Maintenance Guidelines

Maintenance Schedule Page 1 of 8

102-002 Maintenance Schedule

General Information
CAUTION

Maintenance procedures for generator set systems, such as Gas Supply Systems
and Generator Electrical Systems (low, medium and high voltage), must only be
performed by qualified/certified personal. In many regions, accreditation to a
nationally recognized trade organization is also required. It is necessary to comply
with all local and national legislation when performing these maintenance
procedures.
Cummins, Inc. bases its oil drain interval specifications on duty cycle and oil
contamination. This contamination occurs in all engines at varying rates, regardless
of design. Oil drain intervals are influenced by a number of factors, such as
application, load, duty cycle, oil brand, and oil type. Use the following procedure for
information on oil brands and oil types. Refer to Procedure 018-003 in Section V.
Cummins, Inc. strongly recommends regular oil sampling and analysis so that the
condition of the oil can be determined to be 'fit for continued use'. Where regular
sampling and analysis is not performed, then the oil change intervals detailed in this
Operation and Maintenance Manual must be reduced by 50 percent. In addition,
Cummins, Inc. recommends that immediately prior to the oil change, 'end of life' oil
sampling and analysis must be performed to determine that the oil contamination
was below the oil condemnation limits at the time of the oil change. Use the following
procedure for information on oil sampling and analysis. Refer to Procedure 018-003
in Section V.
NOTE: For engines that operate in standby applications or are operated for less
than 750 hours (50 Hz applications) or 375 hours (60 Hz applications),
Cummins, Inc. recommends that the oil and filters are changed annually.
Oil change intervals for Low BTU fueled engines are site specific and are determined
from analysis of the fuel available at site. For further information on Low BTU fueled
engines oil change intervals, contact a local Cummins® Distributor.
For further details and discussion of engine lubricating oil for Cummins® engines,
reference Cummins® Engine Oil Recommendations, Bulletin 3810340.
Reference Table 1 or Cummins, Inc. recommended oil change intervals for engines
mk:@MSITStore:G:\MR_D.CHM::/english/procedures/84/84-102-002-owner-gdng.h... 12/07/2020
using standard pipeline natural gas.
NOTE: These recommendations apply only to high horsepower leanburn
natural gas engines. High horsepower diesel engine recommendations are
different. For information on high horsepower diesel engine lubricating oil
recommendations, reference Cummins® Engine Oil and Oil Analysis
Recommendations, Bulletin 3810340.
Cylinder head service life can be extended only if the valve stem heights are
measured and recorded, as detailed in this manual. Cylinder head replacement can
be extended up to a maximum of 30,000 hours for 1500 rpm/50 Hz engines and
24,000 hours for 1800 rpm/60Hz engines, only if the valve stem heights remain
within the recommended limits and the engine exhibits no other performance
degradation. If the valve stem heights are not regularly measured and recorded, then
the cylinder heads must be replaced at the intervals specified below.
Spark plug service/change interval specifications are influenced by a number of
factors, such as spark plug brand and type, application, load, and duty cycle.
Reference Table 2 for Cummins® recommended spark plug service/change intervals
for engines using standard pipeline natural gas.
Listed below are the section numbers that contain specific instructions for performing
the maintenance checks listed in the maintenance schedule.
Perform the maintenance at whichever interval occurs first. At each scheduled
maintenance interval, perform all previous maintenance checks that are required for
