LBNG QSK60G & QSK60G - High

Efficiency Series Gas Engines

Module 8 - MAINTENANCE

Cummins Corporate Training

1 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.
 Maintenance Module
Learning Objectives
After completing this module you will be familiar with the maintenance intervals
that are unique to the QSK60G / QSK60G HE gas engines. You will be competent
to carry out the recommended daily and weekly checks in addition to performing
some the specific maintenance tasks required up to 6000 hours (M3). You will also
gain an understanding of the maintenance requirements beyond these hours.

Agenda
 Maintenance Procedures and Records
 General Maintenance Schedule
 Spark Plug Maintenance
 Spark Plug Replacement
 Coil-on-Plug – Extension O-Ring Replacement
 ABB Turbo Layout / Inspection Check
 Holset Turbo Inspection
 Service Considerations
 Locate & Identify key Maintenance Points
2 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.
 QSK60G LBNG Engines

Rugged, Integrated, easy to maintain design Charge Air

cooler
Module
Coil on Plug
Design Control &
eliminates Ignition
‘HT’ leads Modules

Spin on Oil
filters

Engine
Nodular Cast Driven HT
Iron Water Pump
Construction
3 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.
 Operation &
Maintenance Record
CW180 OPERATION DATA RECORD
CUSTOMER
SERIAL NUMBER
ENGINE TYPE CW180OC QSV Gas Operation Data Record

 Good record keeping is essential to

APPLICATION
Date
Running hours
Engine speed

identify trends and spot potential Power

Engine room temperature
Atmosphere pressure

problems early. Description

HT coolant temperature (engine outlet)
Sensor
3865346
Unit
°C
TYpe
PT100

 Use O&M records to assist with

LT coolant temperature (RAS outlet) 3865346 °C PT100
Temp. Lub oil temperature after cooler 3865346 °C PT100
Compressor inlet temperature (free end) 3865345 °C PT100
Compressor inlet temperature (flywheel) 3865345 °C PT100

troubleshooting. Intake manifold temperature

HT coolant pressure
3865345
3865337
°C
bar
PT100
4_20mA

 Make entries daily or more

LT coolant pressure 3865337 bar 4_20mA
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

frequently dependant on hours run. Intake restriction pressure (flywheel)

Manifold absolute pressure
3865345
3160404
bar
bar
4_20mA
4_20mA
Crankcase pressure ? bar 4_20mA

 Log separately details in date order Exhaust gas temperature

Exhaust gas temperature
Exhaust gas temperature
3330147
3330147
3330147
°C
°C
°C
Thermocouple K
Thermocouple K
Thermocouple K

of any work carried out, parts Exhaust gas temperature

Exhaust gas temperature
Exhaust gas temperature
3330147
3330147
3330147
°C
°C
°C
Thermocouple K
Thermocouple K
Thermocouple K

replaced or changes in Exhaust Exhaust gas temperature

Exhaust gas temperature
3330147
3330147
°C
°C
Thermocouple K
Thermocouple K
Exhaust gas temperature 3330147 °C Thermocouple K

consumables, i.e. oil used. Exhaust gas temperature

Exhaust gas temperature
3330147
3330147
°C
°C
Thermocouple K
Thermocouple K
temp. Exhaust gas temperature 3330147 °C Thermocouple K
Exhaust gas temperature 3330147 °C Thermocouple K
Exhaust gas temperature 3330147 °C Thermocouple K
Exhaust gas temperature 3330147 °C Thermocouple K
Exhaust gas temperature 3330147 °C Thermocouple K
Exhaust gas temperature 3330147 °C Thermocouple K
Exhaust gas temperature 3330147 °C Thermocouple K

4 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 QSK Gas
Maintenance Schedule
FOR TRAINING USE ONLY
Three Speed Ratings 1200 rpm 1500 rpm 1800 rpm

QSK Gas
COP : Continuous Power rating, No overload available
Unlimited number of hour per year
Time between overhaul levels :12000,24000,48000 hours V16
Code MO M1 M2 M3 M4 M5 M6
Group Controls and maintenance operations Every Every Every Every Every Every Every Every Every Every
day 2 weeks month 750 h 1500 h 3000h 6000 h 12000 h 24000h 48000 h

