QSV Oil Analysis Guidelines, Rev. 02

Service/Parts Date:
02.02.2009
Application:
Generator Unit
Topics
No: Fuel Type: File Group
ESB-SPB 22.2 Natural Gas 07
CUMMINS CONFIDENTIAL
ESB Internal Circulation, Approved Distributors and Partners Only
Author: A. Kitchen
Subject: Oil Analysis Guidelines
Publications Affected by This Service/Parts Topic

Engine Operation and Troubleshooting Shop Other
Maintenance and Repair
QSV81G/91G 4021313
NOTE: Publications identified as Other include the following: Parts

Catalogue, Wiring Diagram.
This Service Bulletin applies to QSV81G/QSV91G 14 and 16Bar BMEP,

QSV91G 18Bar BMEP 2MWe and QSK60G Gensets as indicated in the table
below. The bulletin also details condemning limits for the K38 Natural Gas
Power Generation Product manufactured in India.
Freq. Genset Model Covered By

Engine Speed (rpm) Model Rating
(Hz) Service Topic
QSV 91G 1200 60 1250GQNA Yes
QSV 91G 1500 50 1540GQNA Yes
QSV 91G 1500 50 1750GQNB-50 Yes
QSV 91G 1500 (gearbox) 60 1750GQNB-60 Yes
QSV 91G 1500 50 2000GQNC-50 Yes
QSV 91G 1502 (gearbox) 60 2000GQNC-60 Yes
QSV 81G 1200 60 1200GQMA Yes
QSV 81G 1500 50 1370GQMA Yes
QSV 81G 1500 50 1570GQMB Yes
QSK 60G 1200 60 1000GQKB Yes
QSK 60G 1200 60 1100GQKC Yes
QSK 60G 1500 50 1160GQKA Yes
QSK 60G 1500 50 1400GQKC Yes
QSK 60G 1800 60 1400GQKA Yes
QSK 19G 1500 50 315GFBA No
QSK 19G 1800 60 330GFBA No
Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

Cummins Engine Co. Ltd., Daventry, Northants, England, NN11 8NU
Registered Office: Unit 1-B Uniongate, Ridgeway Trading Estate, Iver, Buckinghamshire SL0 9HX, England
Registered No. 573951 England
Copyright 2007 Cummins Inc.
All rights reserved Page 1 of 7
Service/Parts Date:
02.02.2009
Application:
Generator Unit
Topics
Warranty Impact
Regular Oil Analysis forms a very important part of the engines service and
maintenance regime. The oil change intervals quoted in the relevant
Operation and Maintenance Manuals are maximum oil change intervals and
are subject to the oil analysis results.
It is important to understand that the Genset must be serviced and maintained

in accordance to Cummins published recommendations. Whilst failing to carry
out regular oil analysis will not void Cummins warranty, it must be understood
that Cummins will deny coverage for any corrective work or progressive
damage that Cummins alone determines was caused by not undertaking
regular Oil Analysis as well as failure to carry out appropriate action as
indicated by the Oil Analysis results, or by continuing to operate an engine
with an oil that is deemed not fit for further use.
The information contained within this Service Bulletin does not authorise TRP
or Campaign practices.
The purpose of this Service Bulletin is to define Cummins guidelines for

the oil analysis of Natural Gas fuelled Gensets. Specifically, it defines the
oil analysis interval, as well as the caution limits and condemning limits for
the engine oil.

Service/Parts Date:
02.02.2009
Application:
Generator Unit
Topics
Document Overview
The purpose of this Service Bulletin is to define Cummins guidelines for the oil
analysis of Natural Gas fuelled Gensets. Specifically, it defines the oil analysis
interval, as well as the caution limits and condemning limits for the engine oil.
This Service Bulletin does not define an approval procedure for new oil selection;
for oil approval refer to Cummins Engineering Standard 14615. This Bulletin
assumes that the oil being used has already been approved by Cummins Inc.
This Service Bulletin does not aim to give advice on causes of oil deterioration or
corrective action.
Definitions
Caution Limit: An indication that the engine oil is approaching end of life.
Condemn Limit: An indication that the engine oil has reached its end of life. This
level must not be exceeded. Continued operation beyond the Condemning
Limit may cause serious engine damage and invalidates the engines
warranty.
Oil Analysis
The variation in oil brands, base stocks, additive packages, gas quality, climate
conditions, Genset load factors, engine condition and other influences
necessitate the use of Oil Analysis to maximize life cycle cost and engine
reliability.
The intervals, methods and limits described below are based on operating
experience, oil supplier guidelines, oil analysis laboratory guidelines and other
data sources. Specific site experience and the use of more advanced analysis
techniques may allow scope for adjustments to the recommendations below.
However, any change must be approved through Cummins Inc before being
implemented.
Failure to follow these guidelines may cause engine damage and invalidate
the engines warranty.
Oil Sample Frequency
Natural Gas Fuelled Generator Sets
Until the oil change interval is established, the oil analysis frequency should be at
a maximum of each 250 operating hours or 6 months, whichever occurs first.
Once the oil change interval has been established, the analysis frequency may
Service/Parts Date:
02.02.2009
Application:
Generator Unit
Topics
be extended to a maximum of 20% of the change interval, or 6 months,