scheduled maintenance, with the exception of the Maintenance Procedures at Early
Life Inspection (250 Hours). The procedures listed for this maintenance interval are to
be performed only one time (shortly after placing the engine into service prior to the
first scheduled maintenance interval).
The QSK60 engines are designed to operate on standard pipeline natural gas.
Reference Fuels for Cummins® Engines, Bulletin 3379001, for more information on
fuel specifications. Engine operation on fuels outside of the standard specification for
pipeline natural gas will impact engine durability and service intervals. It is the
customer's responsibility to determine the application/site specific service schedule
for non-pipeline natural gas fueled engines based on condition monitoring.
Alternatively, contact a Cummins® Authorized Repair Location.
There are two different engine ratings: 50 Hz/1500 rpm and 60 Hz/1800 rpm. Due to
these differences, the maintenance schedules are listed in two different schedules.
The schedules are broken down into maintenance times from daily maintenance to
complete overhaul.
Maintenance of original equipment manufacturer (OEM) supplied equipment and
components must also be performed as per the manufacturer's recommendations.
The maintenance of OEM supplied equipment and components are not detailed in
this manual. OEM supplied equipment includes, but is not limited to:
 Radiator
 Radiator cooling fans
 Heat exchangers
 Air filter elements
 Gas pressure regulator
 Engine shutoff valve
 Gas supply proving system
 Gas filter element
 Crankcase recirculation filter
 Alternator drive coupling
 Exhaust silencer
 Engine aftertreatment systems
 Engine pre-lubrication pumps.
Table 1: Premium Grade - Long Change Interval Oils
Mobil Pegasus 805, Shell Mysella XL, Valvoline Premium Blue GEO LA, and
Valvoline Premium Blue GEO MA
Without Oil
With Oil Analysis
Engine Analysis
Model Oil Sampling Oil Change
Oil Change Interval
Interval Interval
QSK60 G,
1500 rpm Up to 1,500 hours, while sample
250 hours 750 hours
50 Hz, 1160 results are within limits.
kWe
QSK60 G,
1800 rpm Up to 750 hours, while sample
250 hours 375 hours
60 Hz, 1400 results are within limits.
kWe
NOTE: The oil filter change interval may be different than the lubricating oil
change intervals shown above. Oil filters must be changed as specified with
the recommendations shown in this procedure.
Table 2: Cummins® Spark Plug, Part Number 4924504
Spark Plug Regap Spark Plug Change
Engine Model
Interval Interval
QSK60 G, 1500 rpm/50
Not recommended Up to 1,500 hours
Hz
QSK60 G, 1200 rpm/50
Not recommended Up to 750 hours
Hz
Engine Models QSK60G, 1500RPM/50Hz, 1160kWe, Using Standard Pipeline
Gas
Maintenance Procedures at Daily Interval
 Coolant Level - Check
 Lubricating Oil Level - Check.
Maintenance Procedures at Early Life Inspection
 Emissions Testing - Check
 Lubricating Oil Filter (Spin-On) - Change
 Overhead Set (OBC) - Adjust
 Valve Stem - Measure
 Lubricating Oil Analysis - Check.
Maintenance Procedures at 250 Hours
 Lubricating Oil Analysis - Check
 Waste Oil Reservoir - Check.
 Battery Cables and Connections - Check
 Charge-Air Piping - Check
 Cooling System Hoses - Check
 Crankcase Breather Tube - Check
 Electrical Connection Engine - Check
 Flexible Hose - Check
 Turbocharger Coolant Hoses, NG - Check
 Turbocharger Oil Drain Line - Check
 Turbocharger Oil Supply Line - Check.
 Air Leaks, Air Intake and Exhaust Systems - Check
 Spark Plugs (Non-Shielded) - Change
 Emissions Testing - Check.
 Coolant Filter - Check
 Engine Mounts - Check
 Gear Cover Trunion Sleeve - Check
 Supplemental Coolant Additive (SCA) - Check
 Valve Stem - Measure.
 Coil-on-Plug - Inspect for Reuse
 Engine Steam Cleaning - Clean
 Rocker Lever Cover, NG - Check
 Spark Plug Adapter, NG - Replace O-Rings
