QSV81 QSV91 CM700 Generator Set Operation and Maintenance Manual


Front
(4021313-titlepage) Titlepage
(om-frwd) Foreword
(refno) Important Reference Numbers

Section i - Introduction
(99-204-001) To the Owner and Operator
(99-204-002-om-pwgn) About the Manual
(99-204-003-om-pwgn) How to Use the Manual
(99-204-004) Symbols
(99-204-005) Illustrations
(99-204-006-om-pwgn) General Safety Instructions
(99-204-007-om-pwgn) General Repair Instructions
(99-204-008) General Cleaning Instructions
(99-204-009) Acronyms and Abbreviations

Section E - Engine Identification
(66-100-001) Engine Identification
(66-100-002) Engine Diagrams

Section 1 - Operating Instructions
(99-101-999-om-pwgn) Operating Instructions - Overview
(66-101-014) Normal Starting Procedure
(66-101-004) Cold Weather Starting
(66-101-018) Starting Procedure After Extended Shutdown or Oil Change
(99-101-015-om-pwgn) Operating the Engine
(99-101-009-om-pwgn) Engine Shutdown
(99-101-008-om-pwgn) Engine Operating Range
(66-101-007) Electronic Controlled Fuel System
(99-101-002) Electromagnetic Interference (EMI)

Section 2 - Maintenance Guidelines
(99-102-999) Maintenance Guidelines - Overview
(66-102-004) Tool Requirements
(66-102-002-om) Maintenance Schedule
(99-102-001) Maintenance Record Form

Section 3 - Maintenance Procedures at Daily Interval
(99-103-999) Daily Maintenance Procedures - Overview
(66-010-086) Air Cleaner Restriction Indicator
(105-019-314) Control Panel Assembly
(99-008-066) Coolant Level
(99-007-043-om) Lubricating Oil Level
(66-016-019-om) Gearbox

Section 4 - Maintenance Procedures at Early Life Inspection
(99-999-999) Maintenance Procedures - Overview
(66-014-011) Emissions Testing
(66-007-002-om) Lubricating Oil and Filters
(66-007-059) Lubricating Oil Filter (Centrifugal)
(66-003-004-om) Overhead Set

Section 5 - Maintenance Procedures at Interval 1
(99-999-999) Maintenance Procedures - Overview
(66-013-007) Batteries
(105-019-314) Control Panel Assembly
(66-007-051) Lubricating Oil Analysis
(66-007-093) Waster Oil Reservoir

Section 6 - Maintenance Procedures at Interval 2
(99-999-999) Maintenance Procedures - Overview
(66-010-014) Air Cleaner Element
(66-010-135) Air Filter Dust Collector
(66-021-027-om-ng) Bearing, Generator
(66-014-011) Emissions Testing
(66-016-017-om) Gearbox Lubricating Oil System
(66-007-002-om) Lubricating Oil and Filters
(66-007-059) Lubricating Oil Filter (Centrifugal)
(66-003-004-om) Overhead Set
(66-013-016-om) Spark Plugs (Non Shielded)
(66-013-024) Coil On Plug

Section 7 - Maintenance Procedures at Interval 3
(99-999-999) Maintenance Procedures - Overview
(66-010-014) Air Cleaner Element
(66-013-033) Electrical Connection, Engine
(66-017-005) Flexible Hose
(66-021-009-om) Generator, Main
(66-007-002-om) Lubricating Oil and Filters
(66-008-060) Supplemental Cooling Additives (SCA)

Section 8 - Maintenance Procedures at Interval 4
(99-999-999) Maintenance Procedures - Overview
(66-010-014) Air Cleaner Element
(66-001-008-om) Camshaft
(66-008-124) Coolant Plumbing
(66-017-018) Crankcase Ventilation Re-circulator Element
(66-016-010) Engine Mounts
(66-006-063-om) Fuel Filter, NG
(66-016-021-om) Gearbox to Alternator Coupler
(66-016-016) Gearbox Lubricating Oil Filter Element
(66-004-014-om) Push Rods or Tubes
(66-003-011-om) Rocker Lever Cover
(66-004-016-om) Tappet Assembly
(66-010-038) Turbocharger Axial Clearance
(66-010-047) Turbocharger Radial Bearing Clearance

