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

CUMMINS CORPORATE TRAINING
G / Maintenance / BMG / 01 - 01 / REV. 03.