 Turbocharger Axial Clearance - Measure
 Turbocharger Radial Bearing Clearance - Measure.
 Aftercooler - Check
 Cam Follower Assembly - Check
 Camshaft - Check
 Coil-on-Plug - Check
 Coolant Thermostat - Replace
 Low-Temperature Aftercooler (LTA) Thermostat - Replace
 Cooling System - Flush
 Cylinder Head - Replace
 Fuel Line Seals, NG - Replace
 Gear Train Backlash, Front - Measure
 Low-Temperature Aftercooler (LTA) Water Pump - Replace
 Push Rods or Tubes - Check
 Rocker Lever Assembly - Check
 Rocker Lever Cover, NG - Replace
 Spark Plug Adapter, NG - Replace
 Water Pump - Replace.
 Bearings, Connecting Rod - Replace
 Connecting Rod - Replace
 Cylinder Liner - Replace
 Lubricating Oil Pump - Replace
 Piston Rings - Replace
 Turbocharger - Replace
 Throttle Body Assembly - Replace.
 Bearing, Main - Replace
 Bearings, Thrust - Replace
 Camshaft Bushings - Replace
 Camshaft Thrust Bearing - Replace
 Crankcase Breather (External) - Replace
 Crankshaft Seal, Front - Replace
 Crankshaft Seal, Rear - Replace
 Exhaust Manifold, Dry - Replace
 Idler Gear, Camshaft (Left Bank) - Replace
 Idler Gear, Camshaft (Right Bank) - Replace
 Idler Gear, Hydraulic Pump - Replace
 Idler Gear, Water Pump - Replace
 Lubricating Oil Cooler - Replace
 Piston - Replace
 Vibration Damper, Viscous - Replace.
Engine Models QSK60G, 1800RPM/60Hz, 1400kWe, Using Standard Pipeline
Gas
Maintenance Procedures at Daily Interval
 Coolant Level - Check
 Lubricating Oil Level - Check.
Maintenance Procedures at Early Life Inspection
 Emissions Testing - Check
 Lubricating Oil Analysis - Check.
 Lubricating Oil Analysis - Check
 Waste Oil Reservoir - Check.
 Battery Cables and Connections - Check
 Charge-Air Piping - Check
 Crankcase Breather Tube - Check
 Electrical Connection Engine - Check
 Flexible Hose - Check
 Turbocharger Coolant Hoses, NG - Check
 Turbocharger Oil Drain Line - Check
 Turbocharger Oil Supply Line - Check
 Lubricating Oil and Filters - Change
 Overhead Set (OBC) - Adjust.
 Air Leaks, Air Intake and Exhaust Systems - Check
 Emissions Testing - Check.
 Coolant Filter - Check
 Engine Mounts - Check
 Gear Cover Trunion Sleeve - Check
 Supplemental Coolant Additive (SCA) - Check.
 Coil-on-Plug - Inspect for Reuse
 Engine Steam Cleaning - Clean
 Rocker Lever Cover, NG - Check
 Spark Plug Adapter, NG - Replace O-Rings
 Turbocharger Axial Clearance - Measure
 Turbocharger Radial Bearing Clearance - Measure.
 Camshaft - Check
 Coil-on-Plug - Replace
 Coolant Thermostat - Replace
 Low Temperature Aftercooler (LTA) Thermostat - Replace
 Cooling System - Flush
 Cylinder Head - Replace
 Fuel Line Seals, NG - Replace
 Push Rods or Tubes - Check
 Rocker Lever Assembly - Check
 Rocker Lever Cover, NG - Replace
 Spark Plug Adapter, NG - Replace
 Water Pump - Replace.
 Bearings, Connecting Rod - Replace
 Connecting Rod - Replace
 Cylinder Liner - Replace
 Lubricating Oil Pump - Replace
 Piston Rings - Replace
 Turbocharger - Replace
 Throttle Body Assembly - Replace.
 Aftercooler - Replace
 Bearings, Main - Replace
 Bearings, Thrust - Replace
 Cam Follower Assembly - Replace
 Camshaft Bushings - Replace
 Camshaft Thrust Bearing - Replace
 Crankcase Breather (External) - Replace
 Crankshaft Seal, Front - Replace
 Crankshaft Seal, Rear - Replace
 Exhaust Manifold, Dry - Replace
 Idler Gear, Camshaft (Left Bank) - Replace
 Idler Gear, Camshaft (Right Bank) - Replace
 Idler Gear, Hydraulic Pump - Replace
 Idler Gear, Water Pump - Replace
 Lubricating Oil Cooler - Replace
 Piston - Replace
 Piston Cooling Nozzle - Check
 Vibration Damper, Viscous - Replace.
Last Modified: 13-Jun-2013
Copyright © 2000-2010 Cummins Inc. All rights reserved.

Maintenance Guidelines

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Maintenance Guidelines

Uploaded by

Copyright:

Available Formats

Maintenance Schedule Page 1 of 8

You might also like