Manual de Servicio Vol2 - QSK60

Service Manual
QSK45 and QSK60 Series Engines

Service Manual
Cummins Inc.
Box 3005
Columbus, Indiana, U.S.A., 47202 QSK45 and QSK60 Series Engines
Registered Office Volume 2
Cummins Engine Company, Ltd
Unit 1-B Uniongate, Ridgeway Trading Estate,
Iver,
Buckinghamshire SL0 9HX,
England
Registration 573951 England
Copyright© 2006
Cummins Inc.
Volume 2
Bulletin 4021530
Printed in U.S.A. 28-FEBRUARY-2006 p167
Service Manual
Volume 2
Copyright© 2006 Bulletin 4021530

Cummins Inc. Printed 28-FEBRUARY-2006
All rights reserved
Foreword
This manual contains instructions for troubleshooting and repairing this engine in the chassis, complete rebuild
procedures and specifications. Disassembly, cleaning, inspection, and assembly instructions are included. A listing
of accessory and component suppliers is located in Section M - Component Manufacturers. Suppliers can be
contacted directly for any information not covered in this manual.
Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i
- Introduction.
The manual is organized to guide a service technician through the logical steps of identifying and correcting problems
related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment
manufacturer for repair procedures.
The repair procedures in this manual are based on the engine or component removed from chassis. Some rebuild
procedures require the use of special service tools. Make sure the correct tools are used as described in the
procedures.
When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used
in place of the recommended item.
A series of specific service manuals (for example: Troubleshooting and Repair, Specifications, and Alternative Repair)
are available and can be ordered by Contacting your local area Cummins Regional office. A Cummins Regional office
listing is located in Service Literature (Section L).
Cummins Inc. encourages the user of this manual to report errors, omissions, and recommendations for improvement.
Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for communicating
your comments.
The specifications and rebuild information in this manual is based on the information in effect at the time of printing.
Cummins Inc. reserves the right to make any changes at any time without obligation. If differences are found between
your engine and the information in this manual, contact a Cummins Authorized Repair Location or call 1-800-DIESELS
(1-800-343-7357) toll free in the U.S. and Canada.
The latest technology and the highest quality components are used to manufacture Cummins engines. When
replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts. These parts
can be identified by the following trademarks:
Table of Contents
Section
Fuel System — Group 05 ......................................................................................................................... 5
Injectors and Fuel Lines — Group 06 ...................................................................................................... 6
Lubricating Oil System — Group 07 ........................................................................................................ 7
Cooling System — Group 08 .................................................................................................................... 8
Drive Units — Group 09 ........................................................................................................................... 9
Air Intake System - Group 10 ................................................................................................................... 10
Exhaust System — Group 11 ................................................................................................................... 11
Compressed Air System - Group 12 ........................................................................................................ 12
Electrical Equipment — Group 13 ............................................................................................................ 13
Engine Testing — Group 14 ..................................................................................................................... 14
Mounting Adaptations — Group 16 ......................................................................................................... 16
Miscellaneous - Group 17 ......................................................................................................................... 17
Service Literature ..................................................................................................................................... L
Component Manufacturers ....................................................................................................................... M
Specifications ........................................................................................................................................... V
QSK45 and QSK60
Section 5 — Fuel System — Group 05 Page 5-a
Section 5 — Fuel System — Group 05

Section Contents
Page
Fuel Consumption .............................................................................................................................................5-3
Initial Check......................................................................................................................................................5-3
Test..................................................................................................................................................................5-3
Off-Highway Applications................................................................................................................................5-3
Fuel Lift Pump .................................................................................................................................................5-44
Finishing Steps...............................................................................................................................................5-47
with Electronically Actuated Injector............................................................................................................. 5-47
Initial Check....................................................................................................................................................5-44
Inspect for Reuse............................................................................................................................................5-46
Install..............................................................................................................................................................5-47
Preparatory Steps...........................................................................................................................................5-45
Remove.......................................................................................................................................................... 5-45
Fuel Pump .........................................................................................................................................................5-4
Assemble........................................................................................................................................................5-26
with Mechanically Actuated Injector..............................................................................................................5-26
Fuel Pump Regulator....................................................................................................................................5-30
Clean and Inspect for Reuse...........................................................................................................................5-21
Disassemble................................................................................................................................................... 5-15
Exploded View..................................................................................................................................................5-6
with Mechanically Actuated Injector................................................................................................................5-6
Finishing Steps...............................................................................................................................................5-37
Install..............................................................................................................................................................5-32
Preparatory Steps.............................................................................................................................................5-9
Pressure Test....................................................................................................................................................5-4
Engine Cranking............................................................................................................................................5-4
Engine Operation...........................................................................................................................................5-5
Remove.......................................................................................................................................................... 5-11
Fuel Pump Gear Pump ....................................................................................................................................5-38
Rotation Check............................................................................................................................................... 5-38
Fuel Shutoff Valve ...........................................................................................................................................5-39
Assemble........................................................................................................................................................5-42
Disassemble................................................................................................................................................... 5-40
QSK45 and QSK60
Page 5-b Section 5 — Fuel System — Group 05

Install..............................................................................................................................................................5-43
Remove.......................................................................................................................................................... 5-39
Service Tools ....................................................................................................................................................5-1
Fuel System......................................................................................................................................................5-1
QSK45 and QSK60 Service Tools
Section 5 — Fuel System — Group 05 Page 5-1
Service Tools
Fuel System
The following special tools are recommended to perform procedures in this section. The use of these tools
is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized
Repair Location.
Tool No. Tool Description Tool Illustration

Fitting, Quick-Disconnect Female
Connects gauges when measuring various fuel pressures.
3376859
Fitting, Quick-Disconnect Male

Used to perform a pressure-side air-in-fuel test.
3377244
Gauge
Use to measure the fuel pump pressure from 0 to 2758 kPa [0 to 400
3824877 psi]. Includes necessary hoses and hardware to attach to a fuel
pump.
Digital Multimeter
Check resistance of fuel shutoff solenoid.
3377161
Digital Multimeter
Check resistance of fuel shutoff solenoid.
3164488
Lubricant DS-ES
Use dielectric lithium grease to lubricate the pins in the electrical
3822934 connectors.
Service Tools QSK45 and QSK60
Page 5-2 Section 5 — Fuel System — Group 05

QD Contact Cleaner
Use a nonpetroleum cleaner to clean electrical connections.
3824510
Remote Starter Switch

Use to crank the engine to measure the cranking fuel pressure.
3376506
Optical Tachometer
Use to measure engine rpm.
3377462
AFC Barrel Puller

Use to pull metering barrel from the fuel pump regulator.
3375599
Injector Orifice Torque Wrench

Use to tighten control orifice and control orifice plug.
3376177
Fuel Pump Lifting Bracket

Used to support the weight of the fuel pump during removal and
4918603 installation on the engine.
QSK45 and QSK60 Fuel Consumption
Fuel Consumption (005-010)

Initial Check
Refer to the fuel consumption checklists in the back of this
section.
The most accurate method to check the fuel consumption
is to weigh the fuel used.
INSITE™ electronic service tool can monitor fuel
consumption. It is not as accurate as weighing the fuel.
Refer to the INSITE™ electronic service tool manual.
Install a remote fuel tank (1) with enough capacity to run

80 km [50 mi] or one hour.
Use a scale capable of measuring within 0.045 kg [0.1 lb]
to weigh the fuel tank.
Fill the fuel tank. Weigh the tank with the fuel. The weight
of Number 2 diesel fuel is nominally 0.844 kg per liter [7.03
lb per gal].
Test
Off-Highway Applications
Measure the time with a stopwatch.
After one hour of operation, weigh the remaining fuel, and

compute the fuel used in liters [gal] as required.
Compute the fuel consumption. Fuel used divided by the
time equals the fuel consumption rate.
Fuel Pump QSK45 and QSK60
Fuel Pump (005-016)

Pressure Test
with Mechanically Actuated Injector
Use the vehicle tachometer or an optical tachometer, Part
Number 3377462, when checking the fuel pump pressure
to the specified engine rpm. Refer to the Fuel System
Specifications in Section V.
Use a remote starter, Part Number 3376506, to crank the

engine when checking the cranking pressure.
Install the pressure gauge, hose, and quick fitting

assembly, Part Number 3376859, or equivalent capable of
0 to 2758 kPa [0 to 400 psi] with a quick-disconnect fitting,
Part Number ST-437-7, to the fuel pump test connection.
NOTE: The fuel pump that is being pressure tested is
not the same model shown in the illustration.
Engine Cranking
Crank the engine to 175 rpm; measure the fuel pressure.
Engine Cranking Fuel Pressure

kPa psi
241 MIN 35
QSK45 and QSK60 Fuel Pump
Engine Operation
Start the engine and operate at high-idle.
Fuel Pressure
kPa psi
1500 rpm (50 Hz) 1572 MIN 228
1800 rpm (60 Hz) 1820 MIN 264
1900 rpm 1896 MIN 275
2070 rpm 1896 MIN 275
The fuel pressure will not change significantly with engine
load.
If the fuel pump pressure is not within specifications,
contact a Cummins Authorized Repair Facility.
Exploded View
Fuel Pump Components

1. Gear housing 10. Lip seal
2. Gear housing o-ring 11. Lip seal retaining ring
3. Ring gear 12. Ball bearing retaining ring
4. Pinion gear 13. Capscrew
5. Front cover 14. Check valve
6. Mechanical seal stationary ring 15. Check valve o-ring
7. Mechanical seal bellows assembly 16. Check valve retaining ring
8. Shaft 17. Dowel pins
9. Ball bearing 18. Spacer.
Exploded View
Regulator Components - Front Top View

1. Threaded plug 8. Threaded plug
2. Threaded plug 9. Injector plug orifice
3. Check valve 10. Injector gasket
4. Filter screen 11. Threaded plug
5. Compression spring 12. Male adapter elbow
6. O-ring seal 13. Coupling nipple.
7. Fuel pump filter cap
Exploded View
Regulator Components - Rear Bottom View

1. Pressure regulator valve 5. Threaded plug
2. Fuel control actuator 6. Threaded plug
3. Coupling nipple 7. Pressure regulator valve body.
4. Pressure relief valve
Preparatory Steps
WARNING
Batteries can emit explosive gases. To reduce the
possibility of personal injury, always ventilate the
compartment before servicing the batteries. To
reduce the possibility of arcing, remove the negative
(• ) battery cable first and attach the negative (-)
battery cable last.
Disconnect the battery cables.
with Electronically Actuated Injector
WARNING
(-) battery cable first and attach the negative (-) battery
cable last.
WARNING
Fuel is flammable. Keep all cigarettes, flames, pilot
lights, arcing equipment, and switches out of work
area and areas sharing ventilation to reduce the
possibility of severe personal injury or death when
working on the fuel system.
WARNING
When using solvents, acids, or alkaline materials for
cleaning, follow the manufacturer's recommendations
for use. Wear goggles and protective clothing to
reduce the possibility of personal injury.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
CAUTION
A very small amount of dirt and debris can be very
harmful to the fuel pump. Extra care is required to
keep the fuel connections clean during removal and
installation. Connections must be covered
immediately to keep them clean when components
are removed from the fuel pump.
• Disconnect the battery cables
• Clean the fuel pump and the surrounding area and
dry with compressed air
• Remove the fuel drain line from the fuel pump. Use
a clean plastic plug to protect the fuel drain line port.
Refer to Procedure 006-013
• Remove the injector supply line from the fuel pump.
Use a clean plastic plug to protect the injector supply
port. Refer to Procedure 006-051
• Remove the fuel supply lines from the fuel pump.
Use a clean plastic plug to protect the fuel supply
ports. Refer to Procedure 006-024
• Remove the intake manifold pressure and intake
manifold air temperature sensors that are located
above the fuel pump. Refer to Procedures 019-061
and 019-059 in the Troubleshooting and Repair
Manual Electronic Control System, QSK50 and
QSK60 Modular Common Rail System Series
Engine.
Remove
WARNING
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
WARNING
CAUTION
Cover all engine openings and electrical equipment to
reduce the risk of water damage.
Clean the fuel pump and the surrounding area.
Steam is the best method for cleaning a dirty fuel pump or
piece of equipment. If steam is not available, use a solvent
to wash the engine.
WARNING
lights, arcing equipment, and switches out of the work
Disconnect the pressure sensor harness connection and
the fuel pump actuator harness connection.
Disconnect the fuel inlet line (1).
Disconnect the electronic fuel control valve supply line (2).
Remove the o-rings.
Remove the four fuel pump mounting capscrews, two

mounting bracket capscrews, and the fuel pump.
Remove the jaw coupling spider.
Remove and discard the gasket.

Disconnect the wiring harness to the fuel pump actuator
and fuel rail pressure sensor.
Remove the p-clip securing the wiring of the inlet metering

valve to the upper fuel pump support.
Remove the capscrew securing the upper fuel pump

support bracket to the cam cover.
Remove the two capscrews and spacers securing the

upper fuel support bracket to the fuel pump. Retain the
two spacers.
Remove the two capscrews (3) securing part 2 of the upper

fuel pump support bracket to part 4.
Remove the four intake manifold capscrews.
Install the mounting bracket from the fuel pump lifting

fixture kit, Part Number 4918603, or equivalent to the
cylinder block.
Install the two spacers and capscrews. Tighten the
capscrews.
Torque Value: 68 N•m [ 50 ft-lb ]
Install the winch onto the mounting bracket. Install the

three capscrews, lock washers, and nuts. Tighten the
capscrews.
Install the lifting bracket on the fuel pump. Install and

tighten the two capscrews.
Attach the lifting hook to the lifting bracket.

Turn the winch handle until the lifting cable is tight.
Attach a 1/2-inch breaker bar in the square notch of the

lifting bracket. This will aid in the removal, installation and
maneuvering of the fuel pump.
CAUTION
The fuel pump weights 63 kg [138 lb]. To reduce the
possibility of personal injury or damage to the fuel
pump, use the fuel pump lifting fixture service tool, a
hoist or get assistance to lift the fuel pump.
Remove the six capscrews securing the fuel pump to the
fuel pump drive.
By using the 1/2-inch breaker bar to negotiate the fuel
pump out of the fuel pump drive, remove the fuel pump
from the engine.
Lower the fuel pump using the hand winch.

Remove the hook from lifting bracket.
Remove the 1/2-inch breaker from the fuel pump.
Remove and discard the o-ring used to seal the oil drilling
from the fuel pump drive to the fuel pump.
Remove and discard the o-ring used to seal the fuel pump
to the fuel pump drive.
Remove the four capscrews (1) securing the fuel pump

support bracket (2) to the engine block.
Disassemble
Remove the four regulator assembly mounting capscrews
and remove the regulator from the pump.
Make certain the bypass plunger does not fall out of the
regulator assembly.
Discard the gasket.
Remove the drive coupling.

A Woodruff key is pressed into the coupling.
Remove the four gear housing mounting capscrews.

Use a screwdriver in the slots on the front cover (1) to
separate the gear housing (2) from the front cover (1).
Discard the o-ring seal.
CAUTION
The chamfered face of the ring gear and pinion gear
must be installed toward the gear pocket of the gear
housing. If not installed correctly, fuel pump damage
can result.
Mark the face of the ring gear and pinion gear for correct
orientation in the gear housing.
Remove the ring gear.
The lip seal retaining ring can not be removed with the
drive coupling installed.
Use external snap ring pliers to remove the lip seal
retaining ring from the coupling end of the pump.
CAUTION
Do not allow the shaft assembly to fall to the floor.
Damage to the shaft can result.
Use a hydraulic press to slowly press the shaft assembly
through the pinion gear and the front cover.
Remove the lip seal from the shaft and discard it.
Remove the mechanical fuel seal by hand with a twisting,

pulling motion.
Use external snap ring pliers to remove the outer retaining

ring from the shaft.
CAUTION
The ball bearing is not reusable once it is removed
from the shaft. It must be replaced. Reuse of the ball
bearing can cause damage to the pump.
Use an arbor press to press the ball bearing from the shaft.
Use external snap ring pliers to remove the inner retaining

ring from the shaft.
Use a screwdriver to remove the check valve locking ring.

Remove the check valve.
Locate a punch in one of the slots of the stationary seal

from the coupling side of the pump.
Lightly tap the punch to remove the seal from the front
housing.
Fuel Pump Regulator

Remove the metering plunger and spring assembly.
Remove the metering barrel using the AFC barrel puller,

Part Number 3375599.
Remove the filter screen cap, spring, and filter screen.
Remove the control orifice plug.
Remove the control orifice using the injector orifice torque

wrench, Part Number 3376177.
Use a 19-mm socket to remove the pressure regulator

from the regulator housing.
Use an allen wrench to remove the pressure relief valve

plug.
Remove the pressure relief valve.
Remove the relief orifice from the pressure relief valve

using the injector orifice torque wrench, Part Number
3376177.

NOTE: The fuel pump is manufactured using metric
fasteners. Use metric size tools during disassembly of the
pump.
Remove the mechanical dump valve (6) from the fuel
pump (1). Discard the o-ring.
Plug the mechanical dump valve port with a clean plastic
plug.
Remove the fuel rail pressure sensor (7).
Plug the fuel rail pressure sensor port with a clean plastic
plug.
Remove the four capscrews and fuel pump pressurizing
assembly (5). Discard the small and large o-rings.
Remove the four capscrews and gerotor cover plate (4).
Discard the o-ring (3).
Remove the gerotor gear (2).
Clean and Inspect for Reuse

Clean and inspect the fuel pump and air compressor or
accessory drive mounting surfaces for damage.
Inspect the fuel pump body and front support for cracks
or other damage.
Inspect the fuel pump assembly for damaged capscrews
and damaged or loose fuel fittings.
Inspect the drive coupling lugs for excessive wear or
damage.
Inspect the coupling inner diameter for damage.

Measure the inside diameter of the coupling. The coupling
inside diameter can not exceed 17.34 ± 0.01 mm [0.683
± 0.0003 in].
Inspect the spider coupling for cracks or damage.
Inspect the ring gear for cracks and chipped or broken

teeth.
Inspect for scratches of the bearing sleeve in the front

cover assembly.
Inspect the pinion gear for cracks and chipped or broken

teeth.
Inspect the shaft for wear nicks and cracks.

Scratches are not acceptable in the shaft seal areas.
Fuel Pump Regulator

Inspect the metering plunger for scuffing.
Inspect the spring for breakage.
Inspect the relief orifice for plugging.

Inspect the control orifice for plugging.
WARNING
Clean all parts with contact cleaner, Part Number
3824510, or equivalent.
Inspect the main pump for signs of damage, cracks, leaks,

or drive shaft damage.
Replace the pump if damage is found.
WARNING
WARNING
personal injury.
Inspect the oil supply and return passages for restrictions,
dirt, and debris.
Clean passages with contact cleaner, Part Number
Dry with compressed air.
Inspect the pressure sensor for damage, cracks, or

stripped threads.
Check the resistance of the pressure sensor. Refer to
Procedure 019-398 in the Troubleshooting and Repair
Manual Electronic Control System, QSK50 and QSK60
Modular Common Rail System Series Engines, Bulletin
4021533.
Inspect the fuel pump pressurizing assembly for damage.