Typical Schedule Header- Refer to Handout

The following maintenance schedule example covers engines which are rated for
continuous power (COP) 1200/1500/1800 rpm.
Always check that the maintenance chart used matches the Genset / Engine
type, rating and speed. Refer to the operation and maintenance manual for full
listings.
Cummins operate a service code system 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.
Major overhaul is estimated at 48,000 to 60,000 hrs dependant on model type for
5 QSK Gas Engines. QSK60G / Maintenance / KLD / April 2010 / REV 1.01.
NOTE: For Training Purposes Only –
Always Refer to QSOL for Latest
General
Service Practices and Information Maintenance
Guide (1 of 8)
Maintenance
Procedure Title - GMG 1160GQKA 1400GQKA 1000GQKB 1100GQKC 1400GQKC
Interval
1500 RPM 1800 RPM 1200 RPM 1200 RPM 1500 RPM
Multiple Turbo Engines Single Turbocharger Engines
Air Cleaner Restriction - Check Daily Daily Daily Daily Daily
Daily Coolant Level - Check Daily Daily Daily Daily Daily
Fan, Cooling - Check Daily Daily Daily Daily Daily
Lubricating Oil Level - Check Daily Daily Daily Daily Daily
Control Panel - Check Daily Daily Daily Daily Daily

Emissions Testing - Check (O2 and

250 250 250 250 250
250 Hours NOx)
(Early Life
Lubricating Oil Filters (Spin-On) -
Inspection 250 250 250 250 250
Change
ONLY)
Overhead Set - Adjust 250 250 250 250 250

Batteries - Check 250 250 250 250 250

250 Hours Control Panel - Clean 250 250 250 250 250
or14 Days Lubricating Oil Analysis - Test 250 250 250 250 250
6 Waste Oil Reservoir - Check 250 250 250 250 250
QSK60G / Maintenance / KLD / April 2010 / REV 1.01.
NOTE: For Training Purposes Only –
Always Refer to QSOL for Latest
General
Service Practices and Information Maintenance
Guide (2 of 8)
CPG Model 1160GQKA / 1400GQKA / 1000GQKB / 1100GQKC / 1400GQKC

500 Hours or 1 Spark Plugs (Non-Shielded) - Replace - - 500 500 500

Month Overhead Set - Adjust - - 500 500 500

Battery Cables and Connections - Check 750 750 750 750 750
Charge Air Piping - Check 750 750 750 750 750
Cooling System Hoses - Check 750 750 750 750 750
Crankcase Breather Tube - Check 750 750 750 750 750
Electrical Connection, Engine - Check 750 750 750 750 750
750 Hours (MO) Flexible Hose - Check 750 750 750 750 750
Lubricating Oil Filters (Spin-on) - Change 750 750 750 750 750
Lubricating Oil and Filters - Change - 750 750 750 750
Spark Plugs (Non-Shielded) - Replace - 750 - - -
Turbocharger Coolant Hoses, NG - Check - - 750 750 750
Turbocharger Oil Drain Line - Check - - 750 750 750

7 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

NOTE: For Training Purposes Only –
Always Refer to QSOL for Latest
General
Service Practices and Information Maintenance
Guide (31160GQKA
CPG Model
of 8)
/ 1400GQKA / 1000GQKB / 1100GQKC / 1400GQKC

Air Cleaner Element - Replace (Panel) 1,500 1,500 - - -

Air Filter Dust Collector - Check 1,500 1,500 1,500 1,500 1,500
Air Leaks, Air Intake and Exhaust System
1,500 1,500 1,500 1,500 1,500
1,500 Hours (M1) - Check
Lubricating Oil and Filters - Change 1,500 - - - -
Overhead Set - Adjust 1,500 1,500 - - -
Spark Plugs (Non-Shielded) - Replace 1,500 - - - -

Air Cleaner Element - Replace (Primary) 3,000 3,000 3,000 3,000 3,000
Bearing, Generator - Lubricate 3,000 3,000 3,000 3,000 3,000
Coolant Filter - Replace 3,000 3,000 3,000 3,000 3,000
Emissions Testing - Check (O2 and NOx) 3,000 3,000 3,000 3,000 3,000
Engine Mounts - Inspect 3,000 3,000 3,000 3,000 3,000
3,000 Hours (M2) Fuel Line Seals, NG - Inspect 3,000 3,000 3,000 3,000 3,000
Gear Cover Trunion Sleeve - Lubricate 3,000 3,000 3,000 3,000 3,000
Supplemental Cooling Additives (SCA)
3,000 3,000 3,000 3,000 3,000
and Antifreeze - Check
Turbocharger Axial Clearance - Inspect 3,000 3,000 - - -
Turbocharger Radial Clearance - Inspect 3,000 3,000 - - -
8 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.
NOTE: For Training Purposes Only –
Always Refer to QSOL for Latest
General
Service Practices and Information Maintenance
Guide (4 of 8)
CPG Model 1160GQKA / 1400GQKA / 1000GQKB / 1100GQKC / 1400GQKC

