Rev: R

Energy Solutions Business Service Group

Global Maintenance Guide

For

QSV 81 & 91 Gas Gen-Sets. 14 Bar B.M.E.P 50 Hertz & 1200rpm 60 Hertz

Position: Name: Signature:

QSV Service Support C. Wooding

Engine Development Manager A. Kitchen

Technical Service Manager R. M. Glover

ENERGY SOLUTIONS BUSINESS SERVICE GROUP

Maintenance guide QSV 81/91 Gas Gen-Sets

Page 2 of 16

1. Contents
1. 2. 3. 4. 5. 6. 7. 8. 9. Contents ...............................................................................................................................................................................................2 Revision ...............................................................................................................................................................................................3 General remarks / Users guide.........................................................................................................................................................4 Code M1 2,000 hours.....................................................................................................................................................................7 Code M2 4,000 hours.....................................................................................................................................................................8 Code M3 6,000 hours.....................................................................................................................................................................9 Code M4 15,000 hours (Interim Service). ................................................................................................................................10 Code M5 30,000 hours (Intermediate Overhaul). ...................................................................................................................12 Code M6 60,000 hours (Major Overhaul). ...............................................................................................................................15

Address :
Energy Solutions Business Service Group, Cummins, Inc. 2851 State Street Columbus, Indiana 47201 U.S.A. Cummins Engine Company, Royal Oak Way South, Daventry, Northamptonshire NN11 5NU England Telephone : Fax: Email: +1 812-377-5265 +1 812-377-8214 c.bass@cummins.com +44 1327 88-60-00 +44 1327 88-61-96 maria.l.pooler@cummins.com

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QSV 81 & 91 14 B.M.E.P MG.doc

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Rev R

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Engine type
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ENERGY SOLUTIONS BUSINESS SERVICE GROUP

Maintenance guide QSV 81/91 Gas Gen-Sets

Page 3 of 16

2. Revision
Issue
K L

Date
31/07/2000 21/09/2000

Modification
Amend Gas Cylinder Head Pt. No. from 3424190 to 3428326. (Phase 1 Cylinder Head Only). Remove 1500 rpm title from guide and rename GLOBAL Maintenance Guide. Add Cylinder Head note, Centrifugal Filter note and DUPLEX Filter note in general remarks and users guide. Add DUPLEX Filter check to 1500 hr interval. Replace back up batteries in the HMI & CPU units from M3 to M2. Add confirmation of air filter differential pressure @ 3000 hr. Add cross-head adjustment operation @ 3000 hrs. Remove emissions check from 1500 hrs.

24/04/01

Added & amended part nos. Amended oil analysis time to every 500 hours. Clarified Operations to be completed at each maintenance internal. Add appendix for air compressor. Remove PH1 gas cylinder head PT No. 3428326 and add new PH1 & PH2 cylinder head part numbers, and add new part numbers for cylinder head overhaul kits in M4 change kit, contents in 4011524 to cover all thermostats. Add note in general comments for spark plug cleaning and air compressor maintenance. Remove air compressor maintenance from M2. Create 14 Bar version.M0 service included. Amended part Nos. Removed overhaul kits for both Ph1/Ph2 cylinder heads, exchange only available. Replacement of oil pump moved out to 30Khrs. Cense module moved out to 60K hrs Removal of all electronic components from scheduled maintenance, note added to advise the inclusion for a provision when pricing contracts. M4 moved from 15Khrs to 24Khrs. Main bearing change moved from M6 to M5, throttle bearing and shaft replacement added to M4. Cylinder head joint set part number change. Exhaust overhaul moved from M6 to M5. Turbo change moved from M6 to M5, turbo drain and feed hose change added to M5. Thermostat change moved from M4 to M5. CAC and oil cooler maintenance moved from M4 to M5. Exhaust blanket change added to M5. Water pump change moved from M4 to M5. Water transfer hose change added to M5. Include emissions check at M2 Removal of M0 service interval. Introduction of Denso spark plug. M1 moved from 1500>2000hrs, M2 service moved from3000hrs>4000hrs, tappet check/adjustment moved from 3000hrs>2000hrs, Cylinder head replacement moved from M4 > M5. Load factor paragraph added. M4 moved from 24000hrs down to 15000hrs. Introduction of sputter main bearings for replacement @ 60000hrs. Backward Compatibility matrix for major changes now included. Piston skirt change-out moved from M6>M5.