Check the resistance of the fuel pump pressurizing
assembly. Refer to Procedure 019-117 in the
Troubleshooting and Repair Manual Electronic Control
System, QSK50 and QSK60 Modular Common Rail
System Series Engines, Bulletin 4021533.
Inspect the mechanical dump valve for stripped threads,

damage, restricted passage, or cracks. Replace the valve
if damaged.
Inspect the cover plate for damage and cracks. The cover
plate also contains the regulator for the fuel pump.
Check the regulator for passage restriction.
NOTE: The gear pumps are a matched set. If the gear

pumps are to be replaced, it must be replaced as a set,
not individual gears.
Inspect the pump gears for wear, cracks, debris, and
broken or missing teeth.
Check for torsional play in the inner gear to the drive spline
in the pump.
Replace the pump gears if damage is found.
Inspect the three fuel pump support brackets for damage,

corrosion, cracks and wear.
Replace if damage is found.
Assemble
Apply a light coat of clean engine oil to the o-ring and the
outside diameter of the new stationary ring.
Assemble the o-ring to the stationary ring.
Place the new stationary ring into the front cover with the
polished side of the ring facing up.
Place the cardboard divider, provided with the seal
assembly, onto the stationary ring face.
Press the stationary ring into place using a 1-5/16-inch 12-

point socket until the stationary ring is fully seated in the
bore.
Remove and discard the cardboard divider.
Wipe the face of the stationary ring clean with a soft, white,
lint-free cloth.
Apply a light coat of oil to the check valve o-ring.

The check valve has a directional arrow engraved onto it.
The arrow must point away from the coupling end of the
pump.
Install the check valve into the front cover by hand with
the o-ring away from the coupling end of the pump. (If
necessary, use a light-duty arbor press.)
Install the locking ring into place with the beveled side
pointing toward the check valve and press evenly until it
is fully seated.
Use external snap ring pliers to install the inner retaining

ring in the inner groove of the shaft.
CAUTION
When installing the ball bearing onto the shaft, press
on the inner race of the ball bearing to reduce the risk
of damage.
Set the new ball bearing onto the shaft and place a 1-5/16-
inch 12-point socket onto the bearing inner race.
Use an arbor press to press the ball bearing onto the shaft
until it is seated against the inner retaining ring.
Use external snap ring pliers to install the outer retaining

ring in the outer groove on the shaft.
CAUTION
Avoid contact with the carbon seal face of the
mechanical fuel seal at all times. Contamination of the
seal can cause damage.
Slide the spacer onto the shaft until it rests against the
shaft inner retaining ring.
Apply a light film of clean engine oil to the inside diameter
of the bellows of the mechanical fuel seal to seal the
surfaces.
Apply a light film of clean engine oil to the shaft.
Place the mechanical fuel seal on the shaft and slide the
seal assembly down the shaft, by hand, until it rests
against the spacer.
CAUTION
The seal and shaft assembly must not be allowed to
rest more than 10 minutes before installing into the
front cover because the seal tends to adhere to the
shaft. Seal damage can result if the shaft is not
installed in this time frame.
With a clean lint-free, soft white cloth, clean the lapped
sealing face of the carbon primary ring of the mechanical
seal.
Wipe both the primary ring sealing face and the stationary
ring sealing face with a clean light oil.
Place the shaft assembly into the front cover.
Place a piece of 60.325-mm [2-3/8-in] hollow, round stock
onto the outer race of the bearing.
Use an arbor press to press the shaft assembly into the
front cover until the bearing is fully seated in the bore.
Apply a light film of Loctite Gasket Eliminator Number 505,

or equivalent, to the outside diameter of the lip seal.
Place the lip seal onto the front cover with the lip of the
seal pointed away from the cover.
Place a piece of 60.325-mm [2-3/8-in] round stock onto the
outer diameter of the lip seal.
Press the lip seal into place.
Use snap ring pliers to install the lip seal retaining ring.
Apply a light film of clean engine oil to the shaft.

Place a piece of 0.0005-inch shim stock on the face of the
front cover on two sides of the shaft.
WARNING
To reduce the possibility of severe burns, wear
protective gloves when installing the heated ring gear.
Heat the pinion gear to 246°C [475°F] for a minimum of
15 minutes.
NOTE: The shaft for the new style of pump has a smaller
diameter, approximately two-thirds of the way down, to
assist in installation of the pinion gear.
With the chamfered face down, slide the hot pinion gear
over the shaft until it rests on the shim stock.
Press on the pinion gear with a tool and hold it in place for
10 seconds.
Remove the shim stock.
Place the o-ring seal into the groove on the gear housing.
Apply a light film of fuel oil onto the ring gear.
Place the ring gear into the housing with the chamfered
face of the ring gear facing the housing.
Place the gear housing on a workbench.

Assemble the front cover and gear housing meshing to the
ring gear and pinion gear. If needed, turn the shaft to allow
the pinion and ring gear to mesh together.
Align the dowel pins in the gear housing to the mating
holes in the front cover.
Install the capscrews and tighten.
CAUTION
To avoid loading the bearing, the shaft of the gear
pump must be supported when installing the
coupling. Pressing force must not exceed 2404 kg
[5300 lb].
Align the coupling and driveshaft with the Woodruff key.
Use a hydraulic press to seat the coupling onto the
driveshaft.
Turn the pump shaft to be certain that the shaft rotates
freely inside the pump.
Fuel Pump Regulator

Install the relief orifice into the pressure relief valve.
Install the pressure relief valve into the regulator body.
Use an allen wrench to install the pressure relief valve
plug and tighten the plug.
Torque Value: 14 ± 1 N•m [ 124 ± 9 in-lb ]
Install new o-rings onto the mechanical regulator.

Use a 19-mm socket to install the mechanical regulator
into the regulator housing.
Install the control orifice and tighten using the injector

orifice torque wrench, Part Number 3376177.
Torque Value: 1 N•m [ 9 in-lb ]
Install the control orifice plug and tighten using the injector
orifice torque wrench, Part Number 3376177.
Install the filter screen with the open part of the screen
pointing toward the gear pump side of the regulator
housing.
Install the filter screen spring and cap and tighten the cap.
Apply a light coat of clean engine oil to the outside

diameter of the regulator barrel.
Press the regulator barrel in by hand until it is fully seated
in the bore.
Press in the metering spring and plunger by hand.
CAUTION
To avoid pump damage, make certain the metering
plunger does not fall out of the regulator when
assembling to the gear housing.
Place the new regulator gasket on the gear housing.
While holding the metering plunger in place, slide the
regulator over the gear pump.
Install the four regulator mounting capscrews and tighten.
Torque Value: 47 ± 5 N•m [ 35 ± 4 ft-lb ]

Install the gerotor gear (2) into the the fuel pump (1).
Lubricate the new o-ring (3) with clean engine oil and
install the o-ring onto the gerotor cover plate (4).
Install the gerotor cover plate (4) and the four capscrews.
Tighten the capscrews.
Install the fuel pump pressurizing assembly (5) and four
capscrews using new o-rings.
Install the fuel rail pressure sensor (7).
Install a new o-ring on the mechanical dump valve (6) and
install.
Install
Install the fuel pump drive coupling, gasket, fuel pump,
and four fuel pump mounting capscrews.
Completely install the fuel pump mounting capscrews, but
do not tighten them.
Install the fuel pump support bracket to the bottom of the

fuel pump and the engine block.
Tighten the support bracket mounting capscrews enough
that the support bracket is in alignment.
Tighten the fuel pump mounting capscrews.

Tighten the fuel pump mounting bracket capscrews to the
fuel pump.
Tighten the fuel pump bracket mounting capscrews to the
engine block.
Install new o-rings in the fuel pump inlet hose fitting and
the fuel supply hose fitting.
Install the fuel pump inlet hose (1) and the fuel supply hose
(2).
Tighten the hoses.
Torque Value:
Fuel pump inlet 120 N•m [ 89 ft-lb ]
hose
Fuel supply 120 N•m [ 89 ft-lb ]
hose
Connect the fuel pump actuator harness connection.
Connect the pressure sensor harness connection.

Install the four capscrews (1) and fuel support bracket (2)
to the engine block.
Hand tighten the capscrews. Do not torque at this time.
Attach the lifting bracket to the fuel pump using the

supplied hardware.
Attach the lifting hook to the lifting bracket.
Use clean engine oil and lubricate a new o-ring and install
it onto the mounting flange of the fuel pump.
Attach a ½ inch breaker bar or ratchet to the notch in the

lifting bracket.
CAUTION
Verify that the o-ring on the flange face of the fuel
pump is in place. If the o-ring is missing, replace.
Failure to do so will cause failure of the fuel pump due
to lack of lubrication.
Raise the fuel pump into place using the hand winch.
Install the fuel pump into the fuel pump drive and use
breaker bar or ratchet to help guide the fuel pump into
place.
Rotate the pump to align the mounting holes and install
the six capscrews.
Remove the ½ inch breaker bar or ratchet from the lifting

bracket.
Remove the hook from the lifting bracket.
Remove the capscrews and lifting bracket from the fuel

pump.
Remove the three capscrews, lock washers and nuts

attaching the winch to the winch support bracket.
Remove the winch.
Remove the capscrews and winch support bracket.
Install the intake manifold capscrews.

Install the two capscrews and spacers securing the upper

fuel support bracket to the fuel pump.
Hand tighten the capscrews.
Install the capscrew securing the upper fuel support

bracket to the camshaft cover.
Install the p-clip securing the wiring of the metering valve

to the upper fuel pump support.
Install the two capscrews (3) securing the fuel pump

support bracket (4) to the support bracket (2) mounted to
the engine block.
Connect the wiring harness to the fuel pump actuator and

fuel pump pressure sensor.
Finishing Steps
WARNING
(• ) battery cable first and attach the negative (-)
battery cable last.
• Connect the battery cables.
• Operate the engine to normal operating temperature
and check for leaks.
Fuel Pump Gear Pump QSK45 and QSK60
WARNING
cable last.
WARNING
lights, arcing equipment, and switches out of work
CAUTION
harmful to the fuel pump. Extra care is required to
keep the fuel connections clean during removal and
installation. Connections must be covered
immediately to keep them clean when components
are removed from the fuel pump.
• Install the intake manifold pressure and intake air
manifold temperature sensors that are located above
the fuel pump. Refer to Procedures 019-061 and
019-059 in the Troubleshooting and Repair Manual
Electronic Control System, QSK50 and QSK60
Modular Common Rail System Series Engine.
• Install the fuel supply line to the fuel pump. Refer to
Procedure 006-024
• Install the injector supply line to the fuel pump. Refer
to Procedure 006-051
• Connect the fuel drain line to the fuel pump. Refer to
Procedure 006-013
• Connect the battery cables.
• Operate the engine and check for leaks.
Fuel Pump Gear Pump (005-025)

Rotation Check
Because the gear pump inlet fitting is located on the side
of the gear pump, the fitting can not be removed to check
the rotation of the gear pump.
QSK45 and QSK60 Fuel Shutoff Valve
Remove the fuel pump. Refer to Procedure 005-016.
Rotate the fuel pump by hand and check for gear pump
rotation.
If the fuel pump gears do not rotate, replace or repair the
fuel pump. Refer to Procedure 005-016.
Using a remote starter, Part Number 3376506, crank the

engine, and make sure the accessory drive rotates
counterclockwise.
Fuel Shutoff Valve (005-043)

Remove
Remove the ECM. Refer to Procedure 019-031 in the
Troubleshooting and Repair Manual, Electronic Control
System, QSK19, QSK23, QSK45, QSK60, and QSK78
Engines, Bulletin 3666113.
Fuel Shutoff Valve QSK45 and QSK60
WARNING
Use solvent to clean the fuel shutoff valve and surrounding
area.
Use a 3/8-inch wrench to remove the nut holding the

electrical connection of the fuel shutoff valve coil.
Remove the connection.
Remove the four capscrews.

Remove the coil housing and the fuel shield.
Discard the o-ring.
Remove the spring washer, valve disc, actuator disc, and
actuator spacer from the valve housing.
Discard the o-ring.
Disassemble
Remove the four capscrews.
Remove the coil housing and the fuel shield.
Discard the o-ring.
Remove the spring washer, valve disc, actuator disc, and
actuator spacer from the valve housing.
Discard the o-ring.

WARNING
Use mineral spirits to clean all of the parts except the coil
assembly.
Do not get solvent on the coil. Clean the coil with a dry
cloth. Use a 200-grit emery cloth and a flat surface to
polish the coil surface.
Inspect the fuel shut off valve housings (7) and (8) for wear
and other damage.
Use a wire brush to clean any corrosion from the coil

terminal.
Inspect the valve disc (2), valve spring (3), actuator disc
(1), and shutoff valve shield (4) for dirt, metal parts,
bonding separation, corrosion, cracks, or wear. Replace if
necessary.
Fuel Shutoff Valve QSK45 and QSK60
Measure the resistance of the coil with a multimeter.
Fuel System Shutoff Valve Specifications

Voltage Resistance Resistance
Minimum (Ohms) Maximum (Ohms)
6 VDC 1 5
12 VDC 6 15
24 VDC 24 50
32 VDC 42 80
36 VDC 46 87
48 VDC 92 145
74 VDC 315 375
115 VAC 645 735
Replace the coil if it does not meet the specifications.

If the coil assembly shows 0 ohms, there is an electrical
short in the coil.
Assemble
Install a new o-ring (6) into the electronic control valve
body (8).
Install the actuator housing (7) with the o-ring groove
toward the coil (1).
Install the actuator disc (5) with the cup side toward the
coil (1).
Place the rubber side to the valve disc (4) on the actuator
disc (5).
Install the valve spring (3) with the cup side toward the coil.
The inner diameter of the spring (3) must rest on the pilot
diameter of the valve disc (4).
Install a new o-ring (6) into the actuator housing (7).
Install the fuel shield (2) and coil (1) on to the front cover
(8).
Tighten the four capscrews.
Install
Install a new o-ring (6) into the electronic control valve
body (8).
Install the actuator housing (7) with the o-ring groove
toward the coil (1).
Install the actuator disc (5) with the cup side toward the
coil (1).
Place the rubber side to the valve disc (4) on the actuator
disc (5).
Install the valve spring (3) with the cup side toward the coil.
The inner diameter of the spring (3) must rest on the pilot
diameter of the valve disc (4).
Install a new o-ring (6) into the actuator housing (7).
Install the fuel shield (2) and coil (1) on to the front cover
(8).
Install the electrical connection on the fuel shutoff valve.

Install the nut on the threaded post of the coil.
Using two 3/8-inch wrenches, hold the post of the nut
firmly while tightening the connection nut.
Install the ECM to the control valve body. Refer to

Manual, Electronic Control System, QSK19, QSK23,
QSK45, QSK60, and QSK78 Engines, Bulletin 3666113.
Tighten the six ECM mounting capscrews.
Fuel Lift Pump QSK45 and QSK60
CAUTION
Use only Cummins recommended lubricant DS-ES.
Other lubricating oil or grease in the connectors can
cause ECM damage, poor engine performance, or
premature connector pin wear.
Apply a thin coat of lubricant to the connector nosepiece.
Spread the lubricant across the connector nosepiece so it

enters every pin hole and lubricates the contacts.
Lubricant must not be visible on the surface of the
nosepiece.
Connect the OEM and engine harness connectors to the

ECM.
Tighten the connector capscrews.
When an ECM is replaced, the new ECM must be
calibrated. Refer to Procedure 019-032 in the
Troubleshooting and Repair, Electronic Control System,
QSK19, QSK23, QSK45, QSK60, and QSK78 Engines,
Bulletin 3666113.
Fuel Lift Pump (005-045)

Initial Check
Remove the plug from the fuel filter head assembly.
Install the compucheck fitting, Part Number 3824844, or
equivalent.
QSK45 and QSK60 Fuel Lift Pump
Connect the pressure adapter, Part Number 3164491, or

equivalent, and the digital multimeter, Part Number
3164488, 3164489, or equivalent, to the compucheck
fitting.
The fuel lift pump will operate for 120 seconds when the
key is switched to the ON position. The fuel lift pump will
also operate while the engine is cranking until the fuel rail
pressure reaches 200 bar [2900 psi].
At the end of 120 seconds of operation the fuel lift pump
must produce pressure. If the lift pump does not, then the
lift must be replaced.
Minimum Fuel Lift Pressure

bar psi
3 43.5
Preparatory Steps
• Disconnect the electrical connection to the fuel lift
pump.
Remove
WARNING
Remove the banjo fittings and washers securing the two
fuel transfer tubes.
Remove the four capscrews securing the fuel lift pump to

the fuel filter head assembly.
Remove the vibration isolators from each end of the fuel

lift pump.
Inspect for Reuse

Inspect the electrical fuel lift pump for any signs of
damage.
Replace the fuel lift pump, if damaged.
Use a digital multimeter to measure the resistance across

the pins in the electrical connector. Reference the table
for resistance value. If not within specification, replace the
fuel lift pump.
Fuel Lift Pump Resistance

Minimum Maximum
1 ohm 3 ohm
Use a digital multimeter, check for a short between each

pin and the electric fuel lift pump body. Replace the fuel
lift pump, if shorted.
QSK45 and QSK60 Fuel Lift Pump
Install
Install vibration isolators to each end of the electric fuel lift
pump.
Install the electric fuel lift pump to the fuel filter head
assembly with four capscrews.
Connect the fuel transfer tubes to the fuel filter head

assembly with the banjo fittings and new washers.
Finishing Steps
• Connect the wire harness to the fuel lift pump.
Notes
QSK45 and QSK60
Section 6 — Injectors and Fuel Lines — Group 06 Page 6-a
Section 6 — Injectors and Fuel Lines — Group 06

Section Contents
Page
Air in Fuel ..........................................................................................................................................................6-4
General Information..........................................................................................................................................6-4
Test..................................................................................................................................................................6-4
Sight Glass Method........................................................................................................................................6-4
Gear Pump Drain Method...............................................................................................................................6-5
Fuel Connection Block (Manifold-Mounted) .....................................................................................................6-6
Assemble..........................................................................................................................................................6-9
Clean and Inspect for Reuse.............................................................................................................................6-8
Disassemble.....................................................................................................................................................6-8
Install................................................................................................................................................................6-9
Remove............................................................................................................................................................6-6
Remove............................................................................................................................................................6-7
Fuel Control Valve Body Assembly ................................................................................................................6-76
Assemble........................................................................................................................................................6-79
Disassemble................................................................................................................................................... 6-78
Finishing Steps...............................................................................................................................................6-81
Install..............................................................................................................................................................6-80
Remove.......................................................................................................................................................... 6-77
Fuel Cooler ......................................................................................................................................................6-90
Finishing Steps...............................................................................................................................................6-93
Install..............................................................................................................................................................6-93
Pressure Test..................................................................................................................................................6-91
Remove.......................................................................................................................................................... 6-90
Fuel Drain Line Restriction .............................................................................................................................6-10
Measure..........................................................................................................................................................6-10
Fuel Drain Lines ..............................................................................................................................................6-11
Finishing Steps...............................................................................................................................................6-18
Install..............................................................................................................................................................6-15
Remove.......................................................................................................................................................... 6-12
Fuel Filter (Spin-On Type) ...............................................................................................................................6-18
QSK45 and QSK60
Page 6-b Section 6 — Injectors and Fuel Lines — Group 06
Clean..............................................................................................................................................................6-19
General Information.........................................................................................................................................6-18
Install..............................................................................................................................................................6-19
Remove.......................................................................................................................................................... 6-18
Fuel Filter Head ...............................................................................................................................................6-21
Assemble........................................................................................................................................................6-27
Disassemble................................................................................................................................................... 6-22
Finishing Steps...............................................................................................................................................6-30
Install..............................................................................................................................................................6-30
Remove.......................................................................................................................................................... 6-22
Fuel Inlet Restriction .......................................................................................................................................6-31
Measure..........................................................................................................................................................6-31
Fuel Manifold (Drain) .......................................................................................................................................6-37
Finishing Steps...............................................................................................................................................6-41
Install..............................................................................................................................................................6-40
Remove.......................................................................................................................................................... 6-37
Fuel Manifold (Supply) ....................................................................................................................................6-42
Assemble........................................................................................................................................................6-44
Disassemble................................................................................................................................................... 6-43
Finishing Steps...............................................................................................................................................6-45
Install..............................................................................................................................................................6-44
QSK45 Engines............................................................................................................................................6-44
QSK60 Engines............................................................................................................................................6-45
Remove.......................................................................................................................................................... 6-42
QSK45 Engines............................................................................................................................................6-42
QSK45 and QSK60
Section 6 — Injectors and Fuel Lines — Group 06 Page 6-c
QSK60 Engines............................................................................................................................................6-43
Fuel Supply Lines ............................................................................................................................................6-45
with Electronically Actuated Injector.............................................................................................................6-49
Finishing Steps...............................................................................................................................................6-52
Install..............................................................................................................................................................6-50
Remove..........................................................................................................................................................6-46
Injector .............................................................................................................................................................6-63
Calibrate.........................................................................................................................................................6-73
Finishing Steps...............................................................................................................................................6-76
Initial Check....................................................................................................................................................6-63
Misfire Using Heat Indicator Marker..............................................................................................................6-63
Misfire using Infared Thermometer...............................................................................................................6-64
Misfire Using Injector Cutout Tool.................................................................................................................6-64
Install..............................................................................................................................................................6-73
Remove..........................................................................................................................................................6-68
Injector Supply Lines (High Pressure) ............................................................................................................6-81
Finishing Steps...............................................................................................................................................6-87
Initial Check....................................................................................................................................................6-82
Install..............................................................................................................................................................6-86
Leak Test........................................................................................................................................................6-88
Remove..........................................................................................................................................................6-83
Service Tools ....................................................................................................................................................6-1
Injectors and Fuel Lines....................................................................................................................................6-1
Static Injection Timing ....................................................................................................................................6-53
Finishing Steps...............................................................................................................................................6-63
Measure..........................................................................................................................................................6-56
QSK45 and QSK60
Page 6-d Section 6 — Injectors and Fuel Lines — Group 06
Setup..............................................................................................................................................................6-55
Section 6 — Injectors and Fuel Lines — Group 06 Page 6-1
Service Tools
Injectors and Fuel Lines
Repair Location.