Air Cleaner Element - Replace

6,000 6,000 6,000 6,000 6,000
(Secondary)
Crankcase Ventilation Re-circulator
6,000 6,000 6,000 6,000 6,000
Element - Replace

6,000 6,000 6,000 6,000 6,000

Coil On Plug Extension - Replace

6,000 6,000 6,000 6,000 6,000

Electrical Connection, Generator - Check

6,000 Hours (M3) 6,000 6,000 6,000 6,000 6,000

Engine, Clean

6,000 6,000 6,000 6,000 6,000

Fuel Filter, NG - Replace
Generator, Main - Check Mounting Cap
6,000 6,000 6,000 6,000 6,000
Screws

- - 6,000 6,000 6,000

Rocker Cover, NG - Replace (Gasket)

- - 6,000 6,000 6,000

Spark Plug Adapter, NG (Replace O-ring)

9 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

NOTE: For Training Purposes Only –
Always Refer to QSOL for Latest
General
Service Practices and Information Maintenance
Guide (5 of 8)
CPG Model 1160GQKA / 1400GQKA / 1000GQKB / 1100GQKC / 1400GQKC
Aftercooler - Clean and Inspect 15,000 12,000 15,000 12,000 12,000
Back-up Batteries - Replace 15,000 12,000 12,000 12,000 12,000
Batteries - Replace 15,000 12,000 15,000 12,000 12,000
Cam Follower Assembly - Inspect 15,000 12,000 15,000 12,000 12,000
Camshaft - Inspect 15,000 12,000 15,000 12,000 12,000
Coil-on-Plug - Replace (Gasket) - - 12,000 12,000 12,000
Control Panel Assembly - Inspect 15,000 12,000 12,000 12,000 12,000
Coolant Thermostat - Replace 15,000 12,000 - - -

12,000 – 15,000 Cooling System - Flush 15,000 12,000 12,000 12,000 12,000
Hours (M4) - Top Cylinder Head - Replace 15,000 12,000 12,000 12,000 12,000
End Overhaul
Flexible Coupling, Generator - Inspect 15,000 12,000 12,000 12,000 12,000
Fuel Line Seals - Replace 15,000 12,000 12,000 12,000 12,000
Fuel Regulator, NG - Check (Seals) 15,000 12,000 12,000 12,000 12,000
Gear Train Backlash, Front - Measure 15,000 12,000 12,000 12,000 12,000
Low Temperature Aftercooler (LTA) Water
15,000 12,000 12,000 12,000 12,000
Pump - Replace
Push Rods or Tubes - Inspect 15,000 12,000 12,000 12,000 12,000
Rocker Assembly, NG -Check 15,000 12,000 12,000 12,000 12,000
Rocker Cover, NG - Replace (Gasket) 15,000 12,000 - - -
10 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.
NOTE: For Training Purposes Only –
Always Refer to QSOL for Latest
General
Service Practices and Information Maintenance
Guide (6 of 8)
OVERHAUL SCHEDULE - CPG Mode l 1160GQKA / 1400GQKA / 1000GQKB / 1100GQKC / 1400GQKC
Spark Plug Adapter, NG (Replace O-ring) 15,000 12,000 - - -
12,000 – 15,000 Turbo Axial Clearance - Inspect (ABB) - - 12,000 12,000 12,000
Hours (M4) - Top
End Overhaul Turbo Radial Clearance - Inspect (ABB) - - 12,000 12,000 12,000
Water Pump - Replace 15,000 12,000 12,000 12,000 12,000

Bearings, Connecting Rod – Replace 30,000 24,000 24,000 24,000 24,000

Coil-on-Plug – Replace (Gasket) 30,000 24,000 - - -
Connecting Rod – Replace 30,000 24,000 24,000 24,000 24,000
Cylinder Liner – Replace 30,000 24,000 24,000 24,000 24,000
Flexible Coupling; Generator - Replace 30,000 24,000 24,000 24,000 24,000
24,000 – 30,000
Hours (M5) – Turbocharger Compressor Bypass Control
- - 24,000 24,000 24,000
Intermediate Valve – Replace
Overhaul Lubricating Oil Pump - Replace 30,000 24,000 24,000 24,000 24,000
Piston Rings - Replace 30,000 24,000 24,000 24,000 24,000
Throttle Body Assembly – Replace - - 24,000 24,000 24,000
Turbocharger – Replace 30,000 24,000 - - -
Fuel Shutoff Valve (FSOV), NG - Replace 30,000 24,000 24,000 24,000 24,000