whichever occurs first.
Low Btu (Landfill and Biogas Fuelled) Applications
For Low Btu (Landfill and Biogas Fuelled) applications, the oil analysis frequency
should be at a maximum of each 168 operating hours or every two weeks,
whichever occurs first.
IMPORTANT NOTE: Where regular Oil Analysis is not performed, then the oil
change interval published in the appropriate engine Operation and Maintenance
manual must be reduced by 50%.
NOTE: Where regular Oil Analysis is not performed, then an end of oil life
analysis must be carried out immediately prior to each oil change to determine
that the oil was within the limits (shown on Table 1 below) and still fit for use.
Oil Sample Baseline
As key elements of the Oil Analysis are based on a change from fresh oil it is
essential that a baseline fresh oil sample is first established. This must be of the
oil supplier, oil grade and source used in the engine and analysed by the analysis
laboratory chosen for the used oil analysis. This baseline should normally be
managed between the oil supplier and the analysis laboratory, but this should not
be presumed. Fresh oil sample analysis must be repeated for any oil formulation
or analysis change.
Oil Sampling
The used oil sample taken for analysis must be representative of the oil in the
engine. Use the following guidelines when collecting used oil samples:
Bring the engine up to normal operating temperature prior to

sampling. This will ensure the representative contaminant levels
are in the sample.
Take the used oil sample before adding any fresh oil to the engine.
Take the used oil sample either directly from the engines sump or
from a suitable sample point before the oil filters.
Always collect the oil in a dry, clean container and collect a
minimum of 0.125 Litre of oil.
The following information should also be supplied:
Engine make, type and serial number.

Type of use, duty cycle and fuel type.
Sample date, sample conditions (intermediate, at oil change, etc.).
Service/Parts Date:
02.02.2009
Application:
Generator Unit
Topics
Engine oils, oil hours, hours since last analysis and oil top-up since
last analysis.
Oil manufacturer, type and viscosity.
Note: Oil manufacturers/suppliers can usually provide suitable oil analysis kits.
Table 1: Oil Caution and Condemning Limits
QSV Engine Range:
Engine Characteristic Units Caution Limit Condemning Limit

Model
QSV TBN g(KOH)/kg 40% reduction from 50% reduction from
fresh oil fresh oil
QSV TAN g(KOH)/kg 2.0 increase from 2.5 increase from fresh
fresh oil oil
QSV Oxidation Abs/cm 15 20
QSV Nitration Abs/cm 10 15
QSV Viscosity Cst at 100 C 2.0 increase from 2.5 increase from fresh
fresh oil oil
QSV Aluminium (Al) ppm 10 15
QSV Chrome (Cr) ppm 3 5
QSV Copper (Cu) ppm 10 15*
QSV Iron (Fe) ppm 15 20*
QSV Lead (Pb) ppm 10 15
QSV Silicon (Si) ppm 10*** 15***
QSV Tin (Sn) ppm 5 10
QSV Calcium (Ca) ** ** **
QSV Zinc (Zn) ** ** **
QSV Phosphorous (P) ** ** **
QSV Boron (B) ** ** **
QSV Sodium (Na) ppm 10 15
QSV Water (H2O) % 0.2 0.2
NOTE: Where oil analysis confirms the source of Copper and Iron is not bearing
related, the condemning limits may be increased to 60ppm for Copper and
80ppm for Iron.
** NOTE: Ca, Zn, P and B are used in the oil additives package for protection
against acid build-up and wear. The levels do vary between oil suppliers and may
not be published. It is recommended to seek advice on Caution and Condemning
Limits for these elements based on a change from the fresh oil sample and
agreed with the oil supplier.
*** NOTE: For Low Btu (Landfill and Biogas) applications, the Silicon (Si) Caution
Limit can be increased to 150ppm and the Condemning Limit can be increased to
180ppm.

