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102002 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 personnel. 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, 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 018003 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 British Thermal Unit (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 and Oil Analysis Recommendations, Bulletin 3810340.
Reference Table 1 and 2 or Cummins Inc. recommended oil change intervals for engines using
standard pipeline natural gas.
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NOTE: These recommendations apply only to high horsepower lean burn 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 3 and Table 4 for
Cummins Inc. recommended spark plug service/change intervals for engines using standard
pipeline natural gas.
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 QSK60G 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 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 nonpipeline natural gas fueled engines based on
condition monitoring. Alternatively, contact a Cummins® Authorized Repair Location.
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 is not detailed in this manual. OEM supplied equipment
includes, but is not limited to:
Radiator
Radiator cooling fans
Heat exchangers
Gas pressure regulator
Engine shutoff valve
Gas supply proving system
Gas filter element
Exhaust silencer
Engine aftertreatment systems
Engine prelubrication pumps
Cooling system pressurization vessels
Air filter elements
Alternator drive coupling
Engine room or container air inlet filter elements
Waste oil reservoir.
NOTE: Following an engine major overhaul or repair, regardless of whether the engine
was repaired on site or removed to an external workshop, the engine should be
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recommissioned. Reference the OEM commissioning manual procedures and also use the
following procedure for Gas Engine Startup. Refer to Procedure 307001 in Section H.
Table 1: Premium Grade Long Change Interval Oils
Mobil Pegasus 805, Shell™ Mysella XL (Shell™ S5N), Valvoline Premium Blue™ GEO LA,
and Valvoline Premium Blue™ GEO MA
Without Oil
With Oil Analysis
Analysis
Engine Model
Oil Sampling Oil Change
Oil Change Interval
Interval Interval
QSK60G Multiple
Up to 1500 hours, while sample
Turbochargers 250 hours 750 hours
results are within limits.
1500 rpm/50 Hz
QSK60G Multiple
Up to 750 hours, while sample results
Turbochargers 250 hours 375 hours
are within limits.
1800 rpm/60Hz
QSK60G Single
Turbocharger Up to 1500 hours, while sample
250 hours 750 hours
1200 rpm/60Hz results are within limits.
1500 rpm/50 Hz
Table 2: Premium Grade Long Change Interval Oils
Mobil Pegasus 1005
Without Oil
With Oil Analysis
Analysis
Engine Model
Oil Sampling Oil Change
Oil Change Interval
Interval Interval
QSK60G Single
Turbocharger Up to 1500 hours, while sample results
250 hours 750 hours
1200 rpm/60Hz are within limits.
1500 rpm/50 Hz
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 3: Cummins® Spark Plug, Part Number 4924504
Engine Model Spark Plug Regap Interval Spark Plug Change Interval
QSK60G
Not recommended Up to 1500 hours
1500 rpm/50 Hz
QSK60G
Not recommended Up to 750 hours
1800 rpm/60Hz
Table 4: Cummins® Spark Plug, Part Number 4302173
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Engine Model
Table 4: Cummins® Spark Plug, Part Number 4302173
Spark Plug Regap Interval Spark Plug Change Interval
QSK60G
Up to 2500 hours Up to 7500 hours
Engine Model
1500 rpm/50 Hz Spark Plug Regap Interval Spark Plug Change Interval
QSK60G
Up to 2000 hours Up to 6000 hours
1800 rpm/60Hz
For convenience, listed below are the section numbers that contain specific instructions for
performing the maintenance checks listed in the maintenance schedule.
Generator Models 1160GQKA and C1160 N5C Using Standard Pipeline Gas
Maintenance Procedures at Daily Interval
Coolant Level Check
Lubricating Oil Level Check.
Maintenance Procedures at Early Life Inspection1
Emissions Testing Test
Lubricating Oil and Filters Change
Valve Stem Measure
Overhead Set (OBC) Adjust.
Maintenance Procedures at Interval 12
Lubricating Oil Analysis Test
Maintenance Procedures at Interval 33
Cooling System Hoses Check
Crankcase Breather Tube Check
Electrical Connection, Engine Check
Flexible Hose Check.
