5-1

SECTION 5 – GAS ENGINE

MAINTENANCE

TABLE OF CONTENTS Detailed Maintenance Schedule

Index
General ---------------------- 5-2
Maintenance Schedule Index --- 5-3
Scheduled Maintenance -------- 5-2
Daily Checks Index ----------- 5-3
Maintenance Schedule --------- 5-2
250 Hours or 6 Months Index –- 5-3
Extending the Maintenance
Schedule --------------------- 5-2
750 Hours or 6 Months Index –- 5-3
Service Tools or Specialized
1500 Hours or 1 Year Index --- 5-3
Mechanics -------------------- 5-2
6000 Hours or 3 Years Index -- 5-3
Daily Checks ----------------- 5-3
Annual Index ----------------- 5-4
250 Hours or 6 Months -------- 5-3
Special Notes Index ---------- 5-4
750 Hours or 6 Months -------- 5-3

1500 Hours or 1 Year --------- 5-3

6000 Hours or 3 Years -------- 5-3

Annual ----------------------- 5-4

Special Notes ---------------- 5-4


GAS ENGINE MAINTENANCE (Cont.)
General
Maintenance is the key to lower
operating costs. A CNGE engine
requires regularly scheduled
maintenance to keep it running
efficiently. Good preventive
maintenance will help in reducing
unnecessary repair costs for
repairs that occur because of
either poor or no maintenance.
Upon investigation of successful
operations where gas engines are
used, you will find good,
regularly scheduled maintenance
programs in effect.
Scheduled Maintenance
Preventive maintenance is the key
to long engine life and low
operating expense. If the engine
is properly maintained, most
potential problems can be
corrected before causing a major
unscheduled breakdown of the
engine.
Accessories must be included in a
maintenance program. Accessory
failures may put an engine out of
operation.
Maintenance Schedule
Use the following maintenance
schedule as a guide to establish
your specific maintenance program.
Engines operating in ambient
temperatures consistently below
–180C [00F] or above 380C [1000F]
5-2
should have maintenance performed
at shorter intervals than those
listed in these schedules. Shorter
maintenance intervals are also
required if the engine is operated
in a dusty environment or if
frequent starts & stops are made.
Also extended periods of idle may
dictate the need for more frequent
maintenance.
Extending the Maintenance
Extending maintenance intervals
should be based on previous
operational experience with the
engine and through a good oil
analysis program. Without these
factors, caution should be used in
extending maintenance intervals.
Service Tools or Specialized
Mechanics
Some maintenance procedures
require special tools and should
be performed by qualified
personnel. These procedures and
tools will be covered in your
various engine shop manuals. CNGE
uses the Cummins Diesel Shop
Manuals where appropriate.
For specialized gas engine tools
refer to Section 17.
Daily Check
• Check operators’ report.
• Check and bring to proper level
• Engine oil
• Engine Coolant
• Check for gas leaks and correct.

• Check Governor sump oil level.
• Visually inspect engine for
damage, leaks, loose or frayed
belts, loose hoses and clamps
and correct.
• Visually inspect radiator core
externally for contamination and
clean if required.
Every 250 Hours, or 6 Months
• Change/Replace
• Lubricating Oil
• Lubricating Oil Filters
• Coolant Filter
• Check
• Engine coolant DCA4(TM)
concentration level. Add
make-up DCA4(TM) if required.
• Check air intake system for
wear points or damage to
piping, loose clamps, and
leaks.
• Check air cleaner
restriction, element and
change if required.
• Shielded Spark Plugs (If
Used)
Every 750 Hours, or 6 Months
• Adjust
• Valves/Crossheads
• Check
• Ignition Timing
• Compression
• Spark Plugs
• Clean
5-3
• Crankcase Breather
Every 1500 Hours, or 1 Year
• Check/Clean/Replace
• Spark Plugs
• Gas Fuel Filter
• Check Gas Pressure to carburetor
• Check Carburetor Adjustment for
Excess Oxygen with Oxygen
Analyzer or Oxygen Meter.
Every 6000 Hours, or 3 Years
• Exchange/Rebuild
• Water Pump
• Fan Hub
• Water Pump Idler Pulley
Assembly
• Inspect/Exchange
• Turbocharger
• Vibration Damper
• Check
• Cylinder Compression
Annual
• Steam clean engine (if
possible).
• Check torque on turbocharger
mounting nuts.
• Check torque on engine mounting
nuts.
• Replace hoses as required.