Service/Parts Date:
02.02.2009
Application:
Generator Unit
Topics
NOTE: Low Btu (Landfill and Biogas) applications only; Chlorine (Cl) should be
monitored. The Caution Limit is 1000ppm and the Condemning Limit is 1400ppm.
QSK60G Engine Range:

Model
QSK60G TBN g(KOH)/kg 40% reduction from 50% reduction from
fresh oil fresh oil
QSK60G TAN g(KOH)/kg 2.0 increase from 2.5 increase from fresh
fresh oil oil
QSK60G Oxidation Abs/cm 15 20
QSK60G Nitration Abs/cm 10 15
QSK60G Viscosity Cst at 100 C 2.0 increase from 2.5 increase from fresh
fresh oil oil
QSK60G Aluminium (Al) ppm 10 15
QSK60G Chrome (Cr) ppm 3 5
QSK60G Copper (Cu) ppm 10 15*
QSK60G Iron (Fe) ppm 15 20*
QSK60G Lead (Pb) ppm 10 15
QSK60G Silicon (Si) ppm 10 15
QSK60G Tin (Sn) ppm 5 10
QSK60G Calcium (Ca) ** ** **
QSK60G Zinc (Zn) ** ** **
QSK60G Phosphorous (P) ** ** **
QSK60G Boron (B) ** ** **
QSK60G Sodium (Na) ppm 10 15
QSK60G Water (H2O) % 0.2 0.2
* NOTE: Where oil analysis confirms the source of Copper and Iron is not
bearing related, the condemning limits may be increased to 60ppm for Copper
and 80ppm for Iron.

Service/Parts Date:
02.02.2009
Application:
Generator Unit
Topics
K38 Natural Gas Power Generation Product (Manufactured in India):

Model
K38G TBN g(KOH)/kg 40% reduction from 50% reduction from
fresh oil fresh oil
K38G TAN g(KOH)/kg 1.5 increase from 2.0 increase from fresh
fresh oil oil
K38G Oxidation Abs/cm 10 15
K38G Nitration Abs/cm 10 15
K38G Viscosity Cst at 100 C 2.0 increase from 2.5 increase from fresh
fresh oil oil
K38G Aluminium (Al) ppm 3 5
K38G Chrome (Cr) ppm 11 14
K38G Copper (Cu) ppm 15 20*
K38G Iron (Fe) ppm 15 20*
K38G Lead (Pb) ppm 7 10
K38G Silicon (Si) ppm 15*** 20***
K38G Tin (Sn) ppm 15 20
K38G Calcium (Ca) ** ** **
K38G Zinc (Zn) ** ** **
K38G Phosphorous (P) ** ** **
K38G Boron (B) ** ** **
K38G Sodium (Na) ppm 11 15
K38G Water (H2O) % 0.2 0.2
* NOTE: Where oil analysis confirms the source of Copper and Iron is not
bearing related, the condemning limits may be increased to 60ppm for Copper
and 80ppm for Iron.


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Service/Parts Date:

Subject: Oil Analysis Guidelines

Publications Affected by This Service/Parts Topic

NOTE: Publications identified as Other include the following: Parts

This Service Bulletin applies to QSV81G/QSV91G 14 and 16Bar BMEP,

Freq. Genset Model Covered By

Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

It is important to understand that the Genset must be serviced and maintained

The purpose of this Service Bulletin is to define Cummins guidelines for

Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

Oil Sample Frequency

Natural Gas Fuelled Generator Sets

be extended to a maximum of 20% of the change interval, or 6 months,

Low Btu (Landfill and Biogas Fuelled) Applications

Oil Sample Baseline

Bring the engine up to normal operating temperature prior to

The following information should also be supplied:

Engine make, type and serial number.

Table 1: Oil Caution and Condemning Limits

QSV Engine Range:

Engine Characteristic Units Caution Limit Condemning Limit

Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

QSK60G Engine Range:

Engine Characteristic Units Caution Limit Condemning Limit

Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

K38 Natural Gas Power Generation Product (Manufactured in India):

Engine Characteristic Units Caution Limit Condemning Limit

Cummins Inc. Box 3005, Columbus, Indiana 47202-3005

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