Maintenance Procedures at Interval 44
Air Leaks, Air Intake and Exhaust Systems Inspect for Reuse
Lubricating Oil and Filters Change
Overhead Set (OBC) Adjust
Spark Plugs (Non Shielded) Replace
Emissions Testing Check
CoilonPlug Replace (Rubber Boot)
Maintenance Procedures at Interval 55
Coolant Filter Change
Engine Mounts Check
Fuel Line Seals, NG Check
Gear Cover Trunnion Sleeve Check
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Supplemental Coolant Additive (SCA) Test
Valve Stem Measure.
Maintenance Procedures at Interval 66
CoilonPlug Inspect for Reuse
CoilonPlug Replace (Rubber Boot)
Engine Clean
Turbocharger Axial Clearance Measure
Turbocharger Radial Bearing Clearance Measure.
Maintenance Procedures at Top End Overhaul 7
Aftercooler Check
Cam Follower Assembly Check
Camshaft Check
Coolant 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
Water Pump Replace
CoilonPlug Replace (Extension)
Charge Air Piping Replace (Orings and Tie Bars)
Throttle Body Driver Module Isolation Grommets Replace.
Maintenance Procedures at Intermediate Overhaul 8
Bearings, Connecting Rod Replace
Connecting Rod Replace
Cylinder Liner Replace
Lubricating Oil Pump Replace
Piston Rings Replace
Throttle Body Assembly Replace
Turbocharger Replace
Exhaust Manifold, Dry Inspect.
Maintenance Procedures at Major Overhaul 9
Aftercooler Replace
Bearings, Main Replace
Bearings, Thrust Replace
Cam Follower Assembly Replace
Camshaft Bushings Replace
Camshaft Thrust Bearing Replace
Cooling System Hoses Check
Crankcase Breather (External) Replace
Crankshaft Seal, Front Replace
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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.
1. 250 Hour Interval
2. 250 Hours or 14 Day Interval
3. 750 Hour Interval
4. 1500 Hour Interval
5. 3000 Hour Interval
6. 6000 Hour Interval
7. 15,000 Hour Interval
8. 30,000 Hour Interval
9. 60,000 Hour Interval.
Generator Models 1400GQKA and C1400 N6C Using Standard Pipeline Gas
Maintenance Procedures at Daily Interval
Coolant Level Check
Lubricating Oil Level Check.
Maintenance Procedures at Early Life Inspection1
Emissions Testing Test
Lubricating Oil and Filters Change
Valve Stem Measure
Overhead Set (OBC) Adjust.
Maintenance Procedures at Interval 12
Lubricating Oil Analysis Test
Maintenance Procedures at Interval 33
Cooling System Hoses Check
Crankcase Breather Tube Check
Electrical Connection, Engine Check
Flexible Hose Check
Lubricating Oil and Filters Change
Overhead Set (OBC) Adjust
Spark Plugs (Non Shielded) Replace
CoilonPlug Replace (Rubber Boot).
Maintenance Procedures at Interval 44
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Air Leaks, Air Intake and Exhaust Systems Inspect for Reuse
Valve Stem Measure
Emissions Testing Check.
Maintenance Procedures at Interval 55
Coolant Filter Change
Engine Mounts Check
Fuel Line Seals, NG Check
Gear Cover Trunnion Sleeve Check
Supplemental Coolant Additive (SCA) Check.
Maintenance Procedures at Interval 66
CoilonPlug Inspect for Reuse
CoilonPlug Replace (Rubber Boot)
Engine Clean
Turbocharger Axial Clearance Measure
Turbocharger Radial Bearing Clearance Measure.
Maintenance Procedures at Top End Overhaul7
Aftercooler Check
Cam Follower Assembly Check
Camshaft Check
Coolant 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
Water Pump Replace
CoilonPlug Replace (Extension)
Charge Air Piping Replace (Orings and Tie Bars)
Throttle Body Driver Module Isolation Grommets Replace.