Section 9 - Maintenance Procedures at Top End Overhaul
(99-999-999) Maintenance Procedures - Overview
(66-010-024) Air Leaks, Air Intake and Exhaust System
(66-013-034) Back-up Batteries
(66-013-024) Coil On Plug
(105-019-314) Control Panel Assembly
(66-008-018) Cooling System
(66-002-004-om) Cylinder Head
(66-013-035) Electrical Connections Generator
(66-017-005) Flexible Hose
(66-016-018-om) Flexible Coupling, Generator
(66-006-063-om) Fuel Filter, NG
(66-006-064) Fuel Line Seals, NG
(66-016-019-om-ng) Gearbox
(66-016-021-om) Gearbox to Alternator Coupler
(66-016-017-om-rep) Gearbox Lubricating Oil System
(66-005-225-om) Throttle Shaft Bearings
(66-010-033) Turbocharger

Section 10 - Maintenance Procedures at Intermediate Overhaul
(99-999-999) Maintenance Procedures - Overview
(66-010-001-om) Aftercooler
(66-013-007) Batteries
(66-021-027-om-rep) Bearing, Generator
(66-001-005-om) Bearings, Connecting Rod
(66-001-006-om-rep) Bearings, Main
(66-001-014-om-rep) Connecting Rod
(66-001-074) Connecting Rod Capscrews
(66-008-013-om) Coolant Thermostat
(66-001-058) Cylinder Block Counter Bore
(66-001-028_rep) Cylinder Liner
(66-011-015-om) Exhaust Manifold Heat Shield
(66-011-007_rep) Exhaust Manifold, Dry
(66-016-018-om-rep) Flexible Coupling, Generator
(66-005-042-om) Fuel Regulator, NG
(66-005-044-om) Fuel Shutoff Valve (FSOV), NG
(66-001-055-om) Gear Train Backlash, Front
(66-021-029-om) Generator (Alternator) Windings
(66-007-003-om) Lubricating Oil Cooler
(66-007-031-om) Lubricating Oil Pump
(66-007-039-om) Lubricating Oil Thermostat
(66-001-043-om) Piston
(66-001-047_rep) Piston Rings
(66-004-014-om-rep) Push Rods or Tubes
(66-004-016_rep) Tappet Assembly
(66-010-033) Turbocharger
(66-010-046-om) Turbocharger Oil Supply Line
(66-010-045-om) Turbocharger Oil Drain Line
(66-001-052-om) Vibration Damper, Viscous
(66-008-062-om) Water Pump

Section 11 - Maintenance Procedures at Major Overhaul
(99-999-999) Maintenance Procedures - Overview
(66-001-006_rep) Bearings, Main
(66-001-007_rep) Bearings, Thrust
(66-001-010-om-rep) Camshaft Bushings
(66-001-056_rep) Camshaft Thrust Bearing
(66-001-072-om) Camshaft Intermediate Gear Assembly
(66-010-028) Charge-Air Piping
(66-001-014-om-rep) Connecting Rod
(66-008-086-om-rep) Cooling System Hoses
(66-001-024_rep) Crankshaft Seal, Rear
(66-011-007-om) Exhasut Manifold, Dry
(66-016-019-om-rep) Gearbox
(66-021-009-om-rep) Generator, Main
(66-007-081-om) Lubricating Oil Check Valve
(66-001-046_rep) Piston Cooling Nozzle
(66-001-043-om-rep) Piston
(66-003-009-om) Rocker Lever Assembly
(66-013-020) Starting Motor
(66-001-052-om-rep) Vibration Damper, Viscous

Section 12 - Maintenance Procedures at Early Life Inspection (Low BTU Only)
(99-999-999) Maintenance Procedures - Overview
(66-014-011) Emissions Testing
(66-007-059) Lubricating Oil Filter (Centrifugal)
(66-007-002-om) Lubricating Oil and Filters
(66-003-004-om) Overhead Set
(66-013-016-om) Spark Plugs (Non Shielded)
(66-013-024) Coil On Plug