• Clean cooling system (internally
and externally) and change
coolant and antifreeze (every
two years).
Special Notes
1. The maintenance interval may
be adjusted based on a good
oil analysis program.
2. At each scheduled maintenance
interval, perform all checks
in addition to the ones
specified.
3. Replace the Vibration Damper
at 15,000 hours.
4. Follow the manufacturer’s
recommended maintenance
procedures for the Starter,
Alternator, Generator,
Batteries, Electrical
Connections, Magnetos or
Ignition generators,
Carburetors, Gas Regulators,
Propane Converters, Governors,
and any other accessory item
that may be supplied with your
CNGE engine.
5. CNGE recommends that a daily
log be maintained showing all
maintenance performed.
Maintenance Schedule Index
Daily Check
Check Operator’s Report –---- 15-1
Engine Oil Level-Checking --- 7-4
Engine Coolant Level –
Checking -------------------- 6-5
Check Gas Leaks & Correct --- 12-2
5-4
Check –
Governor Sump Oil Level ----- 15-1
Visually Inspect Engine ----- 15-2
Check and Adjust Belts ------ 14-2
Visually Inspect –
Radiator Core --------------- 6-9
Every 250 Hours, or 6 Months
Lubricating Oil –
Changing/Replace ------------- 7-6
Lubricating Oil Filters –
Changing --------------------- 7-6
Coolant Filter-Changing ------ 6-6
Check Coolant Concentration –- 6-5
Check Intake System ---------- 8-2
Check –
Air Cleaner Restriction ------ 8-2
Check Shielded Spark Plugs --- 9-7
Every 750 Hours, or 6 Months
Valves – Adjust ------------- 15-2
Crossheads-Adjust ----------- 15-3
Ignition Timing-Check -------- 9-8
Check Compression ----------- 15-5
Check Spark Plugs ------------ 9-6
Every 1500 Hours, or 1 Year
Spark Plug Gap-Check --------- 9-6
 5-5

Spark Plug-Replace ----------- 9-5 Change ----------------------- 6-6

Gas Fuel Filter-Replace ----- 12-2 Special Notes

Gas Pressure – Carburetor – Maintenance Interval –

Check ----------------------- 12-3 Adjustment ------------------- 7-5

Air/Fuel Ration-Adjust ------ 12-3 Oil Analysis ----------------- 7-6

Carburetor Adjustment for Vibration Damper –

Excess Oxygen with Oxygen Replacement ----------------- 15-4
Analyzer -------------------- 12-3
Component Manufacturer’s
Every 6000 Hours, or 3 Years Addresses --------------Section 19

Water Pump-Exchange/Rebuild -- 6-8

Fan Hub-Exchange/Rebuild ----- 6-9

Water Pump –
Idler Pulley Assemble -------- 6-8

Turbocharger –
Inspect/Exchange ------------- 8-3

Vibration Damper –
Inspect/Exchange ------------ 15-4

Cylinder Compression-Check –- 15-5

Annual

Steam Clean –
Engine (If Possible) -------- 15-1

Turbocharger Mounting Nuts –

Check ------------------------ 8-6

Engine Mounting Nuts-Check -- 15-2

Hoses-Replace ---------------- 6-8

Cooling System (Internally and

Externally)-Clean ------------ 6-6

Coolant and Antifreeze –