Maintenance Procedures at Intermediate Overhaul8
Bearings, Connecting Rod Replace
Connecting Rod Replace
Cylinder Liner Replace
Lubricating Oil Pump Replace
Piston Rings Replace
Throttle Body Assembly Replace
Turbocharger Replace
Exhaust Manifold, Dry Inspect.
Maintenance Procedures at Major Overhaul9
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Aftercooler Replace
Bearings, Main Replace
Bearings, Thrust Replace
Cam Follower Assembly Replace
Camshaft Bushings Replace
Camshaft Thrust Bearing Replace
Cooling System Hoses Check
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.
1. 250 Hour Interval
2. 250 Hours or 14 Day Interval
3. 750 Hour Interval
4. 1500 Hour Interval
5. 3000 Hour Interval
6. 6000 Hour Interval
7. 12,000 Hour Interval
8. 24,000 Hour Interval
9. 48,000 Hour Interval.
Generator Models 1000GQKB, 1100GQKC, 1400GQKC, C995 N5C, C1200 N5C, C1400 N5C,
C1000 N6C and C1100 N6C Using Standard Pipeline Gas
Maintenance Procedures at Daily Interval
Schedule 3
Coolant Level Check
Lubricating Oil Level Check.
Maintenance Procedures at Early Life Inspection1
Emissions Testing Test
Lubricating Oil and Filters Change
Valve Stem Measure
Overhead Set (OBC) Adjust.
Maintenance Procedures at Interval 12
Lubricating Oil Analysis Test
Maintenance Procedures at Interval 23
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Overhead Set (OBC) Adjust
Maintenance Procedures at Interval 34
Cooling System Hoses Check
Crankcase Breather Tube Check
Electrical Connection, Engine Check
Flexible Hose Check
Lubricating Oil and Filters Change
Spark Plugs (Non Shielded) Replace
Turbocharger Coolant Hoses, NG Inspect for Reuse
Turbocharger Oil Drain Line Inspect for Reuse
Turbocharger Oil Supply Line Inspect for Reuse
CoilonPlug Replace (Rubber Boot).
Maintenance Procedures at Interval 45
Air Leaks, Air Intake and Exhaust Systems Inspect for Reuse
Lubricating Oil and Filters Change
Valve Stem Measure
Emissions Testing Check.
Maintenance Procedures at Interval 56
Coolant Filter Change
Engine Mounts Check
Fuel Line Seals, NG Check
Gear Cover Trunnion Sleeve Check
Supplemental Coolant Additive (SCA) Check.
Maintenance Procedures at Interval 67
CoilonPlug Inspect for Reuse
CoilonPlug Replace (Rubber Boot)
Engine Clean
Maintenance Procedures at Top End Overhaul8
Aftercooler Check
Cam Follower Assembly Check
Camshaft Check
CoilonPlug Replace (Extension)
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
Turbocharger Axial Clearance Measure
Turbocharger Radial Bearing Clearance Measure
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Water Pump Replace
Throttle Body Driver Module Isolation Grommets Replace.
Maintenance Procedures at Intermediate Overhaul9
Bearings, Connecting Rod Replace
Connecting Rod Replace
Cylinder Liner Replace
Lubricating Oil Pump Replace
Piston Rings Replace
Throttle Body Assembly Replace
Turbocharger Compressor Bypass Control Valve Replace
Exhaust Manifold, Dry Inspect.
Maintenance Procedures at Major Overhaul10
Aftercooler Replace
Bearings, Main Replace
Bearings, Thrust Replace
Cam Follower Assembly Replace
Camshaft Bushings Replace
Camshaft Thrust Bearing Replace
Cooling System Hoses Check
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
Turbocharger Replace
Vibration Damper, Viscous Replace.
1. 250 Hour Interval
2. 250 Hours or 14 Day Interval
3. 500 Hours or 1 Month Interval
4. 750 Hour Interval
5. 1500 Hour Interval
6. 3000 Hour Interval
7. 6000 Hour Interval
8. 12,000 Hour Interval
9. 24,000 Hour Interval
10. 48,000 Hour Interval.
Last Modified: 21Oct2016
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Copyright © 20002010 Cummins Inc. All rights reserved.
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