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QSV81 QSV91 Generator Set Troubleshooting and Repair Manual
front
(4021314-titlepage) Titlepage
(trng-frwd) Foreword
Section i - Introduction
(99-204-002-tr-pwgn) About the Manual
(99-204-003-tr-pwgn) How to Use the Manual
(99-204-004) Symbols
(99-204-005) Illustrations
(99-204-006-tr-pwgn) General Safety Instructions
(99-204-007-tr-pwgn) General Repair Instructions
(99-204-008) General Cleaning Instructions
(99-204-009) Acronyms and Abbreviations
Section E - Engine and System Identification
(66-100-001) Engine Identification
(66-100-002) Engine Diagrams
Section F - Familiarization
(66-000-999) Complete Engine - Overview
(66-001-999) Cylinder Block - Overview
(66-002-999) Cylinder Head - Overview
(66-003-999) Rocker Levers - Overview
(66-004-999) Cam Followers/Tappets - Overview
(66-200-001) Flow Diagram, Fuel System
(66-005-999) Fuel System Overview
(66-006-999) Injectors and Fuel Lines Overview
(66-007-999) Lubricating Oil System - Overview
(66-200-002) Flow Diagram, Lubricating Oil System
(66-008-999) Cooling System - Overview
(66-200-003) Flow Diagram, Cooling System
(66-009-999) Drive Units - Overview
(66-010-999) Air Intake System - Overview
(66-011-999) Exhaust System - Overview
(66-200-005) Flow Diagram, Exhaust System
(66-012-999) Compressed Air System - Overview
(66-013-999) Electrical Equipment - Overview
(66-014-999) Engine Testing - Overview
(66-016-999) Mounting Adaptations - Overview
(66-021-999) Main Power Generator - Overview
Section TS - Troubleshooting Symptoms
(99-t00-001-tr) Troubleshooting Procedures and Techniques
(99-t00-002) Troubleshooting Symptoms Charts
(4021314-t019-tr) Coolant Loss
(4021314-t021-225-tr) Coolant Pressure Low
(4021314-t024-tr) Coolant Temperature Below Normal
(4021314-t025-tr) Coolant in the Lubricating Oil
(4021314-t026-tr) Coolant Temperature Above Normal
(4021314-t027-tr) Crankcase Gases (Blowby) Excessive
(4021314-t031-tr) Cylinder Power is Low (Single Cylinder)
(4021314-t033-tr) Engine Acceleration or Response Poor
(4021314-t041-tr) Engine Decelerates Slowly
(4021314-t045-tr) Engine Difficult to Start or Will Not Start
(4021314-t048-tr) Engine Noise Excessive - Combustion Knocks
(4021314-t057-tr) Engine Power Output Low
(4021314-t061-tr) Engine Runs Rough at Idle
(4021314-t062-tr) Engine Runs Rough or Misfires
(4021314-t064-tr) Engine Shuts Off Unexpectedly or Dies During Deceleration
(4021314-t066-tr) Engine Speed Surges at Low or High Idle
(4021314-t072-tr) Engine Starts But Will Not Keep Running
(4021314-t073-tr) Engine Transient Response Poor
(4021314-t077-tr) Engine Will Not Crank or Cranks Slowly (Air Starter)
(4021314-t078-tr) Engine Will Not Crank or Cranks Slowly (Electric Starter)
(4021314-t080-tr) Engine Will Not Reach Rated Speed (RPM)
(4021314-t081-tr) Engine Will Not Shut Off
(4021314-t082-15-tr) Exhaust Temperature is High (Multiple Cylinders)
(4021314-t087-tr) Fuel Consumption Excessive
(4021314-t093-5-tr) Generator Set Circuit Breaker Will Not Close
(4021314-t096-tr) Intake Manifold Air Temperature Above Specifications
(4021314-t097-tr) Intake Manifold Pressure (Boost) is Below Normal
(4021314-t104-tr) Lubricating Oil Pressure High
(4021314-t105-tr) Lubricating Oil Pressure Low
(4021314-t106-tr) Lubricating Oil Sludge in the Crankcase Excessive
(4021314-t107-tr) Lubricating Oil Temperature Above Specification
(4021314-t107-50-tr) Lubricating Oil Temperature Below Specifications
(4021314-t118-tr) Smoke, White - Excessive