Section 13 - Maintenance Procedures at Interval 2 (Low BTU Only)
(99-999-999) Maintenance Procedures - Overview
(66-010-135) Air Filter Dust Collector
(66-021-027-om-ng) Bearing, Generator
(66-014-011) Emissions Testing
(66-007-002-om) Lubricating Oil and Filters
(66-013-016-om) Spark Plugs (Non Shielded)

Section 14 - Maintenance Procedures at Interval 3 (Low BTU Only)
(99-999-999) Maintenance Procedures - Overview
(66-013-033) Electrical Connection, Engine
(66-017-005) Flexible Hose
(66-016-019-om-pwgn) Gearbox
(66-021-009-om) Generator, Main
(66-003-004-om) Overhead Set

Section 15 - Maintenance Procedures at Interval 4 (Low BTU Only)
(99-999-999) Maintenance Procedures - Overview
(66-010-014) Air Cleaner Element
(66-008-086-om) Cooling System Hoses
(66-003-001) Crankcase Breather (External)
(66-017-018) Crankcase Ventilation Re-circulator Element
(66-006-063-om) Fuel Filter, NG
(66-005-233) Fuel Analysis
(66-010-038) Turbocharger Axial Clearance
(66-010-047) Turbocharger Radial Bearing Clearance

Section 16 - Maintenance Procedures at Top End Overhaul (Low BTU Only)
(99-999-999) Maintenance Procedures - Overview
(66-010-024) Air Leaks, Air Intake and Exhaust System
(66-010-014) Air Cleaner Element
(66-001-008-om) Camshaft
(66-008-124) Coolant Plumbing
(66-002-004-om) Cylinder Head
(66-013-035) Electrical Connections Generator
(66-016-010) Engine Mounts
(66-016-018-om) Flexible Coupling, Generator
(66-017-005) Flexible Hose
(66-006-063-om) Fuel Filter, NG
(66-016-021-om) Gearbox to Alternator Coupler
(66-016-016) Gearbox Lubricating Oil Filter Element
(66-004-014-om) Push Rods or Tubes
(66-003-011-om) Rocker Lever Cover
(66-004-016-om) Tappet Assembly

Section 17 - Maintenance Procedures at Intermediate Overhaul (Low BTU Only)
(99-999-999) Maintenance Procedures - Overview
(66-010-001-om) Aftercooler
(66-013-034) Back-up Batteries
(66-001-005-om) Bearings, Connecting Rod
(66-013-024) Coil On Plug
(105-019-314) Control Panel Assembly
(66-008-018) Cooling System
(66-001-028_rep) Cylinder Liner
(66-006-064) Fuel Line Seals, NG
(66-005-042-om) Fuel Regulator, NG
(66-005-044-om) Fuel Shutoff Valve (FSOV), NG
(66-016-019-om-ng) Gearbox
(66-016-018-om-rep) Flexible Coupling, Generator
(66-007-003-om) Lubricating Oil Cooler
(66-001-047_rep) Piston Rings
(66-004-014-om-rep) Push Rods or Tubes
(66-004-016_rep) Tappet Assembly
(66-005-225-om) Throttle Shaft Bearings
(66-010-033) Turbocharger

