1/19/2017 MaintenanceSchedule

102002MaintenanceSchedule

GeneralInformation

CAUTION

Maintenanceproceduresforgeneratorsetsystems,suchasGasSupplySystemsand
GeneratorElectricalSystems(low,medium,andhighvoltage),mustonlybeperformedby
qualified/certifiedpersonnel.Inmanyregions,accreditationtoanationallyrecognizedtrade
organizationisalsorequired.Itisnecessarytocomplywithalllocalandnationallegislation
whenperformingthesemaintenanceprocedures

CumminsInc.basesitsoildrainintervalspecificationsondutycycleandoilcontamination.This
contaminationoccursinallenginesatvaryingrates,regardlessofdesign.Oildrainintervalsare
influencedbyanumberoffactors,suchasapplication,load,dutycycle,oilbrand,andoiltype.
Usethefollowingprocedureforinformationonoilbrandsandoiltypes.RefertoProcedure018
003inSectionV.

CumminsInc.stronglyrecommendsregularoilsamplingandanalysissothattheconditionofthe
oilcanbedeterminedtobe"fitforcontinueduse".Whereregularsamplingandanalysisisnot
performed,theoilchangeintervalsdetailedinthisOperationandMaintenanceManualmustbe
reducedby50percent.Inaddition,CumminsInc.recommendsthatimmediatelypriortotheoil
change,"endoflife"oilsamplingandanalysismustbeperformedtodeterminethattheoil
contaminationwasbelowtheoilcondemnationlimitsatthetimeoftheoilchange.Usethe
followingprocedureforinformationonoilsamplingandanalysis.RefertoProcedure018003in
SectionV.

NOTE:Forenginesthatoperateinstandbyapplicationsorareoperatedforlessthan750
hours(50Hzapplications)or375hours(60Hzapplications),CumminsInc.recommends
thattheoilandfiltersarechangedannually.

OilchangeintervalsforlowBritishThermalUnit(BTU)fueledenginesaresitespecificandare
determinedfromanalysisofthefuelavailableatsite.ForfurtherinformationonlowBTUfueled
enginesoilchangeintervals,contactalocalCumminsDistributor.

ForfurtherdetailsanddiscussionofenginelubricatingoilforCumminsengines,reference
CumminsEngineOilandOilAnalysisRecommendations,Bulletin3810340.

ReferenceTable1and2orCumminsInc.recommendedoilchangeintervalsforenginesusing
standardpipelinenaturalgas.
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NOTE:Theserecommendationsapplyonlytohighhorsepowerleanburnnaturalgas
engines.Highhorsepowerdieselenginerecommendationsaredifferent.Forinformation
onhighhorsepowerdieselenginelubricatingoilrecommendations,referenceCummins
EngineOilandOilAnalysisRecommendations,Bulletin3810340.

Cylinderheadservicelifecanbeextendedonlyifthevalvestemheightsaremeasuredand
recorded,asdetailedinthismanual.Cylinderheadreplacementcanbeextendeduptoa
maximumof30,000hoursfor1500rpm/50Hzenginesand24,000hoursfor1800rpm/60Hz
engines,onlyifthevalvestemheightsremainwithintherecommendedlimitsandtheengine
exhibitsnootherperformancedegradation.Ifthevalvestemheightsarenotregularlymeasured
andrecorded,thenthecylinderheadsmustbereplacedattheintervalsspecifiedbelow.

Sparkplugservice/changeintervalspecificationsareinfluencedbyanumberoffactors,suchas
sparkplugbrandandtype,application,load,anddutycycle.ReferenceTable3andTable4for
CumminsInc.recommendedsparkplugservice/changeintervalsforenginesusingstandard
pipelinenaturalgas.

Performthemaintenanceatwhicheverintervaloccursfirst.Ateachscheduledmaintenance
interval,performallpreviousmaintenancechecksthatarerequiredforscheduledmaintenance,
withtheexceptionoftheMaintenanceProceduresatEarlyLifeInspection(250Hours).The
procedureslistedforthismaintenanceintervalaretobeperformedonlyonetime(shortlyafter
placingtheengineintoservicepriortothefirstscheduledmaintenanceinterval).

TheQSK60Genginesaredesignedtooperateonstandardpipelinenaturalgas.Reference
FuelsforCumminsEngines,Bulletin3379001,formoreinformationonfuelspecifications.
Engineoperationonfuelsoutsidethestandardspecificationforpipelinenaturalgaswillimpact
enginedurabilityandserviceintervals.Itisthecustomer'sresponsibilitytodeterminethe
application/sitespecificserviceschedulefornonpipelinenaturalgasfueledenginesbasedon
conditionmonitoring.Alternatively,contactaCumminsAuthorizedRepairLocation.