25/01/02

04/04/03

21/12/04

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QSV 81 & 91 14 B.M.E.P MG.doc

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Engine type
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ENERGY SOLUTIONS BUSINESS SERVICE GROUP

Maintenance guide QSV 81/91 Gas Gen-Sets

Page 4 of 16

3. General remarks / Users guide

To order parts or tools Cummins part number shall be given with Engine Serial Number (ESN)

Maintenance Guide.
The maintenance requirements for your engine depend largely on the operating conditions. The intervals of time shown in this schedule are a basis for all operations, however time between maintenance operations can vary depending on the application and duty cycle of your genset. Please refer to your Cummins distributor for a maintenance program specific to your actual requirement. Before you do anything , read carefully through the Operation and Maintenance Manual. Before removing any item, check that the system concerned has been drained and is not under pressure. After removal, immediately seal the oil, fuel and air inlets and outlets with tape, plugs, lint free cloth, etc. When replacing a damaged component that has an identifying mark for a cylinder or bearing number, note down each replacement in the engine logbook and state the reasons for replacement. After refitting , make sure that all nuts and bolts are properly tightened and locked where necessary. Before starting work on the genset, ensure that ELECTRICAL isolation procedures relevant to the installation have been carried out and that the equipment is safe to work on. Before starting work on the genset, ensure that GASEOUS Fuel isolation procedures relevant to the installation have been carried out and that the equipment is safe to work on.

(1) Maintenance Intervals This guide sets out the recommended maintenance intervals for the product. We recommend that at least the following components/consumables are monitored in order to achieve optimum performance. Your Cummins distributor will advise you on the services available.

(2) Oil Analysis

We recommend that an oil sample for condition analysis is taken at least every 250 Hrs up to 4000 Hrs at which point the engine oil and filters should be changed. This cycle is to be repeated throughout the engines life and is dependent on oil type. Please contact ESB Service Group for further advice.

(3) Load Factor

Maintenance intervals should be reviewed if prolonged low load running occurs below 60% of rated load. Please contact ESB Service Group for further advice.

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ENERGY SOLUTIONS BUSINESS SERVICE GROUP

Maintenance guide QSV 81/91 Gas Gen-Sets

Page 5 of 16

3.1

Alternator Bearings & Grease

Depending on the type and specification of the alternator fitted the Drive End and Non Drive End bearings should be greased in accordance with the manufacturers instructions. New bearings must be filled with an appropriate lubricant as instructed below. The lubricant must be a grease type of the same grade as that used during the generators original manufacture. The grease used is based on an Ester Oil Polyurea product, manufactured by KLUBER, of a type called ASONIC GHY72. This grease can be recognised by its whitish-beige colour and its stiff consistency. It has been chosen for its superior lubricating properties under arduous conditions, and to provide the bearing with these lubricating characteristics this grease must not be mixed with any other type. It is important that the correct quantity of grease is used for the initial fill for new bearings, and for periodic re -lubrication with a grease gun during planned maintenance.

3.2

Centrifugal Filter Assembly

Ensure that the build up of sludge does not exceed 15mm in thickness. If a build-up of 15mm or more occurs before 2000 hrs then consideration should be given to cleaning the assembly earlier.

3.3

Turbochargers

Please note that all turbochargers can be ordered under the same number, but be aware that the charge air inlet volute orientation differs with the position each turbocharger is on the engine. These can be ordered separately at the customers discretion if required to be replaced. The volutes have their own unique part number.

3.4

DUPLEX Filter Module

Ensure that the change over valve on the DUPLEX filter module is set for the left bank or right bank before starting the engine. After 2000hrs the change over handle must be moved to the unused bank. Change the oil and filters every 4000 hrs. This cycle is to be repeated throughout the engines life.

3.5 3.6 3.7

Air Start Compressor (if fitted) Spark Plug Electronic Module Provision

Please note that maintenance of the air compressor is addressed in a separate maintenance guide.

Please note that all spark plugs must changed be at 2000 hrs to optimise engine performance.

With electronic modules having an indeterminate life cycle, they no longer form part of the regular maintenance schedule. Consideration needs to be given to these items when costing any maintenance contract.

3.8

Maintenance of Auxiliary Components (Where Applicable)

Auxiliaries include, air compressor, boiler, feed water/circulation pumps, radiators, air conditioners and other items. The Maintenance of these auxiliaries needs to be considered on an individual application and project basis

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ENERGY SOLUTIONS BUSINESS SERVICE GROUP

Maintenance guide QSV 81/91 Gas Gen-Sets

Page 6 of 16

3.9

Service Strategy Compatibility Schedule Matrix

To order parts please refer to the Bill of Material for the specific Engine Serial Number (ESN). Evolutionary changes within the build structures are documented on the QuickServe Online system.