Filter Wrench
Removes fuel filter.
3375049
In-Line Fuel Sight Glass - Number 16 SPG

Used to check for air in the fuel system. The sight glass is used with
3163270 fuel line size SAE 16.
Fitting, Quick-Disconnect - Female

Connects gauges when measuring various fuel pressures.
3376859
Fitting, Quick-Disconnect - Male

Used to perform a pressure-side air-in-fuel test.
3377244
Fluorescent Tracer
Put in engine oil or fuel. Use black light to read oil or fuel leaks.
3376891
Injector Removal/Installation Tool

Used to remove and install the QSK injector.
3824830
Page 6-2 Section 6 — Injectors and Fuel Lines — Group 06

Injection Timing Tool
Check injection timing. The timing fixture is designed to determine
3824942 the push tube travel in relation to the piston travel.
Injector Timing Tool Update Kit

This is an update kit for previous universal injection timing tool, Part
3163303 Number 3824942, used only for QSKV engines.
Pressure Gauge
Used to measure fuel pressure between the fuel drain hose and the
3824241 engine fuel drain fitting.
Pressure Gauge
Measures injector drain line restriction when used with drain adapter.
ST-1273
Single-Injector Diagnostic Cutout Tool

Used to locate defective or weak injector (QSK45 = 7) (QSK60 = 9).
3163194
Torque Wrench - Click Type - 25 to 250 in-lb

This is a [3/8-inch] drive torque wrench used to set injector preload
3398328 adjustments on engines with the high-pressure fuel injection systems
such as on the QSK19, QSK45, and QSK60 Series engines.
Torque Wrench - Dial Type - 300 in-lb

This is a [3/8-inch] drive torque wrench used to set injector preload
3824783 adjustments on engines with the high-pressure fuel injection systems
such as on the QSK19, QSK45, and QSK60 Series.
Vacuum Gauge
Measures fuel pump inlet restriction. Includes most hose adapters.
ST-434

Lubricant DS-ES
Used to lubricate the pins in electrical connectors.
3822934
QD Contact Cleaner
Nonpetroleum cleaner used to clean electrical connections.
3824510
Manometer
Used to check for stuck check balls in injectors for a slow shutdown
ST111-3 symptom.
Air in Fuel QSK45 and QSK60
Air in Fuel (006-003)

General Information
There are two good methods to check for air in the fuel.
1. Sight glass method
2. Gear pump drain method.
Test
Sight Glass Method
WARNING
Depending on the circumstances fuel is flammable.
Keep all cigarettes, flames, pilot lights, arcing
equipment, and switches out of the work area and
areas sharing ventilation to reduce the possibility of
severe personal injury or death when working on the
fuel system.
WARNING
Do not vent the fuel system on a hot engine; this can
cause fuel to spill onto a hot exhaust manifold, which
can cause a fire.
Remove the fuel inlet line.
Install a sight glass in the line.
Operate the engine at high idle with no load.
A small air leak will have a "milky" appearance.
A large air leak will look like bubbles in the fuel.
If an air leak is found, perform the following:

• Tighten the hose connections and the fuel filter.
• Check the drop tube in the fuel tank for damage.
• Check o-rings for damage.
QSK45 and QSK60 Air in Fuel
Continue to test and look for source of air until no air

bubbles are visible.
Remove the sight glass.
Install and tighten the fuel inlet hose.
Gear Pump Drain Method

To perform a pressure-side air-in-fuel test, use the
following items:
• Quick-Disconnect Fitting - Female
• High-pressure hose
• Pressure valve (capable of 2758 kPa [400 psi])
• Clear tubing
• Clean container.
Connect the equipment to the quick-connect fitting at the

fuel pump outlet.
Put the end of the clear tubing into the clean container.
WARNING
Depending on the circumstances fuel is flammable.
fuel system.
WARNING
Do not vent the fuel system on a hot engine; this can
cause fuel to spill onto a hot exhaust manifold, which
can cause a fire.
Operate the engine at high idle with no load. Slowly open
the valve until a steady stream of fuel is visible.
Fuel Connection Block (Manifold-Mounted) QSK45 and QSK60
Put the end of the tube below the surface of the fuel.
If there is an air leak, bubbles will be visible.
If an air leak is found, perform the following:

• Tighten the hose connections on the fuel filter.
• Check the drop tube in the fuel tank for damage.
• Check the o-rings for damage.
Continue to test and look for air leaks until there are no
bubbles visible.
Remove the test equipment.
Install and tighten the fuel inlet hose.
Fuel Connection Block (Manifold-

Mounted) (006-010)
Remove
The fuel transfer block and tube assembly mounts to the
engine between cylinder head number 3 and cylinder
head number 4 on the QSK45 engine and between
cylinder head number 4 and cylinder head number 5 on
the QSK60 engine.
Remove the four capscrews (1) through the fuel manifold
(2) and fuel transfer manifold block (3).
QSK45 and QSK60 Fuel Connection Block (Manifold-Mounted)
Remove the two capscrews (4) and banjo bolt (7) through
the fuel transfer deck block into the engine deck.
Remove the fuel transfer tubes and block assembly (5).
Remove and discard the old gasket (6).
Remove and discard the o-rings (9) and separate the fuel
transfer manifold block (3) from the two transfer tubes (8).
Remove the two transfer tubes (8) and o-rings (7) from the
fuel transfer deck block (5).
Discard the old o-rings (7).
If the old style fuel transfer block is used, o-rings (9) are
not required. The old style fuel transfer manifold block has
molded-in seals.
Remove
The fuel transfer block and tube assembly mounts to the
engine between cylinder head number 3 and cylinder
head number 4 on the QSK45 engine and between
cylinder head number 4 and cylinder head number 5 on
the QSK60 engine.
Remove the four capscrews (1) through the fuel manifold
(2) and fuel transfer manifold block (3).
Remove the two capscrews (4) and banjo bolt (7) through
the fuel transfer deck block into the engine deck.
Remove the fuel transfer tubes and block assembly (5).
Remove and discard the old gasket (6).
Fuel Connection Block (Manifold-Mounted) QSK45 and QSK60
Disassemble
Remove and discard the o-rings (9) and separate the fuel
transfer manifold block (3) from the two transfer tubes (8).
Remove the two transfer tubes (8) and o-rings (7) from the
fuel transfer deck block (5).
molded-in seals.
WARNING
When using solvents, acids or alkaline materials for
WARNING
personal injury.
Clean all parts using solvent and dry using compressed
air.
Check that all gasket material has been removed from the
fuel transfer deck block and mounting surface.
Inspect the tubes and block for cracks and any sign of
damage. If any damage is noticed, replace the
component.
QSK45 and QSK60 Fuel Connection Block (Manifold-Mounted)
Assemble
CAUTION
The tubes, o-rings, and blocks must be free from dirt
and damage. Fuel leaks will result with use of
damaged material causing internal engine damage
and possible crankcase explosion.
Lubricate the o-ring (7) with clean engine oil prior to
assembly.
Install the two fuel transfer tubes (8) with new o-rings (7)
into the fuel transfer deck block (5).
Install the fuel transfer manifold block (3) onto the transfer
tubes (8).
Lubricate the new o-rings (9) with clean engine oil and
install them into the fuel block connection (3).
molded-in seals.
Install
CAUTION
The tubes, o-rings, and blocks must be free from dirt
and damage. Fuel leaks will result with use of
damaged material causing internal engine damage
and possible crankcase explosion.
Lubricate the o-ring (7) with clean engine oil prior to
assembly.
Install the two fuel transfer tubes (8) with new o-rings (7)
into the fuel transfer deck block (5).
Install the fuel transfer manifold block (3) onto the transfer
tubes (8).
Lubricate the new o-rings (9) with clean engine oil and
install them into the fuel block connection (3).
molded-in seals.
The fuel transfer head deck block mounts to the engine

between cylinder head number 3 and cylinder head
number 4 on the QSK45 engine. The head deck block
mounts between cylinder head number 4 and cylinder
head number 5 on the QSK60 engine.
Install the fuel transfer head deck block gasket (6) to the
correct position on the left or right bank.
Slide the fuel transfer tubes and block assembly (5) into
location. Take care that alignment with the gasket (6) is
maintained during assembly.
Install the washer (8) onto the banjo bolt (7).
Install the two mounting capscrews (4) and the banjo bolt
(7) and washer (8) through the fuel transfer head deck
block (5) and gasket (6) into the engine deck.
Finger tighten capscrews (4) and banjo bolt (7).
Fuel Drain Line Restriction QSK45 and QSK60
Install the four capscrews (1) through the fuel manifold (2)
into the fuel transfer manifold block (3).
Tighten the two capscrews (4) through the fuel transfer

deck block into the engine deck.
Tighten the banjo bolt (7).
Fuel Drain Line Restriction (006-012)

Measure
Remove the fuel drain hose.
Install an adapter and pressure gauge between the fuel
drain hose and the engine fuel drain fitting.
If the engine has a drain side check valve, install the

adapter between the fuel drain hose and the check valve.
QSK45 and QSK60 Fuel Drain Lines
Start and operate the engine at high idle, no load.

Check for fuel inlet restriction.
Fuel Inlet Restriction

mm Hg in Hg
With check valve 228 MAX 9
Without check valve 177 MAX 7
If the fuel drain line restriction is above specifications,

inspect the fuel drain line. Refer to Procedure 006-013.
Remove the gauge.

Install the fuel drain line.
Tighten the fuel line.
Fuel Drain Lines (006-013)

Preparatory Steps
• Clean debris from the fittings.
• Remove the Electronic Control Module cooling plate.
Refer to Procedure 008-128.
Fuel Drain Lines QSK45 and QSK60
Remove
NOTE: The option illustrated is a left rear fuel drain
location. The fuel drain can also be located at the right
rear, left front, and right front.
Remove the fuel drain hose from the fuel drain line
connector.
Remove the two capscrews from each fuel drain line

support block.
Remove the support block cap from the support block.
Disconnect the fuel drain line from each fuel manifold.

Remove the fuel drain line assembly.

Remove the capscrew and p-clip which clamp the drain
line between the mechanical dump valve and the drain
manifold block, to the brace that secures it to the engine.
Remove the banjo capscrews and the sealing washers

securing the drain line between the mechanical dump
valve and the drain manifold block. Discard the sealing
washers.
Remove the banjo capscrew and sealing washers

securing the air bleed line from the drain manifold block
to the fuel pump (1). Discard the sealing washers.
Remove the air bleed line from the drain manifold block
(2). Discard the o-ring.
Remove the capscrew, nut and p-clip which clamp the fuel
drain line between the drain manifold block and the fuel
block manifold, to the brace that secures it to the engine.
Remove the fuel drain line that connects the drain

manifold to the fuel block manifold. Discard the o-rings.
If it is necessary to remove the main fuel manifold, the

aftercooler assembly will need to be removed. Refer to
Procedure 010-002.
Remove the double banjo capscrew and sealing washers

that secure the main fuel drain manifold to the block.
Discard the sealing washers.
Remove the remaining eight banjo capscrews, sealing

washers, and the fuel drain manifold. Discard the sealing
washers.
Repeat these procedures on the opposite cylinder bank.

Inspect the inside of the engine-to-fuel tank hose for the
following:
• The inner lining of the hose can separate from the
center hose section
• A separation of the inner flap can cause a restriction
in the fuel flow.
Inspect for any pinches in the hose that can obstruct the
flow.
WARNING
bodily injury.
Flush the fuel drain lines and remove any loose dirt
particles using compressed air.
Inspect the fuel drain line for cracks or sharp bends that
can cause a loss of pressure.

Inspect the drain lines for cracks and visible damage. The
drain lines must be replaced if they are cracked or
damaged.
Inspect the banjo capscrews for visible damage. Replace
if damage is found.
Install
NOTE: The option illustrated is a left rear fuel drain
location. The fuel drain can also be located at the right
rear, left front, and right front.
Install and tighten the fuel drain line to the fuel manifold.
Install the support block clamp over the fuel drain line and
tighten.
Install and tighten the drain hose to the fuel drain line.

Install the fuel drain manifold, eight banjo capscrews and
new sealing washers.
Torque Value:
Fuel Drain 30 N•m [ 22 ft-lb ]
Manifold
Capscrews
Install the double banjo capscrew and new sealing

washers that secure the fuel drain manifold to the block.
Torque Value:
Manifold
Repeat these procedures on the opposite cylinder bank.
Install the fuel drain line that connects the drain manifold
block to the fuel block manifold. Use new o-rings at each
end.
Torque Value:
Fuel Drain Line 45 N•m [ 33 ft-lb ]
Install the screw, nut and p-clips which clamp the fuel
drain line between the drain manifold block and the fuel
block manifold, to the brace that secures it to the cylinder
block.
Torque Value:
P-clip 22 N•m [ 195 in-lb ]
capscrew
Install the banjo capscrew and new sealing washers

securing the air bleed line from the drain manifold block
to the fuel pump (1).
Torque Value:
Air Bleed Line 30 N•m [ 22 ft-lb ]
Install the air bleed line to the drain manifold block. Use a
new o-ring.
Torque Value:
Install the banjo capscrews and new sealing washers

securing the drain line between the mechanical dump
valve and the drain manifold block.
Torque Value:
Banjo
Capscrew
Install the capscrew and p-clip which clamp the drain line
between the mechanical dump valve and the drain
manifold block, to the brace that secures it to the cylinder
block.
Torque Value:
P-clip 22 N•m [ 195 in-lb ]
capscrew
Fuel Filter (Spin-On Type) QSK45 and QSK60
Finishing Steps
• Install the aftercooler assembly. Refer to Procedure
010-002.
• Install the Electronic Control Module cooling plate.
Fuel Filter (Spin-On Type) (006-015)

General Information
The fuel filter consists of the following components:
1. Stage one filter
2. Drain valve
3. Water in fuel sensor
4. Stage two filters.
Remove
WARNING
Depending on the circumstance, fuel is flammable.
fuel system.
Close the fuel line shutoff valve before changing the fuel
filters, or the overhead tank can drain, causing a fuel leak.
Remove the fuel filters with fuel filter wrench, Part Number
Remove the thread adapter sealing ring(s).

Clean sealing surfaces of the filter head with a clean, lint-
free towel.
QSK45 and QSK60 Fuel Filter (Spin-On Type)
WARNING
fuel system.
Close the fuel line shutoff valve before changing the fuel
filters, or the overhead tank can drain.
Disconnect the water in fuel sensor harness from the
stage one filter.
Remove the fuel filters with fuel filter wrench, Part Number
Clean
Remove the thread adapter sealing ring (1).
Use a clean, lint-free towel to clean the sealing surface of
the filter head.
Install
Install a new thread adapter sealing ring supplied with the
new filter. Refer to Procedure 018-024 in Section V.
A fuel-water separator or fuel filter and water separator
combination must be installed.
Apply a light coating of clean engine oil to the surface of
the filter gasket.
Fill the fuel filter with clean fuel.
Install the filter on the filter head. Turn the filter until the
gasket touches the surface of the filter head.
Tighten the filter an additional ½ to ¾ of a turn after the
gasket touches the filter head surface.
Open the fuel line shutoff valve and check for leaks.
Operate the engine and check for leaks.
Fuel Filter (Spin-On Type) QSK45 and QSK60

On the stage one filter, apply a light coating of clean
engine oil to the surface of the filter gasket.
Fill the stage one filter with clean fuel.
CAUTION
The second stage filter is installed dry. Do not fill the
filter with fuel prior to installation. Doing so will send
unfiltered fuel to the pump and injectors which can
cause failure or premature wear.
Install the filter on the filter head. Turn the filter until the
gasket touches the surface of the filter head.
Connect the water in fuel sensor harness.
For the second stage filter apply a light coat of clean
engine oil to the surface of the filter gasket.
Install the second stage filters on the filter head. Turn the
filter until the gasket touches the surface of the filter head.
Open the fuel shutoff valve.
Cycle the keyswitch to prime the stage two filters with the
priming pump.
Once primed, operate the engine and check for leaks.
QSK45 and QSK60 Fuel Filter Head
Fuel Filter Head (006-017)

Preparatory Steps
WARNING
fuel system.
WARNING
cable last.
• Disconnect the battery cables. Refer to Procedure
013-009.
• Remove the fuel filters. Refer to Procedure 006-015.
WARNING
fuel system.
WARNING
cable last.
013-009.
• Disconnect the Fuel Temperature Sensor. Refer to
Procedure 019-119 in the Troubleshooting and
Repair Manual Electronic Control System QSK50
and QSK60 Modular Common Rail System Series
• Disconnect the Fuel Pressure Sensor. Refer to
• Remove the fuel filters. Refer to Procedure 006-015.
• Disconnect the fuel supply lines. Refer to Procedure
006-024
Fuel Filter Head QSK45 and QSK60
Remove
Remove the fuel filter supply and return hoses.
Remove the fuel filter head mounting capscrews and the
fuel filter head.

Remove the five capscrews securing the fuel filter head
assembly to the engine.
Remove the nut securing the fuel filter head assembly to

the engine and remove the fuel filter head assembly.
Disassemble
Remove the straight thread o-ring plugs (1) and the o-ring
seals (2).
Remove the inlet and outlet elbows (3) and the o-rings (2).
The fuel filter adapters (4) do not need to be remove
unless they are loose or damaged.
If it is necessary to remove the fuel adapter, remove the
adapters (4), lock plates (5), and o-ring seals (6).
Discard all removed o-ring seals.

Remove the fuel lift pump. Refer to Procedure 005-045.
Remove the union fittings. Discard the o-rings.
Remove the check valve and check ball. Discard the o-

ring.
Remove the fuel temperature sensor and fuel pressure

sensor. Refer to Procedures 019-119 and 019-188 in the
System QSK50 and QSK60 Modular Common Rail
The cup plug covering the optional fuel heater port must
be replaced if it is damaged or shows signs of leakage.
Use a light duty puller set, Part Number 3375784, or
equivalent, to remove the cup plug.
Remove the three threaded plugs.