(4021314-t130-tr) Kilowatt Load Unstable Due to Fuel
(4021314-t131-tr) Fail to Start Due to Fuel
Section TT - Troubleshooting Symptoms (New Format0
(105-t02-1005a) Vibration Excessive
Section 1 - Cylinder Block - Group 01
(66-022-001_01) Service Tools
(66-001-005-tr-ng) Bearings, Connecting Rod
(66-001-006-tr-ng) Bearings, Main
(66-001-007) Bearings, Thrust
(66-001-008-tr-ng) Camshaft
(66-001-010-tr-ng) Camshaft Bushings
(66-001-012) Camshaft Gear (Camshaft Installed)
(66-001-014-tr-ng) Connecting Rod
(66-001-017) Crankshaft Adaptor
(66-001-018) Crankshaft Gear, Front (Crankshaft Installed)
(66-001-024-tr-ng) Crankshaft Seal, Rear
(66-001-026) Cylinder Block
(66-001-028) Cylinder Liner
(66-001-033) Gear Housing, Front
(66-001-043-tr-ng) Piston
(66-001-046-tr-ng) Piston Cooling Nozzle
(66-001-047) Piston Rings
(66-001-052-tr-ng) Vibration Damper, Viscous
(66-001-054) Piston and Connecting Rod Assembly
(66-001-055-tr-ng) Gear Train Backlash, Front
(66-001-056-tr-ng) Camshaft Thrust Bearing
(66-001-072-tr-ng) Camshaft Intermediate Gear Assembly
(66-001-088) Engine Base Timing
Section 2 - Cylinder Head - Group 02
(66-022-001_02) Service Tools
(66-002-004-tr-ng) Cylinder Head
Section 3 - Rocker Levers - Group 03
(66-022-001_03) Service Tools
(66-003-001-tr-ng) Crankcase Breather (External)
(66-003-004-tr-ng) Overhead Set
(66-003-009-tr-ng) Rocker Lever Assembly
(66-003-011-tr-ng) Rocker Lever Cover
Section 4 - Cam Followers/Tappets - Group 04
(66-004-001) Cam Follower Assembly
(66-004-014-tr-ng) Push Rods or Tubes
(66-004-016-tr-ng) Tappet Assembly
Section 5 - Fuel System - Group 05
(66-022-001_05) Service Tools
(66-005-003) Air/Fuel Mixer
(66-005-042-tr-ng) Fuel Regulator, NG
(66-005-044-tr-ng) Fuel Shutoff Valve (FSOV), NG
(66-005-052) Throttle Body Assembly
(66-005-225-tr-ng) Throttle Shaft Bearings
(66-005-230) Fuel Shutoff Valve Validation Module
(66-005-233) Fuel Analysis
Section 6 - Injectors and Fuel Lines - Group 06
(66-022-001_06) Service Tools
(66-006-049) Fuel Control Valve Body Assembly
(66-006-063-tr-ng) Fuel Filter, NG
(66-006-064) Fuel Line Seals, NG
Section 7 - Lubricating Oil System - Group 07
(66-022-001_07) Service Tools
(66-007-001) Engine Oil Heater
(66-007-002-tr-ng) Lubricating Oil and Filters
(66-007-003-tr-ng) Lubricating Oil Cooler
(66-007-009) Lubricating Oil Dipstick
(66-007-014) Lubricating Oil Filter Bypass Valve
(66-007-024) Lubricating Oil Leaks
(66-007-025) Lubricating Oil Pan
(66-007-028) Lubricating Oil Pressure Gauge
(66-007-029) Lubricating Oil Pressure Regulator (Main Rifle)
(66-007-031-tr-ng) Lubricating Oil Pump
(66-007-038) Lubricating Oil Temperature Gauge
(66-007-039-tr-ng) Lubricating Oil Thermostat
(66-007-051) Lubricating Oil Analysis
(66-007-059) Lubricating Oil Filter (Centrifugal)
(66-007-063) Pre-Lubricating Oil Pump
(66-007-081-tr-ng) Lubricating Oil Check Valve
(66-007-086) Lubricating Oil Pressure Switch, Prelubrication System
(103-007-093) Waste Oil Reservoir
Section 8 - Cooling System - Group 08
(66-022-001_08) Service Tools
(66-008-004) Coolant Temperature Gauge
(66-008-011) Coolant Heater
(66-008-013-tr-ng) Coolant Thermostat
(66-008-018-tr-ng) Cooling System
(66-008-019) Cooling System - Air or Combustion Gas Test
(66-008-045-tr-ng) Radiator Hoses
(66-008-047) Radiator Pressure Cap
(66-008-061) Water Manifold
(66-008-062-tr-ng) Water Pump
(66-008-064) Water Pump Idler Assembly
(66-008-075) Coolant Heater Thermostat
(66-008-076) Circulating Pump
(66-008-125) Coolant Heater and Coolant Circulating Pump Switch