Pre Q1 2005 Strategy EQUIPMENT/OPERATION QSV81/91 14 BAR Plug re-gap Plug change (Denso) Valve clearance adjustment Oil change Cylinder Head replacement Air filter change interval Main bearing change out Damper fluid sampling Damper change out Turbo radial & axial check Flexible drive coupling change Alternator bearing change out Piston skirt change out M0 M1 M2 M2 M4 M1 M5 M4 M5 M2 M6 M6 M6 750 1500 3000 3000 24000 1500 30000 15000 30000 3000 60000 60000 60000 Service Hours

Revised Strategy Plan Service Hours

Compatibility ESN's 0-374 375460 461XXX XXXXXX

N/A M1 M1 M2 M5 M1/3 M6 M5 M6 M3 M5 M5 M5 2000 2000 4000 30000 2000/6000 60000 30000 60000 6000 30000 30000 30000

Backward compatible Not backward compatible

This document contains information, which is the exclusive property of Cummins Energy Solutions Business Service Group. It cannot be duplicated, entirely or partly without the special written authorisation by the company, who reserves the right to modify or change this guide without prior notification to the customer. The information within this document has no reference to any guarantee of component life.

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QSV 81 & 91 14 B.M.E.P MG.doc

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ENERGY SOLUTIONS BUSINESS SERVICE GROUP

Maintenance guide QSV 81/91 Gas Gen-Sets

Page 7 of 16

4. Code M1 2,000 hours

Note: All checks, inspections, maintenance and repair must be carried out in accordance with the Operations and Maintenance manual.

4.1
l l l

Operations to be completed.
Remove Centrifugal Filter Cover, dismantle rotor and clean, replace paper insert. Replace Spark Plugs. Ensure that only one pair of oil filters are in use by confirming that DUPLEX filter module valve is either fully to the A or B bank. The change over handle is factory set to the A bank for the first 2000hrs. At 2000hrs this must be changed over to the B bank. Please ensure that handle is not left in the middle position. Check and adjust cross head and rocker arm to valve tip clearance. Replace Primary Air filters.

l l

4.2

Auxiliaries.
Dismantle and clean air starter pressure regulator assembly, check condition of diaphragm, replace if necessary. (if fitted)

4.3

Analyse and record results.

Check kWe stability whilst under load.

4.4

Work duration
M1 Man Hours V16 V18 7 8 Manpower 1 1

4.5

Parts for maintenance code : M1

Description V16 Quantity V18 1 1 4 18

Cummins Part No. 4010887 4010888 AF25544 4098162

Centrifugal filter paper insert Kit, Sealing Centrifugal Filter. Air Filter, Primary Spark plug

1 1 4 16

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ENERGY SOLUTIONS BUSINESS SERVICE GROUP

Maintenance guide QSV 81/91 Gas Gen-Sets

Page 8 of 16

5. Code M2 4,000 hours

Note: All checks, inspections, maintenance and repair must be carried out in accordance with the Operations and Maintenance manual.

5.1

Operations to be completed.

All M1 operations to be completed in conjunction with the following M2 operations.

l l

Inspect all flexible hoses for deterioration. (Replace if required) Drain lubricating oil, replace lubricating oil filters and renew lubricating oil. Ensure Change over Handle is set to A Bank after oil and filter change.

5.2

Auxiliaries.
l l l

Visually check electrical connections and cleanliness. Check engine/alternator mounting bolts. Grease alternator bearings in accordance with manufacturers instructions.

5.3

Analyse and record.

Sample of cooling water, check anti-freeze and inhibitor concentration Confirm differential pressure alarm status for air filters is clear on the PCC panel/HMI panel. Emissions check for O2 and Nox using gas analyser

5.4

Work duration
M2 Man Hours V16 V18 6 6 Manpower 1 1

5.5

Parts for maintenance code : M2

Description V16 Quantity V18 4 4 8

Cummins Pt. No. LF 16031 3420802 3420807

Oil filter cartridge (3420742) Seal, O Ring Seal, O Ring

4 4 8

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Maintenance guide QSV 81/91 Gas Gen-Sets

Page 9 of 16

6. Code M3 6,000 hours

Note: All checks, inspections, maintenance and repair must be carried out in accordance with the Operations and Maintenance manual.

6.1

Operations to be completed.