11 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

NOTE: For Training Purposes Only –
Always Refer to QSOL for Latest
General
Service Practices and Information Maintenance
Guide (7 of 8)
OVERHAUL SCHEDULE - CPG Mode l 1160GQKA / 1400GQKA / 1000GQKB / 1100GQKC / 1400GQKC
Aftercooler - Replace 60,000 48,000 48,000 48,000 48,000
Bearing, Generator - Replace 60,000 48,000 48,000 48,000 48,000
Bearings, Main - Replace 60,000 48,000 48,000 48,000 48,000
Bearings, Thrust - Replace 60,000 48,000 48,000 48,000 48,000
Cam Follower Assembly - Replace 60,000 48,000 48,000 48,000 48,000
Cam Follower Cover - Replace (Gasket) 60,000 48,000 48,000 48,000 48,000

48,000 – 60,000 Camshaft Bushings - Replace 60,000 48,000 48,000 48,000 48,000
Hours (M6) Camshaft Thrust Bearing - Replace 60,000 48,000 48,000 48,000 48,000
Major Overhaul
Cooling System Hoses - Replace 60,000 48,000 48,000 48,000 48,000
Crankcase Breather - Replace (Hose) 60,000 48,000 48,000 48,000 48,000
Crankshaft Seal, Front - Replace 60,000 48,000 48,000 48,000 48,000
Crankshaft Seal, Rear - Replace 60,000 48,000 48,000 48,000 48,000
Exhaust Manifold, Dry - Replace (Bellows
60,000 48,000 48,000 48,000 48,000
and Heat Shields)
Fuel Regulator, NG - Replace 60,000 48,000 48,000 48,000 48,000

12 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

NOTE: For Training Purposes Only –
Always Refer to QSOL for Latest
General
Service Practices and Information Maintenance
Guide (8 of 8)
OVERHAUL SCHEDULE - CPG Mode l 1160GQKA / 1400GQKA / 1000GQKB / 1100GQKC / 1400GQKC
Fuel Safety Regulator - Replace 60,000 48,000 48,000 48,000 48,000
Generator (Alternator) Exciter Rotating
60,000 48,000 48,000 48,000 48,000
Diodes - Replace
Generator (Alternator) Windings - Clean 60,000 48,000 48,000 48,000 48,000
Idler Gear, Camshaft (Left Bank) - Replace
60,000 48,000 48,000 48,000 48,000
(Idler Shaft Bearings)
Idler Gear, Camshaft (Right Bank) - Replace
60,000 48,000 48,000 48,000 48,000
(Idler Shaft Bearings)
48,000 - 60,000
Hours (M6) Idler Gear, Hydraulic Pump - Replace (Idler
60,000 48,000 48,000 48,000 48,000
Major Overhaul Shaft Bearings)
Idler Gear, Water Pump - Replace (Idler
60,000 48,000 48,000 48,000 48,000
Shaft Bearings)
Lubricating Oil Cooler - Replace 60,000 48,000 48,000 48,000 48,000
Piston - Replace 60,000 48,000 48,000 48,000 48,000
Piston Cooling Nozzle - Replace (O-rings) 60,000 48,000 48,000 48,000 48,000
Turbocharger - Replace (ABB) - - 48,000 48,000 48,000
Vibration Damper, Viscous - Replace 60,000 48,000 48,000 48,000 48,000

13 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 Spark Plug Maintenance

Cleanliness is vital (EHT)

Never Handle Porcelain Part of
the Plug!
4010981 PLUG GAP = 0.2mm
( 0.008 ins)
4098162 PLUG GAP = 0.25mm
( 0.010 - 031 ins).

Plug Electrode Two Approved Plugs Available Plug Electrode

Part No. 4010981 Know the differences! Part No. 4098162

 4010981 – Approved for all QSK engines. Clean and re-gap the spark plugs at 750 hrs,
follow the Cummins recommended procedure. Replace at 1,500 hrs max.
 4098162 – Approved for all QSK engines. No re-gap necessary, replace only at 1,500 hrs
max.
 Important - Use only Cummins approved Spark Plugs. Always replace at the
recommended service interval, even if engine is running normally.