Maintenanceoforiginalequipmentmanufacturer(OEM)suppliedequipmentandcomponents
mustalsobeperformedasperthemanufacturer'srecommendations.ThemaintenanceofOEM
suppliedequipmentandcomponentsisnotdetailedinthismanual.OEMsuppliedequipment
includes,butisnotlimitedto:

Radiator
Radiatorcoolingfans
Heatexchangers
Gaspressureregulator
Engineshutoffvalve
Gassupplyprovingsystem
Gasfilterelement
Exhaustsilencer
Engineaftertreatmentsystems
Engineprelubricationpumps
Coolingsystempressurizationvessels
Airfilterelements
Alternatordrivecoupling
Engineroomorcontainerairinletfilterelements
Wasteoilreservoir.

NOTE:Followinganenginemajoroverhaulorrepair,regardlessofwhethertheengine
wasrepairedonsiteorremovedtoanexternalworkshop,theengineshouldbe

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recommissioned.ReferencetheOEMcommissioningmanualproceduresandalsousethe
followingprocedureforGasEngineStartup.RefertoProcedure307001inSectionH.

Table1:PremiumGradeLongChangeIntervalOils
MobilPegasus805,ShellMysellaXL(ShellS5N),ValvolinePremiumBlueGEOLA,
andValvolinePremiumBlueGEOMA
WithoutOil
WithOilAnalysis
Analysis
EngineModel
OilSampling OilChange
OilChangeInterval
Interval Interval
QSK60GMultiple
Upto1500hours,whilesample
Turbochargers 250hours 750hours
resultsarewithinlimits.
1500rpm/50Hz
QSK60GMultiple
Upto750hours,whilesampleresults
Turbochargers 250hours 375hours
arewithinlimits.
1800rpm/60Hz
QSK60GSingle
Turbocharger Upto1500hours,whilesample
250hours 750hours
1200rpm/60Hz resultsarewithinlimits.
1500rpm/50Hz

Table2:PremiumGradeLongChangeIntervalOils
MobilPegasus1005
WithoutOil
WithOilAnalysis
Analysis
EngineModel
OilSampling OilChange
OilChangeInterval
Interval Interval
QSK60GSingle
Turbocharger Upto1500hours,whilesampleresults
250hours 750hours
1200rpm/60Hz arewithinlimits.
1500rpm/50Hz

NOTE:Theoilfilterchangeintervalmaybedifferentthanthelubricatingoilchange
intervalsshownabove.Oilfiltersmustbechangedasspecifiedwiththe
recommendationsshowninthisprocedure.

Table3:CumminsSparkPlug,PartNumber4924504
EngineModel SparkPlugRegapInterval SparkPlugChangeInterval
QSK60G
Notrecommended Upto1500hours
1500rpm/50Hz
QSK60G
Notrecommended Upto750hours
1800rpm/60Hz

Table4:CumminsSparkPlug,PartNumber4302173

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EngineModel
Table4:CumminsSparkPlug,PartNumber4302173
SparkPlugRegapInterval SparkPlugChangeInterval
QSK60G
Upto2500hours Upto7500hours
EngineModel
1500rpm/50Hz SparkPlugRegapInterval SparkPlugChangeInterval
QSK60G
Upto2000hours Upto6000hours
1800rpm/60Hz

Forconvenience,listedbelowarethesectionnumbersthatcontainspecificinstructionsfor
performingthemaintenancecheckslistedinthemaintenanceschedule.

GeneratorModels1160GQKAandC1160N5CUsingStandardPipelineGas

MaintenanceProceduresatDailyInterval

CoolantLevelCheck
LubricatingOilLevelCheck.

MaintenanceProceduresatEarlyLifeInspection1

EmissionsTestingTest
LubricatingOilandFiltersChange
ValveStemMeasure
OverheadSet(OBC)Adjust.

MaintenanceProceduresatInterval12

LubricatingOilAnalysisTest

MaintenanceProceduresatInterval33

CoolingSystemHosesCheck
CrankcaseBreatherTubeCheck
ElectricalConnection,EngineCheck
FlexibleHoseCheck.

MaintenanceProceduresatInterval44

AirLeaks,AirIntakeandExhaustSystemsInspectforReuse
LubricatingOilandFiltersChange
OverheadSet(OBC)Adjust
SparkPlugs(NonShielded)Replace
EmissionsTestingCheck
CoilonPlugReplace(RubberBoot)

MaintenanceProceduresatInterval55

CoolantFilterChange
EngineMountsCheck
FuelLineSeals,NGCheck
GearCoverTrunnionSleeveCheck
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SupplementalCoolantAdditive(SCA)Test
ValveStemMeasure.