Section 9 - Drive Units - Group 09
(66-009-035) Engine Barring Device
Section 10 - Air Intake System - Group 10
(66-022-001_10) Service Tools
(66-010-001-tr-ng) Aftercooler
(66-010-014) Air Cleaner Element
(66-010-024) Air Leaks, Air Intake and Exhaust Systems
(66-010-031) Air Intake Restriction
(66-010-033-tr-ng) Turbocharger
(66-010-038) Turbocharger Axial Clearance
(66-010-039) Turbocharger Blade Damage
(66-010-040) Turbocharger Compressor Seal Leaks
(66-010-046-tr-ng) Turbocharger Oil Supply Line
(66-010-047) Turbocharger Radial Bearing Clearance
(66-010-049) Turbocharger Turbine Seal Leaks
(66-010-079) Multiduct
(66-010-136-tr-ng) Turbocharger Compressor Bypass Control Valve
Section 11 - Exhaust System - Group 11
(66-022-001_11) Service Tools
(66-011-007-tr-ng) Exhaust Manifold, Dry
(66-011-009) Exhaust Restriction
(66-011-015-tr-ng) Exhaust Manifold Heat Shield
Section 12 - Compressed Air System - Group 12
(66-012-022) Air Starting Motor
Section 13 - Electrical Equipment - Group 13
(66-022-001_13) Service Tools
(66-013-007) Batteries
(99-013-009) Battery Cables and Connections
(66-013-016-tr-ng) Spark Plugs (Non Shielded)
(66-013-020) Starting Motor
(66-013-024) Coil On Plug
(66-013-033) Electrical Connection, Engine
(66-013-034) Back-up Batteries
(66-013-035) Electrical Connection, Generator
Section 14 - Engine Testing - Group 14
(66-022-001_14) Service Tools
(66-014-010-tr-ng) Crankcase Blowby, Measure
(66-014-011) Emissions Testing
(106-014-012-tr-ng) Engine Compression
Section 16 - Mounting Adaptations - Group 16
(66-016-001) Engine Lifting Brackets
(66-016-005) Flywheel
(66-016-006) Flywheel Housing
(00-016-010) Engine Mounts
(66-016-012) Flywheel Position Indicator
(66-016-015) Gearbox Lubricating Oil Level
(66-016-016) Gearbox Lubricating Oil Filter Element
(66-016-017-tr-ng) Gearbox Lubricating Oil System
(66-016-018-tr-ng) Flexible Coupling, Generator
(66-016-019-tr-ng) Gearbox
(66-016-020) Engine to Gearbox Coupler
(66-016-021-tr-ng) Gearbox to Alternator Coupler
(66-016-022) Gearbox Lubricating Oil Cooler
(66-016-023) Coupling Guard
(66-016-024) Gearbox Oil Pump
Section 17 - Miscellaneous - Group 17
(66-017-002) Cup Plug
(66-017-007) Pipe Plug
(66-017-017) Pipe Coupling Assembly
(66-017-018) Crankcase Ventilation Re-circulator Element
Section 21 - Main Power Generator - Group 21
(66-021-005) Generator Fuse Holder
(66-021-009-tr-ng) Generator, Main
(66-021-027-tr-ng) Bearing, Generator
(66-021-028) Generator (Alternator) Exciter Rotating Diodes
(66-021-029-tr-ng) Generator (Alternator) Windings
(66-021-030) Permanent Magnet Generator
(66-021-031) Generator Rotor
Section L - Service Literature
(66-205-001-tr-ng) Additional Service Literature
(99-205-002) Service Literature Ordering Location
(99-205-004) Customized Parts Catalog
Section V - Specifications
(66-018-015) General Engine
(66-018-016) Fuel System
(66-018-017) Lubricating Oil System
(66-018-018) Cooling System
(66-018-019) Air Intake System
(66-018-020) Exhaust System
(66-018-021) Electrical System
(66-018-022) Compressed Air System
(66-018-004) Coolant Recommendations and Specifications
(99-018-009) Capscrew Markings and Torque Values
(99-018-010) Fraction, Decimal, Millimeter Conversions
(99-018-011) Newton-Meter to Foot-Pound Conversions
(99-018-012) Pipe Plug Torque Values
(99-018-013) Tap-Drill Chart - U.S. Customary and Metric
(99-018-014) Weights and Measures - Conversion Factors
File Data
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| File Type | EXE |