All M1 operations to be completed in conjunction with the following M3 operations.

l l l l l

Replace Crankcase Ventilation Re -circulator element. Check and clean the Gas Filter Visual inspection of cam lobes, push rods and tappet roller condition Replace Safety Air filters. Check axial and lateral clearances on turbochargers

6.2

Work duration
M3 Man Hours V16 V18 3 3 Manpower 1 1

6.3

Parts for maintenance code : M3

Description V16 Quantity V18 4 1

Cummins Pt. No AF25545 4011521 Air Filter, Safety

4 1

Element, Crankcase Breather

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Maintenance guide QSV 81/91 Gas Gen-Sets

Page 10 of 16

7. Code M4 15,000 hours (Interim Service).

Note: All checks, inspections, maintenance and repair must be carried out in accordance with the Operations and Maintenance manual.
Remark: - This work must be carried out by Cummins trained and qualified personnel..

7.1

Operations to be completed.

All M4 operations to be completed.

Check condition of flexible hoses in lube oil circuit. (replace if required) Check condition of cooling circuit pipe-work. Check condition of hose connection between Turbocharger inlet and Air Filter box. (replace if required) Replace HT/LT water transfer hoses and clamps. Replace seals and hoses in the gas line. Replace Gas Filter element. Replace cooling water, anti-freeze and inhibitor Replace throttle shafts, bearings and seals Replace ignition coil extensions Replace HMI (Back-up) Battery Replace CPU (Back-up) Battery

7.2

Auxiliaries.
Visually inspect flexible coupling on generator drive. Visually inspect condition of Control Panel. Visually inspect electrical connections/plugs on gen-set.

7.3

Work duration
M4 Man Hours V16 V18 30 32 Manpower 2 2

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Maintenance guide QSV 81/91 Gas Gen-Sets

Page 11 of 16

7.4

Parts for maintenance code : M4

Description V16 Quantity V18 1 1 1 1 1 1 5 10 2 18

Cummins Pt. No. 0249-0821 CPU (Back-up) Battery 0300-5795 HMI (Back-up) Battery 4011501 4011553 4011746 4012251 4012487 4086588 4089707 4917686

1 1 1 1 1 1 5 10 2 16

Kit, Sealing Charge Air Cooler Assembly Filter, Particulate Gas Filter Element 3 DN80 (if fitted) Kit, Sealing for Gas Circuit Filter, Particulate Gas Filter Element 2 DN50 (if fitted) Flexible hose, water transfer Clamp, T bolt Throttle Bearing Repair Kit Extension, Ignition Coil

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Maintenance guide QSV 81/91 Gas Gen-Sets

Page 12 of 16

8. Code M5 30,000 hours (Intermediate Overhaul).

Note :All checks, inspections, maintenance and repair must be carried out in accordance with the Operations and Maintenance manual.

8.1

Operations to be completed.

All M1, M3 and M4 operations to be completed in conjunction with the following M5 operations. Remark: This work must be carried out by Cummins trained and qualified personnel.
Replace liners. Replace cylinder heads (service exchange). Replace piston rings. Replace piston skirts Replace connecting rod bearing (Small End). Replace connecting rod bearing (Big End). Replace oil pump . (service exchange) Replace valve tappet roller assemblies and push rods. Replace seals within Gas Pressure Regulator and Shutoff Valve. Replace the HT, LT and Oil Thermostats. Replace Water Pump (service exchange) Clean and check Lube Oil Cooler. Clean and check Charge Air Cooler. Replace Turbo Drain and feed hoses. Replace Exhaust blanket set. Replace turbochargers, (set of four). Overhaul, exhaust manifold assembly and replace bellows units. Replace Alternator Bearing Set, check and clean windings Replace flexible drive and re -align engine/alternator in accordance with manufacturers instructions. Check backlash and end-float on gear train.

8.2

Analyse and record.

Take Silicon Oil Sample from Vibration Damper for analysis.

8.3

Work duration
M5 Man Hours V16 V18 214 242 Manpower 2 2

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Maintenance guide QSV 81/91 Gas Gen-Sets

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8.4 Parts for maintenance code : M5

Cummins Pt. No. 45-0335 45-0336 TBD 3336218 3420884 3421304 3421699 3422446 3423175 3423613 3424062

Description V16 Alternator drive end bearing kit (Newage) Alternator non drive end bearing kit (Newage) Batterie s Seal O Ring Oil Thermostat Holder HT water thermostat 88 o C Oil thermostat Connecting Rod Bearing Small End Push rod Ring, Retaining LT water thermostat 52 C Screw, Connecting Rod
o