MaintenanceProceduresatInterval66

CoilonPlugInspectforReuse
CoilonPlugReplace(RubberBoot)
EngineClean
TurbochargerAxialClearanceMeasure
TurbochargerRadialBearingClearanceMeasure.

MaintenanceProceduresatTopEndOverhaul7

AftercoolerCheck
CamFollowerAssemblyCheck
CamshaftCheck
CoolantThermostatReplace
CoolingSystemFlush
CylinderHeadReplace
FuelLineSeals,NGReplace
GearTrainBacklash,FrontMeasure
LowTemperatureAftercooler(LTA)WaterPumpReplace
PushRodsorTubesCheck
RockerLeverAssemblyCheck
WaterPumpReplace
CoilonPlugReplace(Extension)
ChargeAirPipingReplace(OringsandTieBars)
ThrottleBodyDriverModuleIsolationGrommetsReplace.

MaintenanceProceduresatIntermediateOverhaul8

Bearings,ConnectingRodReplace
ConnectingRodReplace
CylinderLinerReplace
LubricatingOilPumpReplace
PistonRingsReplace
ThrottleBodyAssemblyReplace
TurbochargerReplace
ExhaustManifold,DryInspect.

MaintenanceProceduresatMajorOverhaul9

AftercoolerReplace
Bearings,MainReplace
Bearings,ThrustReplace
CamFollowerAssemblyReplace
CamshaftBushingsReplace
CamshaftThrustBearingReplace
CoolingSystemHosesCheck
CrankcaseBreather(External)Replace
CrankshaftSeal,FrontReplace

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CrankshaftSeal,RearReplace
ExhaustManifold,DryReplace
IdlerGear,Camshaft(LeftBank)Replace
IdlerGear,Camshaft(RightBank)Replace
IdlerGear,HydraulicPumpReplace
IdlerGear,WaterPumpReplace
LubricatingOilCoolerReplace
PistonReplace
PistonCoolingNozzleCheck
VibrationDamper,ViscousReplace.

1.250HourInterval
2.250Hoursor14DayInterval
3.750HourInterval
4.1500HourInterval
5.3000HourInterval
6.6000HourInterval
7.15,000HourInterval
8.30,000HourInterval
9.60,000HourInterval.

GeneratorModels1400GQKAandC1400N6CUsingStandardPipelineGas

MaintenanceProceduresatDailyInterval

CoolantLevelCheck
LubricatingOilLevelCheck.

MaintenanceProceduresatEarlyLifeInspection1

EmissionsTestingTest
LubricatingOilandFiltersChange
ValveStemMeasure
OverheadSet(OBC)Adjust.

MaintenanceProceduresatInterval12

LubricatingOilAnalysisTest

MaintenanceProceduresatInterval33

CoolingSystemHosesCheck
CrankcaseBreatherTubeCheck
ElectricalConnection,EngineCheck
FlexibleHoseCheck
LubricatingOilandFiltersChange
OverheadSet(OBC)Adjust
SparkPlugs(NonShielded)Replace
CoilonPlugReplace(RubberBoot).

MaintenanceProceduresatInterval44

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AirLeaks,AirIntakeandExhaustSystemsInspectforReuse
ValveStemMeasure
EmissionsTestingCheck.

MaintenanceProceduresatInterval55

CoolantFilterChange
EngineMountsCheck
FuelLineSeals,NGCheck
GearCoverTrunnionSleeveCheck
SupplementalCoolantAdditive(SCA)Check.

MaintenanceProceduresatInterval66

CoilonPlugInspectforReuse
CoilonPlugReplace(RubberBoot)
EngineClean
TurbochargerAxialClearanceMeasure
TurbochargerRadialBearingClearanceMeasure.

MaintenanceProceduresatTopEndOverhaul7

AftercoolerCheck
CamFollowerAssemblyCheck
CamshaftCheck
CoolantThermostatReplace
CoolingSystemFlush
CylinderHeadReplace
FuelLineSeals,NGReplace
GearTrainBacklash,FrontMeasure
LowTemperatureAftercooler(LTA)WaterPumpReplace
PushRodsorTubesCheck
RockerLeverAssemblyCheck
WaterPumpReplace
CoilonPlugReplace(Extension)
ChargeAirPipingReplace(OringsandTieBars)
ThrottleBodyDriverModuleIsolationGrommetsReplace.

MaintenanceProceduresatIntermediateOverhaul8

Bearings,ConnectingRodReplace
ConnectingRodReplace
CylinderLinerReplace
LubricatingOilPumpReplace
PistonRingsReplace
ThrottleBodyAssemblyReplace
TurbochargerReplace
ExhaustManifold,DryInspect.

