between banks is not 180º out of phase. Consecutive
firing order B1...A1 etc. for standard rotation.
• When checking timing just set cylinder to BDC using table (use flywheel pointer
to select corresponding TDC). Then check cam lift as stated for BDC above.
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Valve timing
TBC and BDC cylinder relationship;
BDC TDC BDC TDC
B1 B4 A1 B3
A5 B6
A1 A4 A9 B8
B8 B5 B1 A2
B5 A4
A8 A5 B9 A7
V16 - Only V18 - Only
NOTE: If the camshaft has been removed or split, then timing should be checked on one
exhaust lobe of each section of the camshaft to check accuracy of alignment and that the
parts have been assembled correctly.
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Ignition Timing
Cam sensor ‘clocks’ firing or exhaust cycle. Set tooth
position by eye, no other adjustments required. 90 15º (After)
1st Hole after 2 Speed
Missing Holes 60º.
A1 TDC Sensor
(B1 TDC Position) Position
Tooth
M 22 x 1.5
2 Missing Holes
Tooth position can be
set by eye.
ENGINE
ROTATION Spark timing is set
electronically and can
only be altered by
SSM 558 changing the spark
MCM 700
timing sensor timing offset using
speed sensor
B-Bank side Caltherm.
A-Bank side
72 - 2 Hole Pattern
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Ignition Timing Check
• Engine stopped. Mark flywheel for 20º BTDC, A1 and B1. Set up
• Set C_STIDVA=20. (timing for CALTERM screen with variable names given below.
manual advance). Record Values CALTERM Value, Value, Acceptible
While Cranking Name Bank A, Bank B, value
Engine cranking cranking
• Set C_STMSEL = 1. this will turn Screen 3:
off maps and force timing to 20º. 1 Engine Speed ENGRPM 100-300
• Start engine, go to rated speed, no 2 Intake Manifold ANMAP 5-14 psia
Pressure
load. 3 cyl select (1=manual C STMSEL set = 1
select, 0=run on this test only!
• Check timing (timing light or other maps...reset to zero
procedure) with engine running at fater use!)
4 timing value used C STIDVA set = 20
rated speed, no load. with C STMSEL
5 Timing Map Offset C STMOFF record value
• Check both cylinders A1, B1.
6 Ignition Timing Cal. C STIGDL 75 micro-sec
• If timing is not the same as reading
7 Timing offset, indiv. C STCOF0 N/A N/A N/A
on CALTERM, adjust C_STIGDL. cylinder...replace 0
w. desired cylinder
• Reset C_STMSEL= 0 on, both number. Leave at
banks. zero for now.
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Gas Filter Inspection
• Clean and Inspect every 6,000 hours. Filter element can only be
installed into the housing one
• Isolate gas at supply, ensure gas valve way round.
switch is ‘OFF’ to isolate filter
section.
• Follow safety rules and make safety
checks.
• Vent filter line, remove cover screws.
• Look for physical damage or wetness.
• Replace every 15,000 hours, note
direction of gas flow.
• Always replace filter cover O-ring
Direction of
before fitting cover, torque to 15Nm.
Gas Flow
(Filter + O-ring kit, Part No. 4011553)
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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.
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Practical Exercise
• Locate and Identify the following on the engine:
✔
☛ Twin solenoid gas valve (make adjustment of High / Low
pressure settings).
☛ CENSE module.
☛ Proact actuators and driver modules.
☛ MCM 700 module.
☛ Service connector.
☛ Service connector selector switch.
☛ Exhaust thermocouple power converters.
☛ Sub Systems Module 558 (SSM558).
☛ Coil on Plug Assembly (COP) - Identify LT feed pin.
☛ Capacitor Coil Driver (CCD).
☛ Oxygen Sensor.
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Practical Exercise
• Locate and Identify the following on the engine:
✔
☛ Gas / Air Mixer.
☛ Gas Mass Flow Sensor (GMF).
☛ Duty Cycle Valve (FloTech).
☛ Speed Sensor.
☛ Engine Position Sensor.
☛ Ambient Pressure Sensor.
☛ Ambient Temperature Sensor.
☛ A and B-Bank Identification Connectors - confirm linking
correct.
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Module 8 - Maintenance
End
Cummins Corporate Training
QSV Gas CUMMINS CORPORATION
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G / Maintenance / BMG / 01 - 01 / REV. 03.