14 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 Spark Plug Cleaning

• ALWAYS replace the spark plug sealing washer when refitting any removed spark
plugs (Cummins Part #: 3072541). If necessary, clean the spark plug porcelain with
alcohol or a mineral spirit - REMEMBER: DO NOT touch the porcelain extension of
the spark plug during the cleaning process.

• Only use a good quality commercial spark plug gap adjusting tool. Adjust the gap to
specification by either tapping the spark plug ground electrode on a suitable surface
(to close the gap) or by using the tool to bend the ground electrode open. Ensure
that you check the gap with care so as not to damage the precious-
metal electrodes. Ensure feeler gauges are clean.
Wire type feeler gauges are preferred (if available).
• Refit the spark plugs. DO NOT use any lubricant, etc. on the
spark plug threads. Torque as specified in O&M manual.
• After cleaning, make an entry in the engine maintenance log
showing that a cleaning and re-gapping procedure has been
performed.
IMPORTANT NOTE: Cummins, Inc. recommend that QSK spark plugs are only cleaned ONCE.
15 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.
 Spark Plug Maintenance

WARNING: Maintaining the Spark Plug Gap is Critical for Trouble Free
Operation.
Do not force a feeler gauge into the spark plug gap. This will damage the
precious metal electrodes (platinum & iridium) and shorten the spark plug
life.
NOTE:
The spark plug can be re-gapped up to a maximum of three times. Always
replace the gasket whenever a spark plug is removed from the cylinder head.

Inspect the spark plug gap. Set

the gap according to the
specification in the O&M Manual
for the specific engine.

Use of the ‘Wire’ Type Feeler

Gauge is Recommended.

16 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 Spark Plug Maintenance
WARNING: Cleanliness is Critical for Trouble Free Operation.

When using solvents for cleaning, follow the manufacturer’s

recommendations for use. Wear goggles and protective clothing to reduce
the possibility of personal injury.

Spark plugs must always be kept

clean. Never touch the porcelain
of the spark plug. If the porcelain
becomes dirty, it must be cleaned
before installation. Cleaning can
be done with mineral spirits or
rubbing alcohol and a clean cloth.
DO NOT HANDLE PORCELAIN

17 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 Spark Plug Maintenance

The spark plug socket used for installation must also be kept clean. Do
not use a spark plug socket with a rubber insert. Rubber inserts can
contaminate the spark plugs that you have just cleaned. Spark plug
socket, Part Number 3162231, has a clip retainer at the bottom to hold
the spark plug without contaminating the porcelain.

CAUTION:
Do not let the spark plug fall into its well. Damage to the insulator can
result. If the spark plug falls into the well, replace it with a new spark plug.

Using the spark plug socket,

Part Number 3162231 and a
wrench, remove the spark plug.

18 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 Changing Spark Plugs

 Disconnect COP supply cable. Remove COP fixing

screws, lift out COP.
 Remove / Install plug using a magnetic or clip type spark
plug socket only.
 Install new plug and gasket, torque to 50Nm (38 ft-lbs.).
 Inspect COP boot for damage or signs of tracking,
replace if necessary
 Replace the O-Ring in the end of the COP extension
tube. Apply a small amount of dielectric grease to the o-
ring – do not apply excessive grease!
 Insert COP through valve cover and locate onto spark
plug, Install and tighten COP fixings and supply cable.
NOTE: The o-ring in the coil extension should be
replaced with every spark plug change.

O-Ring

19 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 Spark Plug Care
Summary

 Ensure every spark plug is clean.

 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 Part No 4010981
spark plug.
 Never insert using a socket with a rubber insert, this
will soil a clean plug.
 Check plug with care using clean feeler gauges, to
avoid damaging the special (platinum) electrode
coating.
Cleanliness is
 Always replace at the recommended service interval vital (EHT)
 Clean and re-gap the spark plugs at the Never Handle
recommended interval and following the Cummins Porcelain Part of the
recommended procedure.
Plug!
 Always install a new coil extension o-ring with every
spark plug change.
20 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.
 ABB Turbo / TPS 52 – H/E only
1) Silencer / Filter- inlet
Notes: (replaced by gas mixer)
Oil supply from 2) Compressor Casing
engine circuit.
3) Diffuser
Coolant to bearing
4) Bearing Casing
housing, supplied
from engine LT 5) Axial Thrust Bearing
circuit.
6) Radial plain bearings
7) Turbine
8) Gas Outlet Channel
9) Nozzle Ring
10) Gas Inlet Casing
11/12) Bearing Bushes
(located between Compressor
& Turbine Casings).

