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:

QSV Service Support

Name:
Signature:

C. Wooding

Engine Development
Manager
A. Kitchen

Technical Service
Manager
R. M. Glover

ENERGY SOLUTIONS
BUSINESS
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Maintenance guide
QSV 81/91 Gas Gen-Sets

Page 2 of 16

1. Contents
1.

Contents ...............................................................................................................................................................................................2

2.

Revision ...............................................................................................................................................................................................3

3.

General remarks / Users guide.........................................................................................................................................................4

4.

Code M1 2,000 hours.....................................................................................................................................................................7

5.

Code M2 4,000 hours.....................................................................................................................................................................8

6.

Code M3 6,000 hours.....................................................................................................................................................................9

7.

Code M4 15,000 hours (Interim Service). ................................................................................................................................10

8.

Code M5 30,000 hours (Intermediate Overhaul). ...................................................................................................................12

9.

Code M6 60,000 hours (Major Overhaul). ...............................................................................................................................15

Address :
Energy Solutions Business Service Group,
Cummins, Inc.

Cummins Engine Company,

2851 State Street

Royal Oak Way South,

Columbus, Indiana 47201

Daventry,

U.S.A.

Northamptonshire
NN11 5NU
England

Telephone :

+1 812-377-5265

+44 1327 88-60-00

Fax:

+1 812-377-8214

+44 1327 88-61-96

Email:

c.bass@cummins.com

maria.l.pooler@cummins.com

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Maintenance guide
QSV 81/91 Gas Gen-Sets

Page 3 of 16

2. Revision
Issue

Date

Modification

31/07/2000

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.

21/09/2000

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.

25/01/02

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

04/04/03

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

21/12/04

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.

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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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Maintenance guide
QSV 81/91 Gas Gen-Sets

3.1

Page 5 of 16

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

Air Start Compressor (if fitted)

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

3.6

Spark Plug

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

3.7

Electronic Module Provision

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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Maintenance guide
Page 6 of 16

QSV 81/91 Gas Gen-Sets

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

Revised Strategy Plan

Service

Hours

Service

Hours

Plug re-gap

M0

750

N/A

Plug change (Denso)

Valve clearance
adjustment

M1

1500

M1

2000

M2

3000

M1

2000

Oil change

M2

3000

M2

4000

Cylinder Head replacement

M4

24000

M5

30000

Air filter change interval

M1

1500

M1/3

2000/6000

Main bearing change out

M5

30000

M6

60000

Damper fluid sampling

M4

15000

M5

30000

Damper change out

M5

30000

M6

60000

Turbo radial & axial check

Flexible drive coupling
change
Alternator bearing change
out

M2

3000

M3

6000

M6

60000

M5

30000

M6

60000

M5

30000

Piston skirt change out

M6

60000

M5

30000

Compatibility ESN's
0-374

375460

461XXX

XXXXXX

QSV81/91 14 BAR

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 Gas Gen-Sets

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

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.

4.2

Auxiliaries.

4.3

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

Analyse and record results.

4.4

Check kWe stability whilst under load.

Work duration
M1 Man Hours

4.5

Manpower

V16

V18

Parts for maintenance code : M1

Cummins
Part No.

Description

Quantity
V16

V18

4010887

Centrifugal filter paper insert

4010888

Kit, Sealing Centrifugal Filter.

AF25544

Air Filter, Primary

4098162

Spark plug

16

18

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QSV 81/91 Gas Gen-Sets

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

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

5.3

5.4

Auxiliaries.
l

Visually check electrical connections and cleanliness.

Check engine/alternator mounting bolts.

Grease alternator bearings in accordance with manufacturers instructions.

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

Work duration
M2 Man Hours

5.5

Manpower

V16

V18

Parts for maintenance code : M2

Cummins
Pt. No.

Description

Quantity
V16

V18

LF 16031

Oil filter cartridge (3420742)

3420802

Seal, O Ring

3420807

Seal, O Ring

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QSV 81/91 Gas Gen-Sets

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

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

6.3

Work duration
M3 Man Hours

Manpower

V16

V18

Parts for maintenance code : M3

Cummins
Pt. No

Description

Quantity
V16

V18

AF25545

Air Filter, Safety

4011521

Element, Crankcase Breather

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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

7.3

Auxiliaries.

Visually inspect flexible coupling on generator drive.

Visually inspect condition of Control Panel.

Visually inspect electrical connections/plugs on gen-set.

Work duration
M4 Man Hours

Manpower

V16

30

V18

32

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QSV 81/91 Gas Gen-Sets

7.4

Parts for maintenance code : M4

Cummins
Pt. No.