MaintenanceProceduresatMajorOverhaul9

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AftercoolerReplace
Bearings,MainReplace
Bearings,ThrustReplace
CamFollowerAssemblyReplace
CamshaftBushingsReplace
CamshaftThrustBearingReplace
CoolingSystemHosesCheck
CrankcaseBreather(External)Replace
CrankshaftSeal,FrontReplace
CrankshaftSeal,RearReplace
ExhaustManifold,DryReplace
IdlerGear,Camshaft(LeftBank)Replace
IdlerGear,Camshaft(RightBank)Replace
IdlerGear,HydraulicPumpReplace
IdlerGear,WaterPumpReplace
LubricatingOilCoolerReplace
PistonReplace
PistonCoolingNozzleCheck
VibrationDamper,ViscousReplace.

1.250HourInterval
2.250Hoursor14DayInterval
3.750HourInterval
4.1500HourInterval
5.3000HourInterval
6.6000HourInterval
7.12,000HourInterval
8.24,000HourInterval
9.48,000HourInterval.

GeneratorModels1000GQKB,1100GQKC,1400GQKC,C995N5C,C1200N5C,C1400N5C,
C1000N6CandC1100N6CUsingStandardPipelineGas

MaintenanceProceduresatDailyInterval

Schedule3
CoolantLevelCheck
LubricatingOilLevelCheck.

MaintenanceProceduresatEarlyLifeInspection1

EmissionsTestingTest
LubricatingOilandFiltersChange
ValveStemMeasure
OverheadSet(OBC)Adjust.

MaintenanceProceduresatInterval12

LubricatingOilAnalysisTest

MaintenanceProceduresatInterval23

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OverheadSet(OBC)Adjust

MaintenanceProceduresatInterval34

CoolingSystemHosesCheck
CrankcaseBreatherTubeCheck
ElectricalConnection,EngineCheck
FlexibleHoseCheck
LubricatingOilandFiltersChange
SparkPlugs(NonShielded)Replace
TurbochargerCoolantHoses,NGInspectforReuse
TurbochargerOilDrainLineInspectforReuse
TurbochargerOilSupplyLineInspectforReuse
CoilonPlugReplace(RubberBoot).

MaintenanceProceduresatInterval45

AirLeaks,AirIntakeandExhaustSystemsInspectforReuse
LubricatingOilandFiltersChange
ValveStemMeasure
EmissionsTestingCheck.

MaintenanceProceduresatInterval56

CoolantFilterChange
EngineMountsCheck
FuelLineSeals,NGCheck
GearCoverTrunnionSleeveCheck
SupplementalCoolantAdditive(SCA)Check.

MaintenanceProceduresatInterval67

CoilonPlugInspectforReuse
CoilonPlugReplace(RubberBoot)
EngineClean

MaintenanceProceduresatTopEndOverhaul8

AftercoolerCheck
CamFollowerAssemblyCheck
CamshaftCheck
CoilonPlugReplace(Extension)
CoolingSystemFlush
CylinderHeadReplace
FuelLineSeals,NGReplace
GearTrainBacklash,FrontMeasure
LowTemperatureAftercooler(LTA)WaterPumpReplace
PushRodsorTubesCheck
RockerLeverAssemblyCheck
TurbochargerAxialClearanceMeasure
TurbochargerRadialBearingClearanceMeasure
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WaterPumpReplace
ThrottleBodyDriverModuleIsolationGrommetsReplace.

MaintenanceProceduresatIntermediateOverhaul9

Bearings,ConnectingRodReplace
ConnectingRodReplace
CylinderLinerReplace
LubricatingOilPumpReplace
PistonRingsReplace
ThrottleBodyAssemblyReplace
TurbochargerCompressorBypassControlValveReplace
ExhaustManifold,DryInspect.

MaintenanceProceduresatMajorOverhaul10

AftercoolerReplace
Bearings,MainReplace
Bearings,ThrustReplace
CamFollowerAssemblyReplace
CamshaftBushingsReplace
CamshaftThrustBearingReplace
CoolingSystemHosesCheck
CrankcaseBreather(External)Replace
CrankshaftSeal,FrontReplace
CrankshaftSeal,RearReplace
ExhaustManifold,DryReplace
IdlerGear,Camshaft(LeftBank)Replace
IdlerGear,Camshaft(RightBank)Replace
IdlerGear,HydraulicPumpReplace
IdlerGear,WaterPumpReplace
LubricatingOilCoolerReplace
PistonReplace
PistonCoolingNozzleCheck
TurbochargerReplace
VibrationDamper,ViscousReplace.

1.250HourInterval
2.250Hoursor14DayInterval
3.500Hoursor1MonthInterval
4.750HourInterval
5.1500HourInterval
6.3000HourInterval
7.6000HourInterval
8.12,000HourInterval
9.24,000HourInterval
10.48,000HourInterval.

LastModified:21Oct2016

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Copyright20002010CumminsInc.Allrightsreserved.

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