Application

Engineering
Bulletin
Subject This AEB is for the following applications:

Lubricating Oil Make-up System of Automotive Industrial Marine

QSK and QSV Gas Generating Sets
G-Drive Genset

Filtration Emissions Solution

Date: October 3, 2008 AEB Number 200.02

Engine Models included: QSK19G, QSK60G, QSV81G & QSV91G

Author: John Grainger Approver: per Procedure 9183OPS-04-10-01 Page 1 of 7

This AEB is new

1. Purpose:

This AEB will describe the functionality of the Lubricating Oil Make-up System. It will detail the maximum
and minimum pressures allowable in the valve and provide details on the recommended oils to be used in
the system. Not covered by this AEB is the specification of any external storage system required to deliver
the recommended oil to the maintainer.

2. Introduction:

All Lean Burn Natural Gas generating sets are supplied with an Oil Level Maintainer System. The function of
this system is to ensure that for as long an external supply of the recommended oil is available, the oil level
in the prime-mover of the associated generating set will be maintained at the pre-set optimum level allowing
the prime-mover to operate continuously throughout the oil change interval.

3. Oil Level Maintainers:

For continuous operation of generating equipment and to allow for extended servicing of the prime-mover it
is recommended that the oil level be maintained at a constant level. This requires oil to be added to the
prime-mover as it is consumed during the normal operation. If the equipment is installed as the primary
source of electrical power, and in operation for 24 hours a day, adding oil through the normal fill point can be
difficult and messy. The use of an oil level maintainer, will, while there is an external supply of
recommended lubricating oil available; maintain the oil level in the prime-mover at the recommended level.
There are several different methods of achieving this objective; these vary from gravity fed float valve
devices to electronically controlled pumped systems, an example is shown below.

Cummins Confidential
 Lubricating Oil Make-up System of QSK and QSV
Gas Generating Sets – AEB 200.02

Example of a Float Type Level Indicator.

The item displayed above can be used to display the fluid level in a vessel; it incorporates a float inside a
tube that houses a magnet. As the level of liquid changes in the tube the float, travels up and down the tube.
On the outside of the tube totally separated from the liquid is an indicator, this has a series of segments that
are designed to swivel around a central axis as the magnet passes the rotate on this axis and display a
different coloured side. It is also possible to fit to the outside of the tube reed switches that are also
activated by the passing magnet. These can be used to operate electric motors and solenoids to allow
liquid to pass to make up the level if low etc.

4. Oil Level Maintainers used on Cummins Gensets:

All current QSK19G, QSK60G and QSV based LBNG Gensets use an Oil Level Maintainer from the range
offered by F.W. Murphy. The particular models used are the LM301; this is from the LM 300 series of oil
level maintainers and incorporates a switch for low oil level protection, this is used on the QSK 60 range and
the QSV 81 / 91 range. The QSK 19 range utilizes a LM 2000.

The diagram below shows a typical installation of the LM 301.

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 Lubricating Oil Make-up System of QSK and QSV
Gas Generating Sets – AEB 200.02

Standard Specification of the LM301 is:

Body and Cover are manufactured from Die-cast Aluminum
Polyurethane coated rigid polyurethane float
Maximum ambient temperature of 1218C (250°F)
Top entry oil inlet connection ½ x 14 NPT with in-built filter and 6mm (¼ in.) orifice
Minimum inlet pressure with 6mm orifice 1.2 meters (4ft) head of oil
Maximum inlet pressure with 6mm orifice 4.6 meters (15ft) head of oil
Switch capable of 10 Amps @ 125 and 250 V AC; 10 Amps @ 30 V DC
Capable of a 52mm differential between static and running oil levels
Flow rate tested at 08C using SAE 30 weight oil 17.8 liters/hour @1.2 meters to 117 liters/hour @ 4.6
meters
Flow rate tested at 328F using SAE 30 weight oil 4.7 US GPH @4ft to 31 US GPH @15ft
Oil outlet connections 3 off 1 left, 1 right, and 1 on bottom all ¾ x 14 NPT
Crankcase Balance vent fitting ½ x 14 NPT in the upper cover
Test knob to enable testing of the low oil level shutdown feature
Clear “frog eye” front mounted lens for visual checking of oil level

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 Lubricating Oil Make-up System of QSK and QSV
Gas Generating Sets – AEB 200.02

Detail of Background of Visual Display

Standard Specification of the LM2000 is:
Body and Cover are manufactured from Die-cast Aluminum
Hollow Brass float
Maximum ambient temperature of 1218C (250°F)
Side entry oil inlet connection ½ x 14 NPT with in-built filter and 3mm (⅛ in.) orifice
Minimum inlet pressure with 3mm orifice 0.6 meters (2ft) head of oil
Maximum inlet pressure with 6mm orifice 7.6 meters (25ft) head of oil
Maximum Case pressure of 103 kPa (15psi)
Switch capable of 10 Amps @ 125 and 250 V AC; 10 Amps @ 30 V DC
Capable of a 52mm (2 in) differential between static and running oil levels
Flow rate tested at 08C using SAE 40 weight oil 1.9 liters/hour @ 0.6 meters
Flow rate tested at 328F using SAE 40 weight oil 0.5 US GPH @ 2ft
Oil outlet connections 1 on bottom ¾ x 14 NPT

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 Lubricating Oil Make-up System of QSK and QSV
Gas Generating Sets – AEB 200.02

Crankcase Balance vent fitting ½ x 14 NPT in the upper cover

Clear “frog eye” front mounted lens for visual checking of oil level

5. Installation Instructions.

All bracketry currently released for the installation of the Oil Level Maintainer is pre-drilled to ensure the
device is correctly located. No adjustment is available or required as the device is mounted at the correct
engine running oil level.
When the engine has been filled with oil to the full mark on the engine oil level dipstick; it will be noted that
the sight glass of the oil level maintainer is completely full.
However when the engine is running and at the normal operating temperatures the oil level will be seen to
be on the white line between the two green bands.

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 Lubricating Oil Make-up System of QSK and QSV
Gas Generating Sets – AEB 200.02

As oil is consumed by the engine through operation the level visible in the sight glass will fall and this action
will open the inlet valve to the unit allowing oil from the storage tank to replenish the oil level in the engine oil
pan.
The oil level maintainer requires a connection to a bulk storage tank, containing the recommended oil for the
type of engine being operated. The design of the storage tank is not specified by this document only in that
it is required to contain a minimum of 100 litres (27 US Gallons) of the recommended oil for the engine and
should be mounted remotely from the engine and connected by suitable pipework of at least ¾“ I.D.
If the design of the pipework is too be rigid, consideration should be given too including a flexible length of
pipe at the transition between the rigid and the connection to the generating set baseframe.
The height of the storage tank must also not be less than 4ft (1.2 metres) and cannot be located at a height
greater than 15ft (4.6 metres). If the storage tank is mounted too low there will be insufficient flow too
maintain the correct level and if the storage tank is mounted too high the oil level maintainer will be unable
too stop the flow, this will result in overfilling of the oil pan and engine damage may result.

6. Recommended Lubricating Oils.

Engine Oil Specification

Reference should be made to Cummins Service Bulletin 3810340 – Cummins Engine Oil
Recommendations – which is available via QuickServe Online, as well as the Operation & Maintenance
manual for the relevant engine model.

NOTE: Never use diesel engine oil in a natural gas engine – SERIOUS ENGINE DAMAGE WILL
OCCUR!

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 Lubricating Oil Make-up System of QSK and QSV
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Change Log
Date Author Description Page(s)

10/03/2008 John Grainger Initial Release All

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