Air/Gas Flow 13) Compressor

14) Volute - outlet

Exhaust Flow Weight = 160KG

(without silencer & exhaust elbow).
21 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.
 ABB Turbo –
Service Procedures

1) The ABB turbocharger may only be maintained by skilled and authorized

ABB service centres / personnel. Cummins Personnel authorized for service
inspections and checks only.

NOTE

22 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 ABB Turbo –
Axial & Radial Clearances

• Check Axial & Radial clearances between 8,000

& 12,000 hours of operation as stated on the
Turbo rating plate.
• With the use of a suitable hoist remove the
Cartridge group as shown (Bearing Housing /
Bearings/ Shaft/Compressor & Turbine) from the
Engine.
• Raise the cartridge from the ground and use a
Dial Test Indicator (DTI) to check Axial & Radial
clearances to the specification shown below.
CLEARANCE TPS 52
A (min) 0.1 mm
A (max) 0.18 mm
B (min) 0.61 mm
B (max) 1.15 mm

Caution! - If clearances cannot be obtained contact an authorized ABB service centre.

23 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.
 Holset Axial
and Radial Clearances
Check every 3,000 hrs

CLEARANCE HX 82

A min 0.025

A max 0.152

B min 0.254
DIFFUSER
B max 0.787
Maa

WITH DIFFUSER FITTED (mm)

Compressor Turbine
24 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.
 Service Considerations

Camshaft Drive Gears:

 Use ‘Straight’ keys only.
Use of ‘Offset’ keys is
prohibited.
 Alignment of timing
marks on drive gears
only.

25 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 Service Considerations

 T-handle locks camshaft in

position (15/64)

 Piston Cooling nozzles must be removed from both

banks when removing a piston from either bank
 Camshaft installation tool (guides).

26 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 Service Considerations

 Torque/turn method used

– Head Bolts
– Main Caps
– Rod Caps

 All cap screws have taper at head to shank

joint and all threads are metric

27 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 Service Considerations

 Valves adjusted using OBC

– New, wider feeler gauges required
• Intake valve - 36 mm (.014 in.)
• Exhaust valve 81mm (.032 in.)

 Cam follower rollers and pins are not

serviceable

28 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 Module 9 - Maintenance
Team Tasks - Practical Exercises

Cummins Corporate Training

29 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 Practical Work Rules

 Use the barrier cream and protective clothing provided.

 Lifting and handling equipment provided for large and heavy items.
 When dismantling the engine always set out the work area first, working in
an orderly manner will assist in re-assembly;
1) Spread clean paper on the ground to layout the parts as removed.
2) Layout the components in sets, A1, A2, A3, etc. in the order of removal
starting furthest away from the engine. Replacement is then simplified by
starting with the parts closest to the engine and working outward.
3) Always replace bolts after parts have been removed, they are then at
hand for re-assembly!
 Make reference to the O & M manual for procedures and torque values.

30 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 Practical Exercise (1 of 3)



Locate and Identify the following on the engine:
 CENSE module.
 Woodward Throttle assembly.
 CM700 module.
 Service connector.
 Exhaust thermocouples.
 Control Module CM558 .
 Coil on Plug Assembly (COP) - Identify LT feed pin.
 Ignition Module (CCD).
 Knock (Detonation) Sensor

31 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 Practical Exercise (2 of 3)


Locate and Identify the following on the engine: 

 Gas / Air Mixer.
 Gas Mass Flow Sensor (GMF).
 Fuel Control Valve (FloTech).
 Speed Sensor.
 Engine Position Sensor.
 Turbo Intake Air Pressure Sensor.
 Intake Manifold Pressure & Temperature Sensors.
 Engage and operate the engine barring mechanism (use
1/2” drive).

32 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 Practical Exercise (3 of 3)


Locate and Identify the following on the engine:
 Oil fill & drain points.
 Oil pump and regulator.
 Turbo charger oil and water supply and return lines.
 Water pump seal failure “tell-tale” point
 Cooling system de-aerating point and header tank connection.
 Cooling system engine connections (In / Out).

33 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.

 LBNG QSK60G & QSK60G - High
Efficiency Series Gas Engines

Module 8 - MAINTENANCE

End
Cummins Corporate Training
34 QSK60G / Maintenance / KLD / April 2010 / REV 1.01.