WARNING
WARNING
personal injury.
CAUTION
Use a solvent that will not damage aluminum or the
remaining o-rings.
Use solvent to clean the filter head components.
Dry using compressed air.
Inspect the filter head for damaged threads or cracks in

the housing.
WARNING
Some solvents are flammable and toxic. Read
manufacturer's instructions before using.
WARNING
Inspect the fuel lift pump. Refer to Procedure 005-045.
Inspect the fuel tube and banjo fittings for corrosion,

damage, or signs of leakage. Replace any damaged
components.
Inspect the union fittings for signs of stripped or damaged

threads, cracks, and damage. Replace any damaged
union fittings.
Inspect the check valve for cracks, flat spots, and damage.
Replace if damaged.
Inspect the fuel temperature sensor and fuel pressure

Inspect the fuel filter head assembly for corrosion, cracks,

and stripped or damaged threads. Threads that attach the
fuel filters or union fittings that are damaged can not be
repaired. The threaded holes which hold the optional fuel
heater can be repaired using metric thread insert kit (M6
x 1.00), Part Number 3822698.
Assemble
Install new o-ring seals.
Install the lock plate, locate the 90-degree bend in the
drilled hole in the fuel filter head.
Apply one drop of Loctite® 601 on the threads of the
adapter that engages the threads in the filter head and
install the adapter.
NOTE: The position of the plugs and the inlet and outlet
elbows can be different than illustrated due to the various
fuel plumbing installations.
Using new o-rings (2), install the straight-thread o-ring
plugs (1).
Using new o-rings (2), install the fuel inlet and outlet
elbows (3).

Coat the inside diameter bore where the cup plug is to be
installed in the filter head with Loctite® 277, or equivalent.
Install the cup plug with handle, Part Number 3164085, or

equivalent, and cup plug driver, Part Number 3376813, or
equivalent.
Install the cup plug to the depth shown in the illustration.
Install the check valve in the port and cover with the
threaded plug.
Torque Value:
Check Valve 62 N•m [ 46 ft-lb ]
Plug
Install the fuel lift pump. Refer to Procedure 005-045.

Install the threaded plugs

Install a new o-ring onto the three elbows and install in

them in fuel filter head.
Install the new o-rings on the union fitting and install in the
fuel filter head.
Install the fuel temperature sensor and fuel pressure

Install
Install the fuel filter head and install the fuel filter head
mounting capscrews.
Install the fuel filter supply and return hoses.
Clean the gasket sealing surface with a towel.

Install the fuel filter head assembly to the engine with one
nut and five mounting capscrews.
Finishing Steps
WARNING
cable last.
• Install the fuel filters. Refer to Procedure 006-015.
• Connect the battery cables. Refer to Procedure
013-009.
QSK45 and QSK60 Fuel Inlet Restriction
WARNING
cable last.
• Install the fuel supply lines. Refer to Procedure
006-024
• Install the fuel filters. Refer to Procedure 006-015.
• Connect the Fuel Temperature Sensor. Refer to
• Connect the Fuel Pressure Sensor. Refer to
013-009.
Fuel Inlet Restriction (006-020)

Measure
Use a Compuchek® fitting, vacuum gauge, and adapter.
Connect the gauge to the Compuchek® fitting on the fuel
pump inlet fitting.
Start and operate the engine at high idle, no load.

Fuel inlet restriction:
• With clean fuel filters: 102 mm Hg [4 in Hg]
• With dirty fuel filters: 203 mm Hg [8 in Hg].
Fuel Inlet Restriction QSK45 and QSK60
If the restriction is above specifications:

• Change the fuel filter. Refer to Procedure 006-015.
• Inspect the fuel lines. Refer to Procedure 006-024.

Stage 1 Filters
Remove the air bleed hose (1) from the air bleed check
valve (2).
Remove the air bleed check valve (2) from the drain
manifold block (3).
Install the diagnostic orifice tool, part number, 4918612,

in place of the air bleed check valve.
Install the air bleed hose.
Torque Value:
Air Bleed Hose 45 N•m [ 33 ft-lb ]
Remove the threaded o-ring plug (1) in the inlet and the
threaded o-ring plug (2) in the outlet of stage 1 filter head
and replace them with Compuchek® fittings.
Connect a vacuum gauge and adapter to the Compuchek®

fitting in the inlet port (1).
Start and operate the engine at low idle, no load.
Record the stage 1 inlet restriction.
The fuel inlet restriction maximum is: 102 mm Hg [4 in Hg].
If the restriction is above specifications, inspect the fuel
lines. Refer to the OEM Troubleshooting and Repair
manual to determine the source of the high restriction.
Remove the vacuum gauge and adapter from the inlet port
and install it on the Compuchek® fitting in the outlet port
(2).
Start and operate the engine at low idle, no load.
Record the stage 1 outlet restriction.

Subtract the measurement obtained at the stage 1 inlet
from the measurement obtained at the stage 1 outlet. This
is the stage 1 restriction.
Example:
Stage 1 inlet restriction is 25 mm Hg [1 in Hg]
Stage 1 outlet restriction is 113 mm Hg [4.5 in Hg]
Stage 1 restriction is 113 mm Hg [4.5 in Hg] - 25 mm Hg
[1 in Hg] = 88 mm Hg [3.5 in Hg]
Stage 1 Filter Restriction

mm Hg in Hg
76 MIN 3
152 MAX 6
If the restriction is above specifications, replace the stage
1 fuel filters. Refer to Procedure 006-015.
Remove the vacuum gauge, adapter and Compuchek®

fittings from the first stage fuel filter head.
Install the threaded o-ring plugs inlet port (1), and outlet
port (2) in the filter head.
Torque Value:
Threaded O- 27 N•m [ 20 ft-lb ]
ring Plugs
Remove the air bleed hose and diagnostic orifice tool from
the drain manifold block.
Install the original air bleed check valve (2) into the drain
manifold block (3).
Torque Value:
Air Bleed 55 N•m [ 41 ft-lb ]
Check Valve
Install the air bleed hose to the air bleed check valve.
Torque Value:
Stage 2 Filters:
Remove the threaded o-ring inlet plug (1) and outlet plug
(2) in the inlet of the stage 2 filter head and replace them
with Compuchek® fittings.
Connect a pressure gauge and adapter to the

Compuchek® fitting in the inlet port (1).
Start and operate the engine at high idle.
Record the stage 2 inlet pressure.
Remove the pressure gauge and adapter from the inlet

port and install the pressure gauge and adapter on the
outlet port (2).
Start and operate the engine at high idle.
Record the stage 2 outlet pressure.

Subtract the measurement obtained at the stage 2 outlet
from the measurement obtained at the stage 2 inlet. This
is the stage 2 filter restriction.
Example:
Stage 2 inlet pressure is 731.5 kPa [104.5 psi]
Stage 2 outlet pressure is 714.0 kPa [102.0 psi]
Stage 2 restriction is 728.0 kPa [104.5 psi] - 714.0 kPa
[102.0 psi] = 17.5 kPa [2.5 psi]
Stage 2 Filter Restriction (clean filter)

kPa psi
28 MAX 4
Stage 2 Filter Restriction (dirty filter)

kPa psi
138 MAX 20
If the restriction is above specifications, replace the stage
2 fuel filters. Refer to Procedure 006-015.
Remove the pressure gauge and adapter from the second

stage filter head.
Remove the Compuchek® fittings from the second stage

filter head.
Install the threaded o-ring plugs into the inlet (1) and outlet
(2) ports in the filter head.
Tighten the plugs.
Torque Value:
Threaded O- 27 N•m [ 20 ft-lb ]
ring Plugs
QSK45 and QSK60 Fuel Manifold (Drain)
Fuel Manifold (Drain) (006-021)

Preparatory Steps
WARNING
Depending on the circumstances, fuel is flammable.
fuel system.
WARNING
• Clean debris from the fittings and fuel drain lines.
• Disconnect the fuel drain lines from the fuel
manifold. Refer to Procedure 006-013.
Remove
Remove the two unions from the drain manifold block.
1. This union is used to connect the fuel drain line from
the fuel tank to the drain manifold block.
the fuel block manifold to the drain manifold block.
Remove the check valve/union that is used to connect the

air bleed line from the fuel pump to the drain manifold
block.
Fuel Manifold (Drain) QSK45 and QSK60
Remove the two capscrews that secure the drain manifold

block to the engine and remove the drain manifold block.
Remove the union used to connect the fuel drain line from
the drain manifold block to the fuel block manifold.
Remove the two capscrews that secure the fuel block

manifold to the engine. Discard the gasket.

WARNING
Some solvents are flammable and toxic. Read the
WARNING
Inspect the drain manifold block and fuel block manifold

for cracks, damage, or stripped threads. Replace if
damaged.
Inspect the union fitting for cracks, damage, or stripped

threads. Replace, if damaged.
Inspect the o-rings at each end of the unions/check valve

for signs of tears or damage. The o-rings must be
replaced if damage is found.
Inspect the capscrews for damage. Replace if necessary.

Fuel Manifold (Drain) QSK45 and QSK60
Install
Install the drain manifold block to the engine and tighten
the two capscrews.
Torque Value:
Drain Manifold 20 N•m [ 177 in-lb ]
Block
Capscrews
Install the two unions in the drain manifold block.

the fuel tank to the drain manifold.
Torque Value:
Union to Fuel
Tank
the fuel block manifold to the drain manifold block.
Torque Value:
Union to Fuel
Block Manifold
Install the check valve/union that is used to connect the

air bleed line from the fuel pump to the drain manifold
block.
Torque Value:
Check Valve/ 55 N•m [ 40 ft-lb ]
Union
Install the fuel block manifold, new gasket and two

capscrews that secure the fuel block manifold to the
engine.
Torque Value:
Fuel Block 45 N•m [ 33 ft-lb ]
Manifold
Capscrews
Install the union used to connect the fuel drain line from
the drain manifold block to the fuel block manifold.
Torque Value:
Union
Finishing Steps
• Connect the fuel drain lines. Refer to Procedure
006-013.
Fuel Manifold (Supply) QSK45 and QSK60
Fuel Manifold (Supply) (006-022)

Preparatory Steps
WARNING
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C
[120°F] before removing the pressure cap. Heated
coolant spray or steam can cause personal injury.
WARNING
Coolant is toxic. If not reused, dispose of in
accordance with local environmental regulations.
WARNING
This assembly weighs 23 kg [50 lb] or more. To reduce
the possibility of personal injury, use a hoist or get
assistance to lift this assembly.
• Remove the engine wiring and electrical sensors on
the left-bank, as necessary, to gain access to the
aftercoolers. Refer to the Troubleshooting and
Repair Manual, Electronic Control System, QSK19,
QSK23, QSK45, QSK60, and QSK78 Engines,
Bulletin 3666113.
• Remove the crankcase breathers (if necessary).
• Drain the cooling system. Refer to Procedure
008-018.
• Remove the aftercooler assembly. Refer to
Procedure 010-002.
• Remove the fuel drain line assembly. Refer to
Procedure 006-013.
Remove
QSK45 Engines
Remove the 24 fuel manifold mounting capscrews.
Remove the four fuel transfer manifold block mounting
capscrews.
Remove the left-bank fuel manifold.
Inspect the gaskets for reuse, discard if damaged.
Repeat this process for the removal of the right-bank fuel
manifold.
QSK45 and QSK60 Fuel Manifold (Supply)
QSK60 Engines
On engines equipped with mechanically actuated
injectors, perform the following.
Remove the 32 fuel manifold mounting capscrews.
Remove the four fuel transfer manifold block mounting
capscrews.
Remove the left-bank fuel manifold.
Inspect the gaskets for reuse, discard if damaged.
Repeat this process for the removal of the right-bank fuel
manifold.
Disassemble
Remove the straight thread o-ring plugs from the ends of
the fuel manifold.

WARNING
WARNING
personal injury.
Use solvent to clean the fuel manifolds.
Use compressed air to clean out all of the drillings and dry
the manifold.
Fuel Manifold (Supply) QSK45 and QSK60
Inspect the fuel manifold for cracks in the fuel passages.

The fuel manifold must be replaced if damaged.
Assemble
Use clean engine oil to lubricate the o-rings.
Install the M10, M12, and M27 plugs in the end of the fuel
manifold.
Torque Value:
M10 plug 6 N•m [ 53 in-lb ]
M12 plug 8 N•m [ 71 in-lb ]
M27 plug 47 N•m [ 35 ft-lb ]
Install
Use Lubriplate™ Number 105, Part Number 3163086,
3163087 or equivalent, to position and secure the edge-
molded gaskets to the back of the fuel manifold.
Install the gaskets to align with each cylinder head.
Insert two capscrews per gasket through the manifold
located in the rubber-lined holes of the gasket.
An old style gasket is shown, with old style fuel manifold.
QSK45 Engines
Install the left-bank fuel manifold while making sure the
fuel transfer manifold block and tubes are aligned.
Use the sequence illustrated to tighten the 24 capscrews.
Install and tighten the four mounting capscrews to the fuel
transfer manifold block. Refer to Procedure 006-010.
Repeat the process for the right-bank manifold.
QSK45 and QSK60 Fuel Supply Lines
QSK60 Engines
Install the left-bank fuel manifold while making sure the
fuel transfer block and tubes are aligned.
Use the sequence illustrated to tighten the 32 capscrews.
Install and tighten the four mounting capscrews to the fuel
transfer manifold block. Refer to Procedure 006-010.
Repeat the process for the right-bank manifold.
Finishing Steps
WARNING
• Install the aftercooler assemblies. Refer to
Procedure 010-002.
• Install the fuel drain tubes. Refer to Procedure
006-013.
• Fill the cooling system. Refer to Procedure 008-018.
• Connect the engine wiring harness and brackets.
Refer to the Troubleshooting and Repair Manual,
Electronic Control System, QSK19, QSK23, QSK45,
QSK60, and QSK78 Engines, Bulletin 3666113.
• Install the crankcase breathers (if necessary). Refer
to Procedure 003-001.
Fuel Supply Lines (006-024)

Preparatory Steps
WARNING
WARNING
manufacturer's instructions before use.
WARNING
bodily injury.
Thoroughly clean debris from all fittings and components
before removal. Make sure that the debris, water, steam
or cleaning solution does not get inside the fuel system.
Fuel Supply Lines QSK45 and QSK60
Remove
Use two wrenches to remove the fuel tubes and hoses.
Support the mating fittings with a wrench. Loosen the fuel
tube nuts with the other wrench.
Remove the fuel tubes and hoses.
WARNING
When performing any or all of the following
procedures to remove supply lines and related
components, keep all cigarettes, flames, pilot lights,
arcing equipment, and switches out of the work area
and areas sharing ventilation to reduce the possibility
of severe personal injury or death when working on a
fuel system.
CAUTION
Very small amounts of dirt and debris can be very
harmful to the injectors and the cone seats on the
injectors. Extra care is required to keep the
connections clean during removal and installation.
The fuel supply line(s) must be placed in a plastic bag
or connections be covered immediately to keep them
clean when removed from the engine. Failure to do so
can cause fuel system failure.
Disconnect the fuel inlet (1).
Disconnect the electronic fuel control valve supply tube
(2).
Remove the o-rings.

Remove and cover the fittings with a plastic bag or place
items inside a plastic bag.
1. Stage one filter outlet to gerotor
2. Bypass from inlet actuator back to gerotor
3. Outlet of gerotor to inlet of stage two filter
4. Outlet of stage two filter to inlet actuator.
Remove the following and cover the fittings with a plastic

bag or place items inside a plastic bag.
Disconnect the fuel supply line from the elbow union on
the fuel filter head assembly and from the tee fitting of the
gerotor fuel pump. Discard the o-rings.

Disconnect the fuel supply line from the bypass on the
inlet actuator to the tee fitting on the gerotor fuel pump.
Discard the o-rings.

Remove the union from the fuel pump and discard the o-
ring.

Remove the tee fitting from the gerotor fuel pump. Discard
the o-rings.

Remove the fuel supply line (3) from the gerotor pump
output to the inlet of stage two fuel filter. Discard the o-
rings.

Remove the union from the gerotor pump. Discard the o-
rings.

Remove the fuel supply line (4) from the stage two fuel
filter outlet to the inlet of the fuel pump. Discard the o-
rings.

Remove the union from the inlet of the fuel pump. Discard
the o-ring.

Inspect the inside of the hose.
• The inner lining of the hose can separate from the
center hose section.
• A separation of the inner lining can cause a
restriction in the fuel flow.
Inspect for any pinches in the hose that can obstruct the
flow.
The hose must not have pinches or loops that can
obstruct the flow.
WARNING
bodily injury.
Use compressed air to flush the lines to remove any loose
dirt particles.
WARNING
WARNING
WARNING
bodily injury.
Use solvent to clean the fuel supply lines, tee fittings, and
unions.
Inspect the fuel supply lines for restrictions that can

possibly prevent fuel from flowing freely. Replace the fuel
supply lines if kinked, damaged, or leakage is found.
Inspect the tee fittings and unions for damage. Replace if
damaged, cracked, or stripped threads are found.
Cover the fuel line fittings with a plastic bag or place the
items inside a plastic bag after cleaning and inspection.
Install
Install new o-rings in the fuel pump inlet hose fitting and
the fuel supply tube fitting.
Install the fuel pump inlet hose (1) and the fuel supply tube
(2).
Tighten the hoses.
Torque Value:
Fuel Pump Inlet 120 N•m [ 89 ft-lb ]
Hose
Fuel Supply 120 N•m [ 89 ft-lb ]
Tube

Remove the union from its protective plastic bag and
install new o-rings on the union and install the union in the
outlet of the gerotor fuel pump.
Torque Value:
Gerotor Pump 100 N•m [ 74 ft-lb ]
Outlet Union
Remove the fuel line from its protective plastic bag and
install the fuel supply line (3) from the gerotor fuel pump
to the inlet of the second stage fuel filter.
Torque Value:
Fuel Supply 65 N•m [ 48 ft-lb ]
Line
Remove the tee fitting from its protective plastic bag and
install the tee fitting in the port on the back of the fuel
pump by first positioning the locknut.
1. Locknut
2. Washer
3. O-ring.
Install the tee fitting in the fuel pump port until the backup
washer (1) contacts the port face.
Using two wrenches, hold the tee fitting in the desired

position and tighten the locknut.
Torque Value:
Tee Fitting 100 N•m [ 74 ft-lb ]
Locknut
Remove the union from its protective plastic bag and

install new o-rings in the union and install in the port for
the bypass from the fuel pump inlet actuator.
Torque Value:
Fuel Pump Inlet 170 N•m [ 125 ft-lb ]
to Actuator
Union
Remove the fuel supply line from its protective plastic bag
and install the fuel supply line on the inlet actuator bypass
union to the tee fitting on the inlet of the gerotor fuel pump.
Torque Value:
Gerotor Fuel 91 N•m [ 68 ft-lb ]
Supply Line
and install the fuel supply line from the outlet of the first
stage fuel filter to the inlet of the gerotor fuel pump.
Torque Value:
Fuel Line From 91 N•m [ 68 ft-lb ]
Filter to Gerotor
Pump Inlet
and install the fuel supply line (4) from the outlet of the
second stage fuel filters to the inlet actuator on the fuel
pump.
Torque Value:
Fuel Line From 65 N•m [ 48 ft-lb ]
Filter to Inlet
Actuator
Finishing Steps
Operate the engine and check for leaks. If leaks are found
repair and test again.
QSK45 and QSK60 Static Injection Timing
Static Injection Timing (006-025)

General Information
The injection timing is the relative measurement of the
distance remaining between the injector plunger and the
injector cup when the piston is 5.16 mm [0.2032 in] or 19-
degrees before top dead center on the compression
stroke.
Injector timing is expressed by the amount of push rod
travel remaining.
The injection timing code appears on the engine

dataplate. Codes are alphabetic letters that relate to a
numerical specification.
Specifications can be found in the Control Part List (CPL)
Manual, Bulletin 3379133.
The next four frames are a brief review of injection timing

and how it can be adjusted.
Advanced timing (1) means the fuel is injected earlier into
the cylinder during the compression stroke. Retarded
timing (2) means the fuel injection occurs in the cylinder
closer to top dead center during the compression stroke.
The amount of pushrod travel determines the time of fuel

injection in relation to the piston position.
A low numerical value of the pushrod travel remaining
indicates a greater degree of advanced (1) or fast timing.
A high numerical value of pushrod travel remaining
indicates a greater degree of retarded (2) or slow timing.
Static Injection Timing QSK45 and QSK60
Injection timing changes are accomplished by advancing

or retarding the cam follower action in relation to the piston
position.
This is accomplished by changing the orientation of the
camshaft lobe to the cam follower using different camshaft
gear keys.
Gear train timing (index mark alignment) always remains
the same.
The direction of normal rotation on a QSK45 and QSK60

engine crankshaft is clockwise as viewed from the front.
The camshaft key provides a means of indexing the
camshaft with the gear.
Offset keys allow the camshaft profile to be rotated slightly
while the gear train timing remains the same.
The more the top of the offset is moved in the direction of
the camshaft normal rotation, the more the injection timing
will be retarded. The pushrod travel numerical value will
increase.
If checking or setting the injection timing, it is

recommended to use a testing gear. A testing gear is a
camshaft gear that has been modified to provide a slip-fit
on the camshaft.
Offset keys can be identified by measuring the offset and
referring to the chart at the end of this section.
Each 0.025 mm [0.001 in] of offset will cause a 0.0127-mm
[0.0005-in] change in the pushrod travel from a straight
key.