Quantity V18 1 1 4 3 2 3 18 36 36 2 72 1 0 1 36 2 2 4 18 1 1 1 18 1 1 1 1 1 1

1 1 4 3 2 3 16 32 32 2 64 1 1 0 32 2 2 4 16 1 1 1 16 1 1 1 1 1 1

3428191RX Oil pump 3428829 3428937 3429602 3430252 3430253 3627961 Blanket set, exhaust Blanket set, exhaust Valve tappet roller Hose, turbo drain Hose, turbo drain Seal, Lip Thermostat holder HT/LT

4011430RX Exchange Cylinder Head 4011475 4011500 4011503 4011504 4011507 4011508 4011509 4011510 4011513 4011514 Damper analysis kit Kit, Sealing Power Take-Off Cover. Kit, Sealing Flywheel End Water Pipes. Piston ring set Kit, Sealing Lube Oil Cooler Assembly Kit, Sealing Cylinder Block Inspection Covers Exhaust manifold clamp set Kit, Sealing Charge Air Pipes Kit, Sealing Charge Air Cooler Kit, Sealing Gas Pressure Regulator

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Maintenance guide QSV 81/91 Gas Gen-Sets

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Cummins Pt. No. 4011516 4011517 4011518 4011519 4011526 4011530 4011531 4011540 4011542 4011544 4011545

Description V16 Diaphragm Gas Regulating Valve Kit, Sealing Safety Shutoff Valve Valve Gas Regulating Valve Seal, Diaphragm Gas Regulating Valve Kit, Sealing Water Pipes Exhaust manifold bellow set Exhaust manifold seal Element, Flexible Coupling Drive Kit, Sealing Oil Pump Interface with Block Connecting Rod Bearing Shell Set Big End Connecting Rod Bearing Shell Set Big End 1 1 1 1 1 1 1 1 1 1 0 1 4 16 2 2 16 0 4 4 0 16

Quantity V18 1 1 1 1 1 1 1 1 1 0 1 1 4 18 2 2 18 4 0 0 4 18

4012144RX Water pump (service exchange) 4012250 4012561 4012654 4012655 4012662 4025166 4025206 4025219 4025220 4089435 Kit, O Ring Sealing Thermostats Skirt, Piston Hose, turbo feed Hose, turbo feed Joint, Single Cylinder Head. Turbocharger, Kit (1500rpm ) Turbocharger, Kit (1500rpm ) Turbocharger, Kit (1200rpm ) Turbocharger, Kit (1200rpm ) Cylinder liner assembly

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Maintenance guide QSV 81/91 Gas Gen-Sets

Page 15 of 16

9. Code M6 60,000 hours (Major Overhaul).

Note: All checks, inspections, maintenance and repair must be carried out in accordance with the Operations and Maintenance manual.

9.1

Operations to be completed.

All M1, M2, M3, M4 and M5 operations to be completed in conjunction with the following M6 operations.
Remark: This work must be carried out by Cummins trained and qualified personnel. Replace Piston Pin C/W Circlips. Replace camshaft bearings and thrust washers. Replace Free-end Idler Gear Bushing Replace Intermediate Gear Bushing Replace vibration damper. Replace crankshaft main bearings and thrust washers (sputter) Replace o il non return valve assembly. Replace rear crankshaft oil seal. Replace piston and rings complete. Replace p iston cooling jet O rings. Inspect and clean CAC core.

9.2

Work duration
M6 Man Hours V16 V18 92 102 Manpower 2 2

9.3

Parts for maintenance code : M6

Description V16 3336129 3420513 3420523 3420524 3420525 3420660 Crankcase degassing seal. Camshaft bearing Camshaft thrust washer Intermediate gear bushing Intermediate gear bushing Piston cooling nozzle O-ring 2 18 4 4 2 16 Quantity V18 2 20 4 4 2 18

Cummins Pt. No.

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Cummins Pt. No. 3420921 3421736 3428295 3423104 3679139 TBD TBD 4011513 4011527 4011532 4066223 4089800 4089801 4089803

Description V16 Free-end Idler gear bushing Vibration Damper Oil non return valve assembly Pin, Piston Crankcase degassing seal. Set, Main Bearing (sputter) Set, Main Bearing (sputter) Kit, Sealing Charge Air Cooler. Kit, Seal Engine Cyl. Block Pre-heating sealing set Seal, Crankshaft (Flywheel End) Piston complete (refer option) 12:1 compression ratio Piston complete (refer option) 11.4:1 compression ratio Piston complete (refer option) 10.5:1 compression ratio 2 2 1 16 2 0 1 1 1 1 1 16 16 16

Quantity V18 2 1 1 18 2 1 0 1 1 1 1 18 18 18

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