Description

Quantity
V16

V18

0249-0821 CPU (Back-up) Battery

0300-5795 HMI (Back-up) Battery

4011501

Kit, Sealing Charge Air Cooler Assembly

4011553

Filter, Particulate Gas Filter Element 3 DN80 (if fitted)

4011746

Kit, Sealing for Gas Circuit

4012251

Filter, Particulate Gas Filter Element 2 DN50 (if fitted)

4012487

Flexible hose, water transfer

4086588

Clamp, T bolt

10

10

4089707

Throttle Bearing Repair Kit

4917686

Extension, Ignition Coil

16

18

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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.

8.3

Take Silicon Oil Sample from Vibration Damper for analysis.

Work duration
M5 Man Hours

Manpower

V16

214

V18

242

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Page 13 of 16

QSV 81/91 Gas Gen-Sets

8.4 Parts for maintenance code : M5

Cummins
Pt. No.

Description

Quantity
V16

V18

45-0335

Alternator drive end bearing kit (Newage)

45-0336

Alternator non drive end bearing kit (Newage)

Batterie s

3336218

Seal O Ring Oil Thermostat Holder

3420884

HT water thermostat 88 o C

3421304

Oil thermostat

3421699

Connecting Rod Bearing Small End

16

18

3422446

Push rod

32

36

3423175

Ring, Retaining

32

36

TBD

3423613

LT water thermostat 52 C

3424062

Screw, Connecting Rod

64

72

3428191RX Oil pump

3428829

Blanket set, exhaust

3428937

Blanket set, exhaust

3429602

Valve tappet roller

32

36

3430252

Hose, turbo drain

3430253

Hose, turbo drain

3627961

Seal, Lip Thermostat holder HT/LT

16

18

4011430RX Exchange Cylinder Head

4011475

Damper analysis kit

4011500

Kit, Sealing Power Take-Off Cover.

4011503

Kit, Sealing Flywheel End Water Pipes.

4011504

Piston ring set

16

18

4011507

Kit, Sealing Lube Oil Cooler Assembly

4011508

Kit, Sealing Cylinder Block Inspection Covers

4011509

Exhaust manifold clamp set

4011510

Kit, Sealing Charge Air Pipes

4011513

Kit, Sealing Charge Air Cooler

4011514

Kit, Sealing Gas Pressure Regulator

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QSV 81/91 Gas Gen-Sets

Cummins
Pt. No.

Description

Quantity
V16

V18

4011516

Diaphragm Gas Regulating Valve

4011517

Kit, Sealing Safety Shutoff Valve

4011518

Valve Gas Regulating Valve

4011519

Seal, Diaphragm Gas Regulating Valve

4011526

Kit, Sealing Water Pipes

4011530

Exhaust manifold bellow set

4011531

Exhaust manifold seal

4011540

Element, Flexible Coupling Drive

4011542

Kit, Sealing Oil Pump Interface with Block

4011544

Connecting Rod Bearing Shell Set Big End

4011545

Connecting Rod Bearing Shell Set Big End

4012144RX Water pump (service exchange)

4012250

Kit, O Ring Sealing Thermostats

4012561

Skirt, Piston

16

18

4012654

Hose, turbo feed

4012655

Hose, turbo feed

4012662

Joint, Single Cylinder Head.

16

18

4025166

Turbocharger, Kit (1500rpm )

4025206

Turbocharger, Kit (1500rpm )

4025219

Turbocharger, Kit (1200rpm )

4025220

Turbocharger, Kit (1200rpm )

4089435

Cylinder liner assembly

16

18

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QSV 81/91 Gas Gen-Sets

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

9.3

M6 Man Hours

Manpower

V16

92

V18

102

Parts for maintenance code : M6

Cummins Pt.
No.

Description

Quantity
V16

V18

3336129

Crankcase degassing seal.

3420513

Camshaft bearing

18

20

3420523

Camshaft thrust washer

3420524

Intermediate gear bushing

3420525

Intermediate gear bushing

3420660

Piston cooling nozzle O-ring

16

18

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QSV 81/91 Gas Gen-Sets

Cummins Pt.
No.

Description

Quantity
V16

V18

3420921

Free-end Idler gear bushing

3421736

Vibration Damper

3428295

Oil non return valve assembly

3423104

Pin, Piston

16

18

3679139

Crankcase degassing seal.

TBD

Set, Main Bearing (sputter)

TBD

Set, Main Bearing (sputter)

4011513

Kit, Sealing Charge Air Cooler.

4011527

Kit, Seal Engine Cyl. Block

4011532

Pre-heating sealing set

4066223

Seal, Crankshaft (Flywheel End)

4089800

Piston complete (refer option) 12:1 compression ratio

16

18

4089801

Piston complete (refer option) 11.4:1 compression ratio

16

18

4089803

Piston complete (refer option) 10.5:1 compression ratio

16

18

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