No injection timing adjustment is necessary as it is
controlled electronically by the electronic control module
(ECM). Because of this, only a straight key (no offset)
must be used in the camshaft gear for these engines.
Preparatory Steps
• Remove the rocker lever cover from cylinder number
1 on the right bank. Refer to Procedure 003-011.
• Remove the rocker lever assembly from cylinder
number 1 on the right bank. Refer to Procedure
003-009.
• Remove the injector from cylinder number 1 on the
right bank Refer to Procedure 006-026.
It is not necessary to remove all injectors; however,
engine rotation will be easier if all of the injectors are
removed.
Setup
Use the Injection Timing Tool, Part Number 3824942, or
equivalent. The indicators (1 and 2) are identical.
1. Push rod travel indicator
2. Piston travel indicator
3. Piston plunger support assembly
4. Push rod plunger support assembly
5. Hold-down adapter
6. Extension assembly (adapter wrench)
7. Indicator stem extension.
The pushrod plunger support assembly alignment is

critical.
Install the pushrod plunger support (4) in the outside slot
of the piston plunger support (3).
Align the pushrod plunger support with the mark. Tighten
the capscrew.
Install the indicators (1 and 2) on the posts. Turn the
indicators so they are not over the plungers.
Install the stem extension on the piston travel indicator.
Install the injector pushrod (8) for cylinder number 1 on the

right bank.
Install the timing tool in the injector bore of cylinder
number 1 on the right bank. Install the hold-down
adapters.
Make sure the pushrod plunger and the pushrod are
aligned.
Tighten the support lock (9).
Measure
CAUTION
Only use the crankshaft to rotate the engine. If any
other gear is used, a false measurement will result.
Gear lash must be closed up in the direction of normal
rotation.
For detailed information on the timing marks refer to
Procedure 001-008.
Three guide bolts equally spaced in front of the crankshaft
will help rotate the engine.
Make sure all of the gear index marks are aligned.
Turn the crankshaft in the direction of normal rotation
while observing both of the timing tool plungers. Both
plungers will begin moving upward when the cylinder is on
the compression stroke.
Assuming all the gear index marks were aligned when the
injection timing process was started, the crankshaft will
have to be rotated approximately ¾ of a revolution to get
to the compression stroke for cylinder number 1 on the
right bank.
If both plungers are not moving up (one up and one down),
the engine is on the exhaust stroke. Rotate the crankshaft
one revolution to get on the compression stroke.
Establish top dead center by slowly rotating the crankshaft

in the direction of normal rotation while observing the
piston plunger (10). The plunger will move upward, stop,
then begin to move downward. The stop point of the
plunger is top dead center. Rotate the engine opposite the
direction of normal rotation until the plunger begins to
move down. The cylinder is now slightly before top dead
center.
Turn the indicator so that the stem is touching the plunger.

Carefully move the indicator downward until the needle
has turned a minimum of five revolutions 12.7 mm [0.500
in]. Lock the indicator in position.
Slowly turn the crankshaft in the direction of normal
rotation until the indicator needle stops turning
clockwise (top dead center). Move the indicator down
until there is only one revolution, 2.54 mm [0.100 in], of
travel remaining until the indicator bottoms out.
Adjust the indicator to zero.
Turn the pushrod indicator so that the stem touches the

plunger.
Carefully lower the indicator until it bottoms out. Raise the
indicator until the needle has turned a minimum of three
revolutions, 7.62 mm [0.300 in].
Slowly turn the crankshaft in the direction of normal

rotation until the pushrod indicator stops (1), momentarily
reverses direction (2) (this is the crush nose on the
camshaft), and stops again (3). The cam follower is now
on the outer base circle of the camshaft. The piston is now
approximately 45 degrees after top dead center.
It is important to record the amount of travel remaining in
the pushrod travel indicator for later reference.
Carefully lower the push rod travel indicator until it
bottoms out. Raise the indicator approximately ½ of a
revolution 1.27 mm [0.050 in]. Lock the indicator in
position.
Set the indicator at zero.
Set the piston at 5.16 mm [0.203 in] before top dead

center.
Observe the piston travel indicator as the crankshaft is
slowly rotated in the opposite direction of normal rotation.
Stop rotating the crankshaft when the piston travel
indicator indicates the piston is at top dead center (zero).
Recheck top dead center (zero)
The crankshaft must be turned slowly to count the

indicator revolutions accurately.
Turn the crankshaft opposite the direction of normal
rotation until the indicator needle moves 2-½ revolutions
or 6.35 mm [0.250 in].
The piston is now 6.35 mm [0.250 in] before top dead
center.
Only move the piston to 5.161 mm [0.203 in] before top

dead center by turning the crankshaft in the direction of
normal rotation. If the crankshaft is turned too far, it
must be turned the opposite direction of normal rotation
more than 5.161 mm [0.203 in] before top dead center.
Then, very slowly turn the crankshaft in the direction of
normal rotation until the indicator indicates that the piston
is 5.161 mm [0.203 in] before top dead center.
All QSK45 and QSK60 injection timing specifications are
more than one indicator revolution, 2.54 mm [0.100 in].
Read the pushrod travel indicator counterclockwise from

zero. This is the injection timing measurement to compare
to the specification. An example of 3 mm [0.118 in] is
shown.
If unsure of the number of pushrod indicator revolutions,

check by carefully lifting the indicator stem until the
indicator has bottomed out. Lower the stem the amount of
excess travel that was set in the third step of this
procedure. Lower the stem to the plunger. Read the
indicator.
If the injection timing is within specification, and a slip-fit
gear is used, install the standard gear. Refer to Procedure
001-012. Repeat the injection timing procedure after the
camshaft gear has cooled.
CAUTION
To avoid engine damage, the timing measurement
must be confirmed after changing the key.
If the injection timing is not within specification, repeat the
measurement procedure to check the tool setup and the
zero settings.
If the timing is still not within specification, the camshaft
key must be changed. Refer to Procedure 001-012 for
instructions to remove the camshaft gear.
Record the orientation of any offset of the key. Use the
following worksheet to determine an alternate key.
Repeat this procedure on a front and rear cylinder of the
bank(s) from which the camshaft or camshaft key was
replaced.
QSK45 and QSK60 Injector
Finishing Steps
• Install the injector from cylinder number 1 on the
right bank Refer to Procedure 006-026.
• Install the rocker lever assembly from cylinder
number 1 on the right bank. Refer to Procedure
003-009.
• Install the rocker lever cover from cylinder number 1
on the right bank. Refer to Procedure 003-011.
Injector (006-026)
General Information
The injector consists of the following components:
1. O-ring/damper
2. Capscrew
3. Injector hold down clamp
4. Seal
5. O-rings
6. Injector.
Initial Check
Misfire Using Heat Indicator Marker
NOTE: This procedure will possibly not be effective when
the symptoms occur only at low idle or when the engine is
cold.
If the engine exhibits symptoms of a possible injector
not firing, perform the following check:
• Operate the engine to normal operating coolant
temperature of 80°C [180°F].
• Stop the engine and allow the exhaust manifold to
cool for 10 minutes.
• Apply a mark (1) using a 204°C [400°F] temperature
indicator marker, Part Number 3165163, on the
surface of all exhaust manifold ports. The mark
must be as close to the cylinder head as possible,
but not directly on the exhaust manifold mounting
flange.
• Start the engine and operate under light load for a
short time. Do not operate the engine under heavy
load or for an extended period of time as this can
cause inaccurate results.
Injector QSK45 and QSK60
NOTE: It is not recommended to use the temperature

indicator markers to troubleshoot for cylinders that are
operating too hot.
If the 204°C [400°F] mark melts (1) the color will disappear
and leave only a transparent glazed appearance where
the mark was. This indicates that the cylinder is operating
at a temperature above 204°C [400°F].
If the 204°C [400°F] mark does not melt (2) the mark color
remains present. This indicates that the cylinder is not
operating at or above a temperature of 204°C [400°F],
indicating a possible injector malfunction.
Go to the Engine Performance Troubleshooting Tree for
additional troubleshooting information.
Misfire using Infared Thermometer

If the engine exhibits symptoms of a injector not firing,
perform the following check:
• Operate the engine to normal operating coolant
temperature of 80°C [180°F].
• Once the engine has reached normal operating
temperature, continue operating the engine and
perform the following check.
Use an infrared thermometer, Part Number 3164487 or

equivalent, to measure and record the surface
temperature of the exhaust manifold ports.
NOTE: It is important to measure as close to the cylinder
head as possible and in the same location on each of the
exhaust manifold ports.
If an exhaust manifold is more than 40°C [100°F] (for
electronically actuated injectors) or 93°C [200°F] (for
mechanically actuated injectors) colder than the average
surface temperature of all exhaust ports, this indicates a
possible injector malfunction.
Misfire Using Injector Cutout Tool
CAUTION
This tool is not intended to be used above engine idle
speed. Do not use above 900 rpm engine speed.
Doing so can damage the engine.
NOTE: This tool is only used on Mechanically Actuated
Injector equipped engines.
Start and operate the engine until the coolant is at a
normal operating temperature of 80°C [180°F]. Then,
shut off the engine.
If the faulty injector can be isolated to a particular bank

when the engine is running, remove the existing plugs
from the topside of the cast-iron valve covers on the
opposite bank of the engine with a 12 mm hex socket or
Allen wrench.
NOTE: Do not thread the injector cutout tool entirely into

the valve cover until the injector cutout test is ready to be
performed.
Thread the injector cutout tools, Part Number 3163194,
clockwise into the valve covers on one bank of the
engine.
The fuel rail passage is the bottom tap of the three taps in
the fuel manifold.
Install a metric Compuchek® fitting in the end of the fuel
rail manifold at a convenient location, front left, front right,
rear left, or rear right.
Install a pressure/vacuum adapter, Part Number 3164491,
on the metric rail fitting located at the front of the fuel
manifold on the side of the engine. Use a multimeter, Part
Number 3164488 or 3164489, that has pressure
measurement capability.
CAUTION
This tool is not to be used above engine idle speed.
Do not use the tool above 900 rpm engine speed. If
the cutout tool is used above engine idle speed,
damage to the engine can result.
NOTE: With the engine running, some of the cutout tools
can loosen. Be sure that the cutout tools remain tightened
down to obtain the best results.
Start and operate the engine at idle speed not exceeding
900 rpm. Completely thread the injector cutout tools into
the valve covers. Let the engine idle for approximately 30
seconds. Record the rail pressure, from the multimeter, as
a baseline.
Rail-pressure reading
(baseline):_______________________ psi.
With the injector cutout tools completely threaded into the
valve covers, thread a cutout tool into the valve cover, for
the first injector on the opposite bank, until it bottoms out.
Let the engine idle for 30 seconds, and record the rail
pressure from the multimeter in the table below.
Repeat the procedure for each of the remaining injectors
on that bank, and record the corresponding rail pressure
for each injector.
Engine Speed:__________ RPM for Right/Left-Bank

Cutout
Cylinder Number Cutout Rail Pressure in PSI
_____1
_____2
_____3
_____4
_____5
_____6
_____7 (QSK60)
_____8 (QSK60)
After cutting out all of the injectors on the bank, compare

the rail-pressures readings to the baseline value.
If the injector being cut out is working properly, the fuel
rail pressure will be much higher than the baseline
pressure reading.
If the injector being cut out is not firing, the fuel rail
pressure will show little or no change from the baseline
reading.
Shut the engine off. If the faulty injector can not be

determined from this bank of injectors, repeat the above
procedures for the opposite bank.
Engine Speed:__________ RPM for Right/Left-Bank

Cutout
Cylinder Number Cutout Rail Pressure in PSI
_____1
_____2
_____3
_____4
_____5
_____6
_____7 (QSK60)
_____8 (QSK60)
Replace any faulty injector as outlined in this procedure.

Make sure the valve covers are installed in their original
location.
There are four color-coded o-rings on the injector. Each o-
ring must be placed on the injector in the appropriate
location.
After engine diagnostic testing, remove the injector

diagnostic cutout tools from the valve covers, and install
the plugs.
Preparatory Steps
• Remove the rocker lever cover and all related parts.
• Remove the rocker lever assembly. Refer to
Procedure 003-009.

• Remove the injector fuel supply lines. Refer to
Procedure 006-051.
• Remove the two-piece rocker lever cover. Refer to
Procedure 003-011.
Remove
The injector hold-down clamp can not be removed until
the injector is removed.
Remove the injector hold-down capscrew. Remove the
injector and injector hold-down clamp.
Use the injector puller, Part Number 3824830, to remove
the injector. Insert the pin of the tool into the hole provided
in the body of the injector. The hole faces the front of the
engine.
NOTE: If the injector puller mentioned above is not
available, carefully use a pry bar. Pry upward on the
injector against the cylinder head.
Sealing rings are available in different thickness to adjust

injector protrusion.
Remove the sealing washer (1). Note the thickness and
cylinder location.
Remove and discard the remaining o-rings (2, 3, 4 and 5).

Remove the injector hold down capscrew.
Remove the injector using either injector puller, Part
Number 3824830 or Part Number 4918218 (shown).
Cover the injector bore in the cylinder head to prevent
foreign objects entering and possibly damaging the bore
and combustion chamber.
Remove and discard the seal on the end of the injector.
Remove and discard the two o-rings on the injector.
Do not remove the o-ring/damper at this time.


Use a lint-free cloth to clean the exterior of the injector.
Carefully check the area where the sealing ring touches
the injector.
Inspect the o-ring grooves for damage.
Inspect the injector body and cup retainer for cracks or
other damage.
Inspect the injector links for damage, excessive wear, and
pitting or scoring on the ball ends.
If the link is damaged or pitting/scoring can be seen or felt,
the injector must be replaced.
WARNING
When using solvents, acid, or alkaline materials for
Use solvent to clean the filters. The screens must be
thoroughly dry prior to installation.
Check the rail (6) and timing (7) filter screens for debris,
tears, or punctures. Replace the filter screens if damaged
or dirty.
Check the rail (6) and timing (7) filter screen for proper
installation.
The screens must be securely snapped into the correct
position.
If the filter screens are not in the correct position, use a

small screwdriver to unsnap the filter screen by gently
prying up on the connector clip.
Move the filter around the injector body until it is in the

correct position.
Secure connector by snapping the ends together.

A properly secured connector will create a single snapping
sound.
Apply pressure on the filter screen connector clip.
WARNING
Clean the injector assembly with contact cleaner, Part
Number 3824510, or equivalent. Allow to air dry
completely.
Do not use compressed air to dry or clean injector.
Inspect the nozzle tip for damage.

Replace injectors with damaged nozzles that prevent fuel
delivery into the combustion chamber.
If the injector tip is damaged, inspect the cylinder bore and
combustion chamber for damage as well.
Inspect the injector body for signs of damage, corrosion,

or cracks.
Inspect the o-ring grooves for damage that does not allow
the o-rings to seal properly.
Inspect the t-fitting on top of the injector where the injector

supply lines attach.
Inspect for corrosion, damage, and cracks that do not
allow proper sealing of the injector supply lines.
Replace damaged injectors.
Inspect the o-ring/damper for cracks, damage, or wear.

Replace, if damaged.
If the valve cover shows signs of oil leakage around the

injector replace the o-ring/damper.
Inspect the injector wiring for damaged wires, shrink
tubing, elbow, and connector.
Calibrate
NOTE: This applies to the Mechanically Actuated
Injectors only.
This procedure requires special equipment and must be
done at a Cummins® Authorized Repair Location.
Install
Install the new o-rings. Do not twist the o-rings during
installation.
Do not lubricate the o-rings until the injector is ready for
installation in the cylinder head.
Install a new sealing ring with the same thickness as noted
at removal.
O-ring number 2 is black and is smaller in diameter when
compared to the other three.
O-ring number 3 is green.
O-ring number 4 is blue.
O-ring number 5 is black and is the largest in diameter and
cross section.
Completely lubricate the o-rings with clean 15W-40 oil.

When installing the injector make sure the o-rings are
not pinched, cut, or rolled.
Install the hold-down clamp on the side of the injector.

Install the injector and hold-down clamp in the cylinder
head.
Use injector installation tool, Part Number 3824830, to
seat the injector in the bore.
The slide hammer will make a dull sound when the injector
is seated properly.
NOTE: If the injector installation tool is not available, use
a 40 mm [1-9/16 inch] socket with an extension and a
rubber mallet to install the injector.
Use clean engine lubricating oil to lubricate the injector
hold-down capscrew.
Install the injector hold-down capscrew.

If the o-ring/damper is damaged, install a new o-ring/
damper on the injector.
Install the new o-rings on the injector body.

Install the new seal on the end of the injector.
WARNING
WARNING
WARNING
personal injury.
CAUTION
Keep the injector bore and combustion chamber
protected when using compressed air to prevent
contamination. Failure to do so can cause engine
damage.
Lubricate all o-rings with a light coating of clean
lubricating engine oil.
Clean the injector hold-down capscrew with contact
cleaner, Part Number 3824510, or equivalent. Clean
threads of all debris.
Clean the injector bore with contact cleaner, Part Number
3824510, or equivalent, in the cylinder head to make sure
proper sealing of the o-rings occurs.
Clean the threaded hole in the cylinder head where the
injector hold-down capscrew will be installed with contact
cleaner, Part Number 3824510, or equivalent, and
compressed air.
Lubricate the threads and underside of the capscrew with
clean lubricating engine oil.
Assemble the injector hold-down clamp and capscrew on
to the injector. Install the injector into the cylinder head
bore by tapping gently on of the injector with a soft face
mallet.
To align the injectors, install the injector supply lines finger
tight. Refer to Procedure 006-051.
Tighten the injector hold-down capscrew using the 60
degree torque angle method.
Fuel Control Valve Body Assembly QSK45 and QSK60
The 60 degree torque angle can be achieved by marking

the location of one corner of the capscrew to a location on
the injector hold-down clamp.
Torque Value:
Injector Hold Step1 68 N•m [ 50 ft-lb ]
Down Clamp
Capscrew
Step2 Loosen capscrew
completely.
Step3 20 N•m [ 177 in-lb ]
Step4 Rotate the capscrew 60
degrees.
Finishing Steps
• Install the rocker lever assembly. Refer to Procedure
003-009.
• Adjust the valves and injectors. Refer to Procedure
003-006.
• Install the rocker lever cover and all related parts.

• Install the two-piece rocker lever cover. Refer to
Procedure 003-011.
• Install the injector fuel supply lines. Refer to
Procedure 006-051.
Fuel Control Valve Body Assembly

(006-049)
Preparatory Steps
Remove the electronic control module (ECM). Refer to
Manual, Electronic Control Systems, QSK19, QSK23,
QSK45, QSK60, and QSK78 Engines, Bulletin 3666113.
QSK45 and QSK60 Fuel Control Valve Body Assembly
Remove
Clean the control valve body and the surrounding area.
Disconnect the fuel supply line at the control valve body.
It is a good service practice to label parts during removal.