Section 18 - Maintenance Procedures at Major Overhaul (Low BTU Only)
(99-999-999) Maintenance Procedures - Overview
(66-013-007) Batteries
(66-021-027-om-rep) Bearing, Generator
(66-001-006_rep) Bearings, Main
(66-001-007_rep) Bearings, Thrust
(66-001-010-om) Camshaft Bushings
(66-001-056_rep) Camshaft Thrust Bearing
(66-001-014-om) Connecting Rod
(66-001-074) Connecting Rod Capscrews
(66-008-013-om) Coolant Thermostat
(66-001-024_rep) Crankshaft Seal, Rear
(66-001-058) Cylinder Block Counterbore
(66-011-015-om) Exhaust Manifold Heat Shield
(66-011-007-om) Exhaust Manifold, Dry
(66-016-018-om-rep) Flexible Coupling, Generator
(66-001-055-om) Gear Train Backlash, Front
(66-021-029-om-rep) Generator (Alternator) Windings
(66-007-081-om) Lubricating Oil Check Valve
(66-007-031_rep) Lubricating Oil Pump
(66-007-039-om) Lubricating Oil Thermostat
(66-001-046_rep) Piston Cooling Nozzle
(66-001-043-om-rep) Piston
(66-010-045-om) Turbocharger Oil Drain Line
(66-010-046-om) Turbocharger Oil Supply Line
(66-001-052-om) Vibration Damper, Viscous
(66-008-062-om) Water Pump

Section 19 - Maintenance Procedures at Complete Overhaul (Low BTU Only)
(99-999-999) Maintenance Procedures - Overview
(66-010-001-om-rep) Aftercooler
(66-001-010-om-rep) Camshaft Bushings
(66-001-056_rep) Camshaft Thrust Bearing
(66-001-008-om-rep) Camshaft
(66-001-072-om) Camshaft Intermediate Gear Assembly
(66-001-014-om-rep) Connecting Rod
(66-008-086-om-rep) Cooling System Hoses
(66-016-019-om-rep) Gearbox
(66-021-009-om-rep) Generator, Main
(66-003-009-om) Rocker Lever Assembly
(66-013-020) Starting Motor
(66-001-052-om-rep) Vibration Damper, Viscous

Section A - Adjustment, Repair, and Replacement
(66-000-006) Engine Storage - Short Term
(66-007-009) Lubricataing Oil Dipstick
(66-012-022) Air Starting Motor

Section D - System Diagrams
(66-200-999) System Diagrams - Overview
(66-200-001) Flow Diagram, Fuel System
(66-200-002) Flow Diagram, Lubricating Oil System
(66-200-003) Flow Diagram, Cooling System
(66-200-005) Flow Diagram, Exhaust System
(66-200-009) Crankcase Ventilation

Section L - Service Literature
(66-205-001-om) Additional Service Literature
(99-205-002) Service Literature Ordering Location
(99-205-004) Customized Parts Catalog

Section S - Service Assistance
(99-202-002) Routine Service and Parts
(99-202-003) Emergency and Technical Service
(99-202-004) Problem Solving
(99-202-005) Division and Regional Offices
(99-202-006) Distributors and Branches
(99-202-007) Regional Offices - International
(99-202-008) Distributors - International

Section ES - Engine Storage
(99-000-005-om) Engine Storage - Long Term

Section TS - Troubleshooting Symptoms
(99-t00-001-om) Troublershooting Procedures and Techniques
(99-t00-002) Troubleshooting Symptoms Charts
(4021313-t024-om) Coolant Temperature Below Normal
(4021313-t026-om) Coolant Temperature Above Normal
(4021313-t033-om) Engine Acceleration or Response Poor
(4021313-t045-om) Engine Difficult to Start or Will Not Start
(4021313-t057-om) Engine Power Output Low
(4021313-t062-om) Engine Runs Rough or Misfires
(4021313-t064-om) Engine Shuts Off Unexpectedly or Dies During Deceleration
(4021313-t066-om) Engine Speed Surges at Low or High Idle
(4021313-t072-om) Engine Starts But Will Not Keep Running
(4021313-t073-om) Engine Transient Response Poor
(4021313-t077-om) Engine Will Not Crank or Cranks Slowly (Air Starter)
(4021313-t078-om) Engine Will Not Crank or Cranks Slowly (Electric Starter)
(4021313-t080-om) Engine Will Not Reach Rated Speed (RPM)
(4021313-t081-om) Engine Will Not Shut Off
(4021313-t087-om) Fuel Consumption Excessive
(4021313-t105-om) Lubricating Oil Pressure Low
(4021313-t130-om) Load Unstable Due to Fuel
(4021313-t131-om) Fail to Start Due to Fuel

Section V - Maintenance Specifications