Identification of the connections at the time of removal
with a label will aid in the installation process.
Label the electrical connections to the actuators, fuel
pressure sensors, fuel temperature sensor, and ambient
air pressure sensor.
Disconnect the actuators and pressure sensor

connections.
Use a 3/8-inch wrench to remove the nut holding the

electrical connection of the fuel shutoff valve coil.
Remove the connector.
Move the wiring harness away from the control valve body
to gain access, as needed.
Remove the control valve body assembly mounting
capscrews, control valve body assembly, and gasket.
The fuel control valve body assembly gasket is an edge
molded gasket. Inspect the gasket. If any damage is found
it must be replaced.
Disassemble
Use a 1¼-inch deep well socket to remove and install both
actuators.
Remove the two fuel timing rail actuators (7).
Remove the fueling rail actuator (5).
Use a 1¼-inch deep well socket to remove the following

sensors.
• Fuel timing rail pressure sensor (1)
• Fuel temperature sensor (3)
• Fuel rail pressure sensor (4).
Do not use a 1¼ inch deep well socket to remove the
Ambient Air Pressure Sensor (2) (if installed on the
electronic fuel control valve assembly). Damage to the
sensor will result.

WARNING
When using solvents, acids, or alkaline material for
WARNING
personal injury.
Use solvent to clean the fuel control valve body.
QSK45 and QSK60 Fuel Control Valve Body Assembly
Inspect the fuel control valve body sensor mounting areas

for damaged threads and cracks in the housing.
Inspect the actuator threads for damage.

Inspect the actuator screens for debris and damage.
Make sure the screen filter is in its groove and the two
ends of the screen are nearly joined.
Using a pair of needle nose pliers, carefully join the screen
filter ends.
Assemble
Use a 1¼-inch deep well socket to install both actuators.
Install the two timing actuators (7).
Install the fueling rail actuator (5).
Use a 1¼-inch deep well socket to install the following

sensors except the ambient air pressure sensor.
Install the timing rail pressure sensor (1).
Install the fuel temperature sensor (3).
Install the fuel rail pressure sensor (4).
Do not use a 1¼ inch deep well socket to Install the
Ambient Air Pressure Sensor (2) (if installed on the
electronic fuel control valve assembly). Damage to the
sensor will result.
Install
Install the fuel control valve body gasket.
Install the fuel control valve body assembly and mounting
capscrews.
Tighten the mounting capscrews.
Install the electrical connection on the fuel shutoff valve.

Install the nut on the threaded post of the coil.
Use two 3/8-inch wrenches to hold the post of the nut
firmly while tightening the connection nut.
Inspect the actuator and pressure sensor connections for

dirt and debris.
Use QD contact cleaner, Part Number 3824510, or
equivalent, to clean the connections and actuator, as
needed.
If the electrical connections were not labeled for

identification purposes during disassembly, verify the
types of connections on the wiring diagram.
Connect the actuator and pressure sensor connections.
QSK45 and QSK60 Injector Supply Lines (High Pressure)
Connect the fuel supply line to the control valve body.
It is a good service practice to use two wrenches when

tightening the fuel fittings.
Support the fitting. Use a crowfoot wrench and a torque
wrench to tighten the fuel supply line nut.
Finishing Steps
Install the electronic control module (ECM). Refer to
Manual, QSK19, QSK23, QSK45, QSK60, and QSK78
Injector Supply Lines (High Pressure)

(006-051)
General Information
The high-pressure injector supply lines consist of the
following components:
1. Outerwall pipe
2. Rectangular grommet nut
3. Grommet
4. Connector fitting
5. O-ring Groove
6. Sealing cone
7. Innerwall pipe.
Injector Supply Lines (High Pressure) QSK45 and QSK60
Initial Check
WARNING
The fuel pump, high-pressure fuel lines, and injector
supply lines contain very high-pressure fuel. To
reduce the possibility of injury and property damage,
do not loosen any fittings while the engine is running.
Wait at least 10 minutes after shutting down the
engine before loosening any fittings in the high-
pressure fuel system to allow the pressure to
decrease to a lower level.
Inspect the injector high-pressure supply lines for cracks,
chafe, leaks, and loose or broken clamps.
Preparatory Steps
• Thoroughly clean all fittings and components before
removal from the engine.
• Make sure that debris, water steam, or cleaning
solution does not get inside the fuel system.
Remove
WARNING
WARNING
The pressure of the fuel in the line can penetrate the
skin and cause serious personal injury. Wear gloves
and protective clothing when working on the fuel
system.
WARNING
Pressure within the high-pressure fuel system must
never be measured using a mechanical gauge. Fuel
pressure values of over 1724 bar [25,000 psi] are
possible. Under high pressure, a mechanical gauge
can fail causing a high-pressure fuel leak resulting in
personal injury and property damage.
CAUTION
harmful to the injectors and the cone seats on the
injector high-pressure supply connections. Extra care
is required to keep the fuel connections clean during
removal and installation. The injector supply line must
be placed in a plastic bag or the connections be
covered immediately to keep them clean when they
are removed from the engine.
Remove the vent hose bracket (1).
Loosen the two clamps securing the fuel vent hoses (2).
Remove the hoses (3).
Connect the INSITE™ electronic service tool and verify
that the fuel pressure has bled down by monitoring the fuel
pressure.
Disconnect the clamps (1) securing the injector supply line

the to engine.
Back off the rectangular grommet nut and grommets.
NOTE: Supply line from the connection block (2) to the
right bank cylinder 1, does not have a rectangular
grommet nut or grommet at the connection block end.
Disconnect the injector supply line from the fuel pump (3),
connection block (2), and the injectors (4). Remove and
discard the o-ring.
Cover both ends of the injector supply line with plastic

bags. Do not use tape, or any products on the injector
supply line connections which can cause contamination
such as adhesive residue, plastic shavings, or dirt from
protective caps. A small piece of dirt or debris can cause
injector failure.
Back off the rectangular grommet nuts and grommets.

Disconnect the injector supply line between the injectors
and discard the o-rings.
Place the injector supply line in a plastic bag. Do not use

tape or any products on the injector supply line
connections which can cause contamination such as
adhesive residue, plastic shavings or dirt from protective
caps. A small piece of dirt or debris can cause injector
failure.
Note the location of the injector supply line on the bag so
it can be installed in the same location.
Remove the plug on the last injector of each bank and

discard the o-ring.
Place the plug in a plastic bag.

WARNING
WARNING
If the injector supply lines have been properly protected to
prevent dirt from entering then there is no need to clean
the line.
If the line has been inadvertently dropped and became
dirty then clean with Cummins® aerosol cleaner, Part
Number 3824510, or equivalent. Do not dry with
compressed air, allow the cleaner to evaporate completely
before installing the injector supply line.
Inspect the injector supply lines for obvious damage, such

as lines that have been bent, to facilitate injector removal.
Bent fuel lines must be replaced.
Inspect the injector supply line fittings for cracks, damage,
stripped threads. Inspect the sealing surface on the cone
for damage, scratches, and severe deformation which can
cause leakage.
Inspect the grommet for signs of damage, cracks, or tears.
Replace damaged injector supply lines.
Inspect the plug for cracks, damage, or stripped threads.

Inspect the sealing surface on the cone for damage,
scratches, and severe deformation which can cause
leakage.
A damaged plug must be replaced.
Install
CAUTION
Do not overtighten or undertighten the injector supply
line fittings. A fuel leak can occur.
Assemble the new o-rings onto the plugs.
Install the plugs into the injector connections.
Lubricate the grommet with clean engine oil on the outside

and inside diameters. The inside diameter can be
lubricated by placing a few drops of clean engine oil on
the injector outerwall pipe.
The vee-shaped bends in the injector supply lines must
all be oriented in the downward direction.
It is important to install both ends of the injector supply
line simultaneously to each pair of injectors. If one end of
the fuel line is installed and tightened before the other then
the fuel line will have to bend in order to install and tighten
the second end.
Install the new o-rings on each cone end of the injector
supply line.
Insert the cone seat tips of both ends of the injector supply
line into the injectors. Be careful to reduce the possibility
of damaging the cone seats during installation.
Start the first thread of the connector nut on both ends of
the injector supply line by hand. Only start the first thread
for one connector then start the first thread for the second
connector. Be careful to properly engage the first thread
to reduce the possibility of cross-threading. If the thread
can not be started by hand, then the injector clamp needs
to be loosened and the injectors rotated until the injector
supply line can be started by hand.
Refer to Procedure 006-026 for removal and installation of
the injectors.
Thread the connector nuts into the injectors until finger
tight. Both nuts must be snug before tightening either
end.
Check for alignment or installation issues before final
tightening.
Tighten both connector nuts with a suitable M27 [1-1/16
in] crow's foot and torque wrench.
Install the rectangular grommet nuts with a suitable M27
[1-1/16 in] crow's foot and torque wrench.
Support the connector nut with a wrench while tightening
the rectangular grommet nut.
Install the new o-rings on the injector supply line which

connects the fuel pump to the first injector of each bank.
Carefully insert the cone seat tips of both ends of the
injector supply lines to reduce the possibility of damaging
the cone seats during installation.
Start the first thread of the connector nut on both ends of
the injector supply line by hand. Only start the first thread
for one connector. Be careful to properly engage the first
thread to reduce the possibility of cross-threading.
Thread the connector nuts into the injectors until finger
tight. Both nuts must be snug before tightening either
end.
Check for alignment or installation issues before final
tightening.
Tighten both connector nuts with a suitable M27 [1-1/16
in] crow's foot and torque wrench.
Install the rectangular grommet nuts with a suitable M27
[1-1/16 in] crow's foot and torque wrench.
Support the connector nut with a wrench while tightening
Attach the two clamps (2) that secure the fuel vent hoses.
Install the vent hoses (3) and mounting bracket (1).
Finishing Steps
• It is not necessary to vent air from the high-pressure
fuel system before starting the engine. Cranking the
engine will prime the fuel system.
• Perform a leak test.
Leak Test
WARNING
The fuel pump, high-pressure fuel lines, and injector
supply lines contain very high-pressure fuel. To
reduce the possibility of injury and property damage,
do not loosen any fittings while the engine is running.
Wait at least 10 minutes after shutting down the
engine before loosening any fittings in the high-
pressure fuel system to allow the pressure to
decrease to a lower level.
WARNING
WARNING
The pressure of the fuel in the line can penetrate the
skin and cause serious personal injury. Wear gloves
and protective clothing when working on the fuel
system.
WARNING
Pressure within the high-pressure fuel system must
never be measured using a mechanical gauge. Fuel
pressure values of over 1724 bar [25,000 psi] are
possible. Under high pressure, a mechanical gauge
can fail causing a high-pressure fuel leak resulting in
personal injury and property damage.
Back off the rectangular grommet nut on the injector
nearest the rear of the engine for each bank.
Support the connector nut with a wrench while backing off
WARNING
personal injury.
Place a rag over the injectors that have the rectangular
grommet nuts backed off to prevent accidental spraying
of fuel on the engine.
Blow compressed air into the vent hoses located on the
side of the fuel pump to remove any fuel and debris from
the outer wall of the injector supply lines.
Back off the rectangular grommet nuts from each side of

the injectors.
Support the connector nut with a wrench while backing off
Slide the grommets away from the connecting fittings.
Operate the engine at idle and check for leaks at each fuel
supply line to injector fitting.
If leakage occurs, note which connection(s) are leaking
then shut off the engine.
Check to make sure the connecting nut(s) are properly
torqued by backing off a half turn, then torque again.
Operate the engine at idle again and see if the leak has
stopped. If the leak has stopped, install the grommet and
the rectangular grommet nut on each fitting to complete
the repair.
If leakage still occurs, remove the injector supply line and
check for damage to the injector supply and injector fitting
mating surfaces. Replace damaged components as
necessary.
If no signs of damage are located, the leakage is most
likely caused by misalignment during installation. Install
the injector supply line again, making sure to seat the
sealing cone, and torque each fitting to the proper torque.
Operate the engine at idle and check for leaks. If leakage
still occurs, replace the leaking injector supply line.
If no leakage is detected, connect the rectangular
grommet nut and tighten.
Fuel Cooler QSK45 and QSK60
Fuel Cooler (006-062)

Preparatory Steps
WARNING
cable last.
WARNING
Wait until the temperature is below 50°C [120°F]
before removing the pressure cap. Heated coolant or
steam can cause personal injury.
WARNING
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
013-009.
• Disconnect the air supply line. Refer to the OEM
Service Manual.
008-018.
Remove
WARNING
Keep all cigarettes, flames, pilot lights, arching
fuel system.
Remove the fuel drain line that connects the fuel cooler to
the fuel tank. Drain the fuel from the fuel cooler into a
container.
Disconnect the fuel drain to fuel tank line from the fuel
cooler.
Remove and discard the o-ring.
Disconnect the coolant supply and return lines from the
fuel cooler.
Remove and discard the o-rings.
QSK45 and QSK60 Fuel Cooler
Remove the connectors from the fuel cooler fuel and

coolant ports.
The fuel cooler is positioned between the front and rear

cooler brackets, and is not directly connected with
mounting capscrews.
Remove the six front bracket mounting capscrews.
Remove the front fuel cooler bracket and the fuel cooler.
Inspect for Reuse

Inspect the fuel cooler plates for damage. If the fuel cooler
plates or shell is damaged the fuel cooler must be
replaced.
Inspect the fuel cooler fuel and coolant port threads for
damage.
If the threads are damaged beyond repair the fuel cooler
must be replaced.
Pressure Test
Install the connectors into the fuel cooler fuel ports.
Place a 7/8-14 UN-28 threaded cap on one fuel connector.
Place a 7/8-14 UN-28 threaded cap fitted with an air fitting
on the other connector.
Install a pressure regulator onto the cap and air fitting.

Connect shop air to the pressure regulator.
Adjust the pressure regulator to 170 kPa [25 psi].
CAUTION
To reduce the possibility of damage to the fuel cooler,
the water in the test tank must be treated with a
noncorrosive additive.
Submerge the fuel cooler in a tank of treated water for 10
minutes.
If air bubbles escape from the fuel side of the fuel cooler
in the last two minutes of the test, the fuel cooler must be
replaced.
Remove the fuel cooler from the tank of treated water.
Remove the pressure regulator from the air fitting.

Remove the caps from the fuel connectors of the fuel
cooler.
WARNING
compressed air. Flying dirt and debris can cause
personal injury.
Drain the treated water out of the fuel cooler.
Use compressed air to dry the coolant side of the fuel
cooler.
QSK45 and QSK60 Fuel Cooler
Install
Place the fuel cooler and fuel cooler front bracket onto the
engine.
Thread the six fuel cooler front bracket capscrews into the
fuel cooler rear bracket.
Install the connectors into the fuel and coolant ports of the
fuel cooler.
Install the o-rings onto the fuel and coolant connectors.

Install the fuel and coolant lines.
Tighten the fuel and coolant lines.
Finishing Steps
WARNING
cable last.
013-009.
• Connect the air supply line. Refer to the OEM
Service Manual.
Notes
QSK45 and QSK60
Section 7 — Lubricating Oil System — Group 07 Page 7-a
Section 7 — Lubricating Oil System — Group 07

Section Contents
Page
Cylinder Smokes (Blue Smoke) ...................................................................................................................... 7-86
Finishing Steps...............................................................................................................................................7-88
Industrial and Power Generation...................................................................................................................7-88
QSK60 Marine Applications..........................................................................................................................7-88
Fluorescent Dye Tracer...................................................................................................................................7-86
Eliminator Filter ...............................................................................................................................................7-96
Assemble......................................................................................................................................................7-122
Clean and Inspect for Reuse.........................................................................................................................7-119
Disassemble..................................................................................................................................................7-111
Exploded View................................................................................................................................................7-98
Install............................................................................................................................................................7-132
Pressure Test................................................................................................................................................7-133
Remove.......................................................................................................................................................... 7-96
Fleetguard® Centrifuge ..................................................................................................................................7-134
Assemble......................................................................................................................................................7-135
Disassemble..................................................................................................................................................7-134
Lubricating Oil Contamination ........................................................................................................................7-78
Lubricating Oil Dilution.................................................................................................................................7-78
Pressure Test..................................................................................................................................................7-78
Coolant-Diluted Lubricating Oil.....................................................................................................................7-78
Lubricating Oil Cooler Cover ..........................................................................................................................7-83
Finishing Steps...............................................................................................................................................7-85
QSK45 and QSK60 Single Stage..................................................................................................................7-85
QSK60 Two Stage Insdustrial and Power Gerneration.................................................................................. 7-86
Install..............................................................................................................................................................7-85
QSK45 and QSK60 Single Stage..................................................................................................................7-83
QSK60 Two Stage Insdustrial and Power Gerneration.................................................................................. 7-84
Remove.......................................................................................................................................................... 7-84
Lubricating Oil Cooler Element .........................................................................................................................7-3
Clean and Inspect for Reuse.............................................................................................................................7-4
Finishing Steps.................................................................................................................................................7-6
QSK45 and QSK60 Single Stage....................................................................................................................7-6
QSK60 Two Stage Insdustrial and Power Gerneration....................................................................................7-7
QSK60 Marine Applications............................................................................................................................7-7
Install................................................................................................................................................................7-6
QSK45 and QSK60 Single Stage....................................................................................................................7-3
QSK60 Two Stage Insdustrial and Power Gerneration....................................................................................7-3
Pressure Test....................................................................................................................................................7-6
Remove............................................................................................................................................................7-4
Lubricating Oil Dipstick ....................................................................................................................................7-8
Calibrate...........................................................................................................................................................7-9
Standard........................................................................................................................................................7-9
Running Level Dipstick.................................................................................................................................7-11
Install................................................................................................................................................................7-8
QSK45 and QSK60
Page 7-b Section 7 — Lubricating Oil System — Group 07
Running Level Dipstick...................................................................................................................................7-8

Remove............................................................................................................................................................7-8
Lubricating Oil Dipstick Tube .........................................................................................................................7-12
Standard Tube.............................................................................................................................................7-15
Install..............................................................................................................................................................7-16
Standard Tube.............................................................................................................................................7-16
Extended Tube.............................................................................................................................................7-17
Remove.......................................................................................................................................................... 7-12
Standard Tube.............................................................................................................................................7-12
Extended Tube.............................................................................................................................................7-12
Lubricating Oil Fill Tube ................................................................................................................................. 7-93
Install..............................................................................................................................................................7-95
Stand-alone..................................................................................................................................................7-95
Integral Crankcase Breather.........................................................................................................................7-95
Remove.......................................................................................................................................................... 7-93
Stand-alone..................................................................................................................................................7-93
Integral Crankcase Breather.........................................................................................................................7-93
Lubricating Oil Filter (Spin-On) .......................................................................................................................7-19
Inspect............................................................................................................................................................7-19
Install..............................................................................................................................................................7-20
Pressure Differential Test................................................................................................................................7-21
Spin-on Type................................................................................................................................................7-21
Eliminator.....................................................................................................................................................7-22
Remove.......................................................................................................................................................... 7-19
Lubricating Oil Filter Head ..............................................................................................................................7-24
Assemble........................................................................................................................................................7-28
Two-Piece Filter Head, Spin-on Filter............................................................................................................7-28
One-Piece Filter Head, Spin-on Filter............................................................................................................7-29
Disassemble................................................................................................................................................... 7-25
Exploded View................................................................................................................................................7-24
Finishing Steps...............................................................................................................................................7-30
Install..............................................................................................................................................................7-29
Remove.......................................................................................................................................................... 7-25
Lubricating Oil Filter Head Adapter ................................................................................................................7-31
Finishing Steps...............................................................................................................................................7-32
Install..............................................................................................................................................................7-31
Remove.......................................................................................................................................................... 7-31
Lubricating Oil High Pressure Relief Valve ....................................................................................................7-32
Finishing Steps...............................................................................................................................................7-35
QSK45 and QSK60
Section 7 — Lubricating Oil System — Group 07 Page 7-c
Install..............................................................................................................................................................7-34
Remove..........................................................................................................................................................7-32
Lubricating Oil Leaks ......................................................................................................................................7-36
Lubricating Oil Pan ..........................................................................................................................................7-38
Finishing Steps...............................................................................................................................................7-40
Install..............................................................................................................................................................7-39
Remove..........................................................................................................................................................7-38
Lubricating Oil Pan Adapter ............................................................................................................................7-43
Finishing Steps...............................................................................................................................................7-47
Install..............................................................................................................................................................7-45
QSK45 Engines............................................................................................................................................7-45
QSK60 Engines............................................................................................................................................7-46
Remove..........................................................................................................................................................7-44
Lubricating Oil Pan Adapter Cover Plate .......................................................................................................7-40
Finishing Steps...............................................................................................................................................7-42
Install..............................................................................................................................................................7-42
Remove..........................................................................................................................................................7-41
Lubricating Oil Pressure Gauge ......................................................................................................................7-48
Lubricating Oil Pressure Regulator (Main Rifle) .............................................................................................7-49
Finishing Steps...............................................................................................................................................7-51
Install..............................................................................................................................................................7-50
Remove..........................................................................................................................................................7-49
Lubricating Oil Pressure Regulator (Piston Cooling) .....................................................................................7-51
Install..............................................................................................................................................................7-52
Remove..........................................................................................................................................................7-51
Lubricating Oil Pump ......................................................................................................................................7-53
Adjust.............................................................................................................................................................7-65
Assemble........................................................................................................................................................7-61
Disassemble...................................................................................................................................................7-54
Finishing Steps...............................................................................................................................................7-66
Install..............................................................................................................................................................7-64
Remove..........................................................................................................................................................7-53
Lubricating Oil Suction Tube (Block-Mounted) ..............................................................................................7-66
Install..............................................................................................................................................................7-68
Remove..........................................................................................................................................................7-66
Lubricating Oil System ....................................................................................................................................7-68
Drain...............................................................................................................................................................7-68
Fill...................................................................................................................................................................7-69
Lubricating Oil Temperature Gauge ...............................................................................................................7-71
Finishing Steps...............................................................................................................................................7-73
Lubricating Oil Transfer Tube .........................................................................................................................7-73
QSK45 and QSK60
Page 7-d Section 7 — Lubricating Oil System — Group 07

Finishing Steps...............................................................................................................................................7-78
Install..............................................................................................................................................................7-76
S-Shape type................................................................................................................................................7-76
Elbow type...................................................................................................................................................7-77
Straight type.................................................................................................................................................7-77
Remove..........................................................................................................................................................7-74
S-Shape type................................................................................................................................................7-74
Elbow type...................................................................................................................................................7-74
Straight type.................................................................................................................................................7-74
Oil Transfer Connection ..................................................................................................................................7-88
Pre-Lubricating Oil Pump ................................................................................................................................7-89
Finishing Steps...............................................................................................................................................7-93
Install..............................................................................................................................................................7-91
Remove..........................................................................................................................................................7-89
Service Tools ....................................................................................................................................................7-1
Lubricating Oil System......................................................................................................................................7-1
Section 7 — Lubricating Oil System — Group 07 Page 7-1
Service Tools
Lubricating Oil System
Repair Location.

Portable Pressure Kit
Used to measure the engine oil pressure 1103.2 kPa [0 to 160 psi].
3375273
Oil Filter Wrench

Used to remove spin-on filter.
3375049
Valve Spring Tester

Used to check the high-pressure relief valve spring.
3375182
Tube Cutter
Used to open spin-on oil filters for troubleshooting and analysis.
3376579
Fluorescent Tracer Dye

Added to oil. Used with black light, Part Numbers 3824754 and
3376891 3824524, to find oil leaks.
Battery Black Light/Lamp

Used in conjunction with fluorescent tracer dye, Part Number
3824754 3376891, to check for oil.
Page 7-2 Section 7 — Lubricating Oil System — Group 07

High-Intensity Black Light
Used in conjunction with fluorescent tracer dye, Part Number
3824524 3376891, to check for oil.
Nylon Lift Sling (2 in x 6 ft)

Aids in the removal and installation of heavy components.
3375958
Nylon Lift Sling (1 in x 6 ft)

Aids in the removal and installation of heavy components.
3375957
Magnetic Base Indicator Holder

Used in conjunction with dial indicator assembly, Part Number
3377399 3376050, to check lubricating oil pump idler gear end clearance.
Dial Indicator Assembly

Used in conjunction with magnetic base indicator holder, Part
3376050 Number 3377399, to check lubricating oil pump idler gear end
clearance.
QSK45 and QSK60 Lubricating Oil Cooler Element
Lubricating Oil Cooler Element

(007-007)
Preparatory Steps
QSK45 and QSK60 Single Stage
Remove the turbochargers. Refer to Procedure 010-034.
Remove the exhaust manifolds. Refer to Procedure
011-007.
Remove the oil cooler covers. Refer to Procedure

007-045.
QSK60 Two Stage Insdustrial and Power Gerneration

Remove the two-stage platform. Refer to Procedure
010-082.
Remove the high-pressure turbochargers. Refer to
Procedure 010-034.
Remove the exhaust manifolds. Refer to Procedure
011-007.
Remove the oil cooler covers. Refer to Procedure

007-045.
Lubricating Oil Cooler Element QSK45 and QSK60
QSK60 Marine Applications

• Remove the turbocharger heat shields. Refer to
Procedure 010-076.
• Remove the turbochargers. Refer to Procedure
010-034.
• Remove the exhaust manifold heat shields. Refer to
Procedure 011-015.
• Remove the exhaust manifolds. Refer to Procedure
011-007.
• Remove the oil cooler covers. Refer to Procedure
007-045.
Remove
CAUTION
Do not damage the oil cooler elements by prying with
tools that have sharp or pointed edges or corners. The
sharp tools can penetrate the oil cooler element and
cause a leak.
Remove the three oil cooler elements (2) on the QSK45
engine or the four oil cooler elements (2) on a QSK60
engine.
Remove and discard four o-rings (1) from each oil cooler
element (2).

Remove the gaskets (1) from the oil cooler element (3).
WARNING
WARNING
Wear safety glasses or a face shield, as well as
protective clothing, to prevent personal injury when
using a steam cleaner or high-pressure water.
WARNING
personal injury.
CAUTION
All water or cleaning solution must be removed from
the interior of the oil cooler element. A failure can
result from a contaminated lubrication system if all of
the liquid is not removed.
Use solvent that will not harm copper. Clean the oil cooler
elements.
Use steam or hot, high pressure water. Clean the exterior
of the oil cooler element. Flush the interior of the oil cooler
element until all engine oil is removed.
Check the exterior of the oil cooler element for scale
formed from minerals in the coolant. If there is evidence
of scale, clean the exterior of the oil cooler element using
the same method as for the interior of a radiator.
Discard the oil cooler element if the engine experienced a
major failure.
WARNING
Clean the covers with solvent.
Inspect the covers for corrosion.
Lubricating Oil Cooler Element QSK45 and QSK60
Pressure Test
Plug the oil cooler element as illustrated and connect to a
source of compressed air.
Pressure-test each oil cooler element to check for leaks.
Air Pressure: 517 kPa [ 75 psi ]
NOTE: Heating the water in the tank to 50°C [122°F] will
improve the test results.
If the oil cooler element leaks, it must be replaced. Do
not attempt to repair an oil cooler element.
Install
CAUTION
All water or cleaning solutions must be removed from
the interior of the oil cooler element. A failure can
result from a contaminated lubrication system if all of
the liquid is not removed.
CAUTION
When installing new oil cooler elements, make sure
that all of the shipping plugs have been removed from
the oil cooler elements or the engine will be severely
damaged by lack of lubrication.
Install the four o-rings (1) in the grooves on each oil cooler
element.
Lubricate the four o-rings (1) with vegetable oil for each oil
cooler element.
The QSK45 engine contains three oil cooler elements and
the QSK60 contains four oil cooler elements.
Install the oil cooler elements.
Install the support gaskets (6) on the top post of the oil
cooler element.
Finishing Steps
Install the oil cooler covers. Refer to Procedure 007-045.
Install the exhaust manifolds. Refer to Procedure 011-007.

Install the turbochargers. Refer to Procedure 010-034.

Install the oil cooler covers. Refer to Procedure 007-045.
Install the exhaust manifolds. Refer to Procedure 011-007.

Install the high-pressure turbochargers. Refer to
Procedure 010-034.
Install the two-stage platform. Refer to Procedure
010-082.

• Install the oil cooler covers. Refer to Procedure
007-045.
• Install the exhaust manifolds. Refer to Procedure
011-007.
• Install the exhaust manifold heat shields. Refer to
Procedure 011-015.
• Install the turbochargers. Refer to Procedure
010-034.
• Install the turbocharger heat shields. Refer to
Procedure 010-076.
Lubricating Oil Dipstick QSK45 and QSK60
Lubricating Oil Dipstick (007-009)

Preparatory Steps
Running Level Dipstick
NOTE: This step is only to be used when installing
Running Level Dipstick hardware for the first time.
Park vehicle on level ground. Turn the engine off.
With the engine static for at least 15 minutes, check and
note oil level on current dipstick. (The new dipstick
arrangement should give an identical reading).
Remove
Remove existing oil filler and dipstick hand hole cover,
retaining any brackets and capscrews for reuse.
Install
Fit new hand hole cover using existing capscrews and
brackets. Care should be used when inserting the
extended dipstick tube into the aperture in the block to
reduce the possibility of damaging the tube.
Fit new dipstick in place of the original dipstick.
Still with the engine turned off, using the new dipstick,
check the static engine oil level. Use markings on the
'Engine Stopped' side of the blade. This should compare
to the reading taken with the original dipstick.
QSK45 and QSK60 Lubricating Oil Dipstick
Remove plug from weep hole.

Add or remove oil from the sump to bring the oil level to
the oil pan weep hole. Check using dipstick — the weep
hole level should coincide with the static high reading on
the new dipstick.
Refit plug.
Calibrate
Standard
WARNING
To reduce the possibility of personal injury, avoid
contact of hot oil with your skin.
WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause
reproductive toxicity. Avoid inhalation of vapors,
ingestion, and prolonged contact with used engine
oil. If not reused, dispose of in accordance with local
NOTE: For marine applications only, the lubricating oil
dipstick can not be calibrated until the engine is in the
vessel and the vessel is in the water.
Drain the lubricating oil. Refer to Procedure 007-037.
Allow five minutes for the oil to drain into the oil pan. If the
engine and/or oil temperature is below 4°C [39°F], a
longer period of time will be required for full drain.
The engine must be level to perform this procedure.

Install the dipstick in the dipstick tube housing.
Use the correct volume of clean 15W-40 oil. Fill the oil pan
to the specified low or L oil level. Refer to Lubricating Oil
System - Specifications, in Procedure 018-017 for the
correct engine oil capacity for the application.
Lubricating Oil Dipstick QSK45 and QSK60
CAUTION
Exercise care when marking the dipstick, or the
dipstick will break if the scribe mark is too deep.
Remove the dipstick, and scribe a mark across the stick
at the oil level. Label the mark with an L to indicate the low
oil level.
If a new, blank dipstick is being used, cut the dipstick
approximately 38 mm [1.5 in] below the low or L oil level
mark.
CAUTION
Only add the difference between low volume and high
volume when adding oil to the specified high or low
level. Excessive oil in the crankcase can cause
premature engine failure.
Wipe the excess oil from the dipstick, and install it in the
dipstick tube housing.
Use the correct volume of oil to fill the oil pan to the
specified high or H oil level. Refer to the Lubricating
System Specification, in Procedure 018-017, for engine oil
capacity.
Remove the dipstick, and scribe a mark across the stick

at the oil level. Label the mark with an H to indicate the
high oil level.
QSK45 and QSK60 Lubricating Oil Dipstick

To calibrate the running level dipstick, the following
procedure must be followed:
1. With the oil level to the static high mark on the
dipstick and confirmed by using the weep hole,
operate the engine to bring the pan temperature up
to approximately 99°C [210°F].
2. Return the engine to the low idle condition,
disengage any engine driven accessories and put
the transmission in neutral.
3. Allow to idle for 5 minutes.
4. Remove the oil filler cap.
5. Remove the dipstick from the tube and wipe clean.
6. Insert the dipstick fully and immediately withdraw.
7. Check the oil level marking on the engine idling side
of the dipstick.
8. The running level readings must be between the
high and low level range and produce a clearly
readable line. If not, repeat steps 4 and 5. The oil
level indicated can be near to the HIGH level mark.
9. Take further readings to confirm that readings are

repeatable. However, it is not unusual for the level
in the sump to vary slightly while the engine is idling.
It can however remain near to the HIGH level mark.
Total idling time can not exceed 10 minutes.
10. Install the oil filler cap.
When satisfied that the dipstick registers the high running
level correctly, it is suggested that the same test be run
with the oil pan drained to the static low level mark.
At all times during the low level test, monitor the low oil
pressure and temperature warning lamps and gauges.
Repeat the procedure used for the high level testing. The
run level readings must be between the run high and low
level range indicated on the dipstick. Total idling time
must not exceed 10 minutes.
When satisfied that the dipstick markings are reflective of
the behavior of the oil in the oil pan at low levels, add oil
to the oil pan in equal steps until the high level is reached.
Each time an amount of oil is added check that the dipstick
registers a change in the oil level. Each quantity of oil
added can register a change in the level on the dipstick.
If it is practical and safe while the engine is idling use the
engine running dipstick procedure. If it is not possible use
the static level checking method.
As a guide, 10 mm [0.394 in] on the dipstick equates to
approximately 30.3 liters [8 gal] of oil on a QSK60 engine.
When the above tests have been completed and the
operator is confident with the results, the vehicle can be
returned to normal operations.
Lubricating Oil Dipstick Tube QSK45 and QSK60
Lubricating Oil Dipstick Tube

(007-011)
Remove
Standard Tube
WARNING
WARNING
direct contact of hot oil with your skin.
For hand hole cover removal, refer to Procedure 001-035.
NOTE: The location of the hand hole cover incorporating
the dipstick tube is dependent on the application of the
engine.
Remove the two capscrews (1), securing the dipstick tube
(2) or the dipstick tube and oil fill tube and cap (3).
Extended Tube
Remove the capscrews and the upper dipstick tube
supporting bracket (1).
Remove the capscrew and p-clip (1) supporting the

dipstick tube.
QSK45 and QSK60 Lubricating Oil Dipstick Tube
Loosen the clamps, and slide the sleeve (3) away from the
hand hole cover (1).
Remove the two capscrews (2) and remove the hand hole
cover (1).
WARNING
WARNING
Remove the dipstick by grasping the handle, turning
counterclockwise then pulling straight out.
If the engine is equipped with a short dipstick tube,

remove the plastic oil dipstick tube and discard the o-ring.
If the engine is equipped with a long dipstick tube, remove

the upper two capscrews, plate and clamps.
If the engine is equipped with a long dipstick tube, remove

the plastic oil dipstick tube and discard the o-ring.
Remove the nut and bolt securing the p-clip to the metal
dipstick tube tab.
Remove the two capscrews securing the metal dipstick

tube to the engine block. Remove the metal dipstick tube
and discard the gasket.

Standard Tube
WARNING
fro use. Wear goggles and protective clothing to
reduce the possibility of injury.
WARNING
personal injury.
Clean the dipstick tube hand hole cover with solvent and
dry it with compressed air.
Inspect the dipstick tube hand hole cover for cracks and
other damage.
WARNING
fro use. Wear goggles and protective clothing to
reduce the possibility of injury.
WARNING
personal injury.
Clean all parts with parts cleaner, Cummins® Part
Number, 3824510 or equivalent.
Protect the open hole in the block to prevent cleaner from

contaminating the engine lubricating oil.
Clean the mating surface of the engine block where the
metal dipstick tube attaches with parts cleaner, Cummins®
Part Number, 3824510 or equivalent and an abrasive
hand pad Cummins® Part Number, 3824541.
Inspect the dipstick tube for cracks, corrosion, proper and

legible oil level identification markings. Replace if
damaged.
Inspect the plastic dipstick tube for cracks, stripped

threads, and damage. Replace if damaged.
Inspect the metal dipstick tube for corrosion, stripped

threads, and damage. Replace if damaged.
Install
Standard Tube
For hand hole cover installation refer to Procedure
001-035.
NOTE: The location of the hand hole cover incorporating
the dipstick tube and oil filler tube can vary depending on
the application of the engine.
Install the dipstick and dipstick tube (2), or the dipstick
tube and oil filler tube assembly (3) with the two mounting
capscrews (1).
Tighten the two capscrews (1).
Extended Tube
Install the dipstick hand hole cover (1) and two capscrews
(2).
Slide the sleeve (3) over the filler tube and tighten the
clamps.
Install the p-clip (1) and capscrew supporting the dipstick

tube.
Tighten the capscrew.
Install the upper dipstick support bracket (1) and two

capscrews.

Install the metal dipstick tube and new gasket to the
engine. Tighten the capscrews.
Install the dipstick tube p-clip.

Install a new o-ring on the plastic dipstick tube and install

it onto the metal dipstick tube.
If the engine is equipped with a long dipstick tube, secure

the dipstick tube to the upper bracket with clamps, plate
and capscrews.
Install the dipstick by inserting, pushing down on the

handle and turning it clockwise.
QSK45 and QSK60 Lubricating Oil Filter (Spin-On)
Lubricating Oil Filter (Spin-On)

(007-013)
Remove
WARNING
WARNING
The QSK45 engine has three combination oil filters and
the QSK60 has four combination oil filters.
Use an oil filter wrench, Part Number 3375049, or
equivalent to remove the oil filters.
Discard the filter if not required for failure analysis.
Inspect
WARNING
Carefully cut the combination oil filter open. The filter
element spring is under compression and can cause
personal injury.
Use tube cutter, Part Number 3376579, to open the full-
flow oil filter.
Inspect the filter element for evidence of moisture and
metal particles.
Metal Probable Source

Copper Bearings and bushings
Chromium Piston rings
Cylinder liners, gears, and
Iron
camshafts
Lead Bearing overlay material
Piston skirts, camshaft
Aluminum bushings, and crankshaft
thrust bearings
Lubricating Oil Filter (Spin-On) QSK45 and QSK60
Install
Clean the oil filter head sealing surface with a lint free
cloth.

the QSK60 engine has four combination oil filters.
Use engine oil to lubricate the oil filter's rubber seal.
Fill the oil filters with clean engine oil.
CAUTION
Mechanical overtightening can distort the threads or
damage the filter element seal. If the threads appear
damaged, replace the oil filter head adapter.
CAUTION
Locate the oil filter wrench, Part Number 3375049,
near the top of the oil filter canister. This will reduce
the possibility of damaging the oil filter.
Install the oil filter turning it until the seal contacts the filter
head's sealing surface.
Turn the oil filter an additional 3/4 to 1 turn.
Install and tighten the drain plug.

Pressure Differential Test

Spin-on Type
This test will indicate oil pressure before and after the oil
flows through the filters.
Use a differential pressure gauge or one pressure gauge
with two oil hoses and two valves to eliminate gauge error.
Use a gauge with a minimum pressure capacity of 1400
kPa [200 psi].
Be sure the engine is switched off.
Remove the M14 hex plug (7) from the outlet end of the
oil filter head (10) and install end 7 of the valve assembly
in the port of the filter head from where the hex plug (7)
has been removed.
This reading will indicate the oil pressure after the oil flows
through the filters.
Remove the hex plug (18) from the oil pump inlet end of
the filter head (10) and install end 6 of the valve assembly
oil hose into where the second hex plug (18) has been
removed.
This reading will indicate the oil pressure before the oil
flows through the filters.
Operate the engine at rated rpm until the engine oil

reaches its normal operating temperature. Continue
running the engine at rated rpm for the duration of the
pressure test.
Close valve (7) and open valve (6) to read the oil pressure
before the filters.
Close valve (6) and open valve (7) to read the oil pressure
after the filters.
If the difference in pressure is more than the maximum
allowable value, an oil filter with excessive restriction is
being used. Replace the filters and check the pressure
differential again.
Maximum Oil Filter Pressure Differential
New/clean oil filters 83 kPa [ 12 psi ]
Lubricating Oil Filter (Spin-On) QSK45 and QSK60
Switch off the engine.

Remove the end of the valve assembly (5) from the oil
pump end of filter head (2) and install the hex plug (4).
Tighten the hex plug.
Remove the hose (3) from outlet end of filter head (2) and
install the hex plug (1).
Tighten the hex plug.
Eliminator
This test will indicate oil pressure before and after the oil
flows through the eliminator.
Use a differential pressure gauge or one pressure gauge
with two oil hoses and two valves to eliminate gauge error.
Use a gauge with a minimum pressure capacity of 1400
kPa [200 psi].
Be sure the engine is switched off.
Remove the two plugs from the filter housing.

Install end 6 of the valve assembly in the port of the filter
nearest to the centrifuge from where the plug has been
removed.
Install end 7 of the valve assembly in the port of the filter
furthest away from the centrifuge from where the other
plug has been removed.
Operate the engine at rated rpm until the engine oil

reaches its normal operating temperature. Continue
running the engine at rated rpm for the duration of the
pressure test.
Close valve (7), open valve (6), and record the pressure
value before the eliminator.
Close valve (6), open valve (7), and record the pressure
value after the eliminator.
If the difference in pressure is more than the maximum
allowable value, inspect and clean the eliminator screens
before checking the oil pressure differential again.
Maximum Oil Pressure Differential 60 kPa [ 9 psi ]
Switch off the engine.

Remove the valve assembly from the eliminator and
reinstall the two plugs.
Tighten the plugs.
Lubricating Oil Filter Head QSK45 and QSK60
Lubricating Oil Filter Head (007-015)

Preparatory Steps
WARNING
WARNING
To reduce the possibility of personal Injury, direct
contact of hot oil with your skin.
Remove the lubricating oil filters. Refer to Procedure
007-013.
Exploded View
One Piece Oil Filter Head

1. Pressure regulator plunger 10. Lubricating oil filter head
2. Bypass valve body 11. Filter head gasket
3. Threaded plug 12. Filter head adapter
4. Hexagon heap capscrew 13. Cover plate gasket
5. Threaded plug 14. Filter head adapter
6. Threaded plug 15. Filter head gasket
7. Threaded plug 16. Cover plate
8. Hexagon head capscrew 17. Compression Spring
9. Hexagon head capscrew 18. Threaded plug.
QSK45 and QSK60 Lubricating Oil Filter Head
Remove
Two-Piece Filter Head, Spin-on Filter
WARNING
This component weighs 23 kg [50 lb] or more. To
reduce the possibility of personal injury, use a hoist
or get assistance to lift this component.
Use guide pins for removal and installation of the
lubricating oil filter head.
If the engine is equipped with a pre-oil filter and post-oil
filter sensor remove it.
Remove the 12 capscrews (1), filter head (2), and two
gaskets (3 and 4) from the engine (5).
One-Piece Filter Head, Spin-on Filter
WARNING
Use guide pins for removal and installation of the
lubricating oil filter head.
filter sensor remove it.
Remove the eight capscrews (1), filter head (2), and two
gaskets (3 and 4) from the engine (5).
Disassemble
Oil filter heads that use the combination oil filter have an
adapter for the filter.
Remove the four adapter capscrews (1).
Remove the filter head adapter (2) from the oil filter head
(3).
Remove and discard the o-ring (4).

Remove the adapter only if the threads are damaged.
Removing the adapter will cause damage to the threads.
Use a large pipe wrench to remove the adapter from the
filter head.
Remove the four capscrews (12) and the lock washers.

Remove the following:
- Cover plate (13)
- Gasket (14)
- Filter bypass valve spring (15)
- Plunger (16)
- Housing (17)

Check the lubricating oil filter head for cracks or other
damage.
If any of the components are damaged, the filter head
must be rebuilt or replaced.
WARNING
WARNING
personal injury.
Clean the adapter with solvent and dry with compressed
air.
Inspect the adapter for cracks and other damage.
If any damage is found the filter head must be replaced.

Check the oil filter head for cracks or other damage.
If any of the components are damaged, the filter head
must be rebuilt or replaced.
Use a gasket scraper to remove the two mounting gaskets

if they remained on the filter head.
WARNING
When using solvents, acid or alkaline materials for
reduce the risk of personal injury.
WARNING
personal injury.
Clean all gasket and sealing surfaces.
Use solvent. Clean the oil filter head.
Check the oil filter head for cracks or other damage.
Inspect the oil filter adapter threads for signs of damage.

Replace the adapter if the threads are damaged.
Check the surfaces of all the plungers and their mating

bores in the housing or the filter head.
If it is not possible to remove the scratches or marks with
a fine crocus cloth, the part must be replaced.
Measure the free length of the spring.
Free Length
mm in
93.65 MIN 3.687
96.85 MAX 3.813
Compress the spring using the tool to a height of 69.85
mm.
Read the load of the gauge.
Load
N lbf
409.2 MIN 91.99
480.4 MAX 107.99
Assemble
The QSK45 engine has three combination filters, and the
QSK60 engine has four combination filters.
Lubricate the o-ring (4), and place it into the filter head (3).
Install the adapter (2). Install the capscrews (1).

Use clean engine oil. Lubricate the filter bypass valve
housing (17) and the plunger (16). Install the filter bypass
valve housing and plunger.
Be sure that the plunger moves freely in the housing. If
the part does not move freely, check for debris or burrs
on the part and assemble again.
Install the:
- Spring (15)
- Gasket (14)
- Cover plate (13)
- Capscrews (12)
Tighten capscrews.
To install the adapter a tool can be fabricated. Use an

appropriate size drive socket and weld two 6 mm x 6 mm
square teeth 180 degrees apart. These teeth will engage
into the slot on the adapter thread.
Apply Loctite™ 270 to the adapter threads.
Tighten the adapter.
Install
WARNING
Position the filter head (2) and the gaskets (3 and 4) on the
engine (5) with 12 capscrews (1).
Tighten the capscrews in the sequence shown.

filter sensor install and connect the sensors.
WARNING
The component weighs 23 kg [50 lb] or more. To
reduce the risk of personal injury, use a hoist or get
assistance to lift this component.
Position the filter head (2) and the gaskets (3 and 4) on the
engine (5) with eight capscrews (1).

filter sensor install and connect the sensors.
Finishing Steps
Install new combination oil filters. Refer to Procedure
007-002.
Operate the engine to normal operating temperature and

check for leaks.
QSK45 and QSK60 Lubricating Oil Filter Head Adapter
Lubricating Oil Filter Head Adapter

(007-018)
Preparatory Steps
Remove the oil filters. Refer to Procedure 007-013.
Remove
Remove the four capscrews (1).
Remove the filter head adapter (2) from the oil filter head
(3).
WARNING
When using solvents, acids, alkaline materials for
Use solvent to clean the adapter.
Inspect the adapter for cracks or other damage.
Install
The QSK45 engine has three combination oil filters, and
Lubricate the o-ring (4), and install in the filter head (3)
before the adapter (2).
Install the adapter (2). Install the capscrews (1). Tighten
the capscrews.
Lubricating Oil High Pressure Relief Valve QSK45 and QSK60
Finishing Steps
Only use Fleetguard filters, Part Number 3919823, or
Cummins filters, Part Number 4016413. Do not use
Fleetguard LF9000 or LF9001 filters.
Install new combination oil filters. Refer to Procedure
007-013.

check for leaks.
Lubricating Oil High Pressure Relief

Valve (007-021)
Preparatory Steps
WARNING
avoid personal injury, use a hoist or get assistance to
lift this component.
• Remove the oil pump. Refer to Procedure 007-031.
Remove
Remove the three oil pump gear cover mounting
capscrews and the oil pump gear cover.
QSK45 and QSK60 Lubricating Oil High Pressure Relief Valve
Remove the main rotor bearing retaining snap ring.
CAUTION
The oil pump must be properly supported to prevent
falling and damaging the oil pump.
Slide the rotor assembly forward 152 to 203 mm [6 to 8 in].
Do not remove the rotor assembly unless damage is seen.
Install a 5/16-inch x 10-inch threaded rod through the

center of the high pressure relief valve assembly.
The threaded rod must protrude all of the way through the
high pressure relief valve assembly.
Install a 32 mm [1.25 in] washer and nut on the end of the
threaded rod at the rear of the oil pump.
Install a washer, that has a smaller diameter than the snap
ring and a nut on the other end of the threaded rod.
Tighten the nuts until the spring is compressed enough to

allow the snap-ring to be removed.
Remove the snap-ring.
Remove the threaded rod and the high-pressure relief
valve assembly.
Disassemble the threaded rod and high-pressure relief
valve assembly.
Lubricating Oil High Pressure Relief Valve QSK45 and QSK60

Inspect the spring, spring retainer, and snap-ring for
damage.
If any damage is found the damaged part must be
replaced.
Inspect the spool valve for scuffing or scoring.
If any damage is found, inspect the high-pressure relief
valve bore in the oil pump.
Polished areas on the spool valve is normal wear.
Clean the spool valve and its bore in the oil pump.
Lightly oil the spool valve with clean engine oil.
Install the spool valve. Slide the valve back and forth in
the valve bore to make sure no binding or sticking occurs.
If binding or sticking does occur, determine which part is
defective and replace it.
Install
Make sure all components of the high-pressure relief valve
assembly are clean.
Lightly oil the spool valve.
Install the spool valve and spring into the oil pump.
Install the threaded rod through the spool valve and

spring.
Install the spring retainer over the threaded rod.
Install the washers and nuts onto the threaded rod.
Tighten the nuts until there is enough clearance to install
the snap-ring.
Install the snap-ring and remove the threaded rod.
QSK45 and QSK60 Lubricating Oil High Pressure Relief Valve
Slide the oil pump rotor assembly into the oil pump
housing.
Install the oil pump main rotor bearing snap-ring.
Install the oil pump gear cover and capscrews.

Torque Value:
M8 Capscrews 23 N•m [ 17 ft-lb ]
M12 80 N•m [ 60 ft-lb ]
Capscrews
Finishing Steps
WARNING
This component weights 23 kg [50 lb] or more. To
• Install the oil pump. Refer to Procedure 007-031.
Lubricating Oil Leaks QSK45 and QSK60
Lubricating Oil Leaks (007-024)

Fluorescent Dye Tracer
Add one unit of Fluorescent Tracer, to each 38 liters [10
gal] of engine lubricating oil. Refer to Procedure 018-017
in Section V for oil pan capacity.
Operate the engine at low idle for 10 minutes.
Shut the engine off.
Use a High-Intensity Black Light to inspect for oil leakage.

Oil will glow a dark blue color.
QSK45 and QSK60 Lubricating Oil Leaks
If an oil leak into the coolant is suspected, check the

coolant.
WARNING
Wear safety glasses or a face shield, as well as
protective clothing, to prevent personal injury when
using a steam cleaner or high-pressure water.
Use a steam cleaner or a high-pressure washer to clean
the engine.
Operate the engine until the coolant temperature reaches

80°C [176°F]. Inspect the exterior of the engine for
leaking gaskets, seals, o-rings, pipe plugs, or fittings.
NOTE: Before replacing any gaskets, verify that the
capscrews are tightened to the correct torque values.
Refer to Procedure 018-009 for the capscrew torque
listings.
Check for a loose, broken, or missing oil dipstick tube,

dipstick, or oil filler cap.
Lubricating Oil Pan QSK45 and QSK60
Check the engine crankcase breather elements and

breather hose for restriction.
If not restricted, check blowby. Refer to Procedure
014-005. High blowby can cause gasket and seal leakage.
Lubricating Oil Pan (007-025)

Preparatory Steps
WARNING
used engine oil can be carcinogenic and caused
WARNING
• Drain the engine oil. Refer to Procedure 007-037.
• Remove the lubricating oil filters. Refer to Procedure
007-013.
Remove
WARNING
The component weighs 23 kg [50 lb] or more. To
or get assistance to lift the component.
The QSK 45 and QSK60 engines use a variety of
lubricating oil pan and cover plate configurations. Only
single and double oil pans are used. When a double oil
pan is used, only cover plates will be used to cover the
remainder of the oil pan adapter. Full length deep and
shallow sumps are available as options.
Single oil pans and cover plates are mounted with 24
capscrews and double oil pans are mounted with 38
capscrews.
Remove the capscrews (1), oil pan (2), and gasket (3) from
the oil pan adapter (4).
Inspect gaskets for reuse (3).
QSK45 and QSK60 Lubricating Oil Pan
WARNING
WARNING
WARNING
personal injury.
Clean all gasket surfaces on the oil pan.
Steam clean all parts and dry with compressed air.
Use solvent to clean drain plug magnets and dry with
compressed air.
Inspect all areas of the oil pan for cracks or other damage.
If any of the areas are cracked or damaged, the oil pan
must be replaced.
Install
WARNING
CAUTION
Do not use gasket cement on the oil pan gaskets.
Gasket cement will prevent the gasket from sealing
properly.
Single oil pans and cover plates are mounted with 24
capscrews, and double oil pans are mounted with 38
capscrews.
Position the oil pan (2) and gaskets (3) on the oil adapter
(4) with capscrews.
Lubricating Oil Pan Adapter Cover Plate QSK45 and QSK60
Tighten the capscrews in the pattern as shown.

Install and tighten the drain plug(s).
Finishing Steps
• Install new lubricating oil filters. Refer to Procedure
007-013.
• Fill the engine with clean engine oil. Refer to
Procedure 007-037.
• Operate the engine at idle speed and inspect for
engine lubricating oil leaks.
Lubricating Oil Pan Adapter Cover

Plate (007-026)
Preparatory Steps
WARNING
WARNING
• Drain the lubricating oil. Refer to Procedure 007-037.
007-013.
QSK45 and QSK60 Lubricating Oil Pan Adapter Cover Plate
Remove
Remove the capscrews (1), cover plates (2), and gaskets
(3) from the oil pan adapter (4).

Inspect the gaskets (3) for reuse.
WARNING
WARNING
WARNING
personal injury.
Clean all gasket surfaces on cover plates.
Steam-clean the cover plates and dry with compressed
air.
Use solvent to clean the drain plug magnets and dry with
compressed air.
Lubricating Oil Pan Adapter Cover Plate QSK45 and QSK60
Inspect all areas of the adapter cover for cracks or other

damage. If any of the areas are cracked or damaged, the
cover plate must be replaced.
Install
CAUTION
Do not use gasket cement. Gasket cement will prevent
the gasket from sealing properly.
Position the cover plates (2) and gaskets (3) on the oil pan
adapter (4) with capscrews (1).
Tighten the capscrews in the sequence as shown.

Finishing Steps
• Install the new lubricating oil filters. Refer to
Procedure 007-013.
• Fill the engine with clean lubricating oil. Refer to
Procedure 007-037.
• Operate the engine at idle speed and inspect for oil
leaks.
QSK45 and QSK60 Lubricating Oil Pan Adapter
Lubricating Oil Pan Adapter (007-027)

Preparatory Steps
WARNING
WARNING
WARNING
007-013.
• Remove the fuel filters, if needed. Refer to
Procedure 006-015.
• Remove the fuel filter head. Refer to Procedure
006-017
• Disconnect the pre-lubrication suction hose. Refer to
Procedure 007-063.
• Remove the oil pan from the oil pan adapter. Refer
• Remove the cover plates from the oil pan adapter, if
needed. Refer to Procedure 007-026.
Lubricating Oil Pan Adapter QSK45 and QSK60
WARNING
WARNING
WARNING
007-013.
Procedure 006-015.
006-017
• Disconnect the pre-lubrication suction hose. Refer to
Procedure 007-063.
• Remove the oil pan from the oil pan adapter. Refer
• Remove the cover plates from the oil pan adapter, if
needed. Refer to Procedure 007-026.
• Disconnect the crankcase breather hoses from the
oil pan adapter. Refer to Procedure 003-001.
• Remove the lubricating oil dipstick. Refer to
Procedure 007-011.
Remove
The clearance must be sufficient from the oil suction tube
before the adapter can be removed from the bottom of the
engine.
The QSK45 oil pan adapter assembly is held on by 36
capscrews, and the QSK60 oil pan adapter assembly is
held on by 46 capscrews.
Remove the capscrews (1) from the oil pan adapter
assembly (2), the gasket (3), and the engine (4).
Remove the oil pan adapter assembly (2) and the gasket
(3).

Inspect the gasket (3) for reuse.
WARNING
WARNING
personal injury.
Clean all gasket surfaces on cover plates, sumps, and oil
pan adapter.
Steam clean the oil pan adapter and dry with compressed
air.
Inspect all areas of the oil pan adapter for cracks or other
damage. If any area is cracked or damaged, the oil pan
adapter must be replaced.
Install
QSK45 Engines
CAUTION
To ease in assembly, plastic wire ties can be used to retain
the gasket until the capscrews can be installed, then cut
and remove the ties before tightening the capscrews.
Install the gasket (3) on the oil pan adapter assembly (2).
Lubricating Oil Pan Adapter QSK45 and QSK60
WARNING
Position the oil pan adapter assembly (2) with the gasket
(3) on the engine (4) with the capscrews (1).

QSK60 Engines
CAUTION
To ease in assembly, plastic wire ties can be used to retain
the gasket until the capscrews can be installed, then cut
and remove the ties before tightening the capscrews.
Install the gasket (3) on the oil pan adapter assembly (2).
WARNING
Position the oil pan adapter assembly (2) with the gasket
(3) on the engine (4) with the capscrews (1).

Finishing Steps
• Install the oil pan onto the oil pan adapter. Refer to
Procedure 007-025.
• Install the cover plates on the oil pan adapter, if
removed. Refer to Procedure 007-026.
• Install the fuel filter head. Refer to Procedure
006-017
• Install the new fuel filters, if removed. Refer to
Procedure 006-015.
Procedure 007-013.
Procedure 007-037.
• Connect the pre-lubrication suction hose. Refer to
Procedure 007-063.
leaks.

• Install the oil pan onto the oil pan adapter. Refer to
Procedure 007-025.
• Install the cover plates on the oil pan adapter, if
removed. Refer to Procedure 007-026.
006-017
Procedure 006-015.
Procedure 007-013.
• Install the pre-lubrication suction hose. Refer to
Procedure 007-063.
• Install the crankcase breather hoses to the oil pan
adapter. Refer to Procedure 003-001.
• Install the lubricating oil dipstick. Refer to Procedure
007-011.
Procedure 007-037.
leaks.
Lubricating Oil Pressure Gauge QSK45 and QSK60
Lubricating Oil Pressure Gauge

(007-028)
Inspect for Reuse
Inspect for the following defects:
• Electrical wiring that is broken
• Sending unit malfunction
• Plumbing that is loose or broken.
Inspect the connector to verify a good connection to the

suspect gauge.
Use a reference gauge of known accuracy to verify the

reading of the suspect gauge.
Connect the line from the master gauge at location (1).

If the line from the master gauge is not accessible, remove
the plug on the output side of the lubricating oil filter head
(2).
Minimum Gauge Capacity: 830 kPa [ 120 psi ]
Operate the engine. Compare the pressure reading of the
master gauge and the suspect gauge.
The sending unit must be replaced if it is defective.
QSK45 and QSK60 Lubricating Oil Pressure Regulator (Main Rifle)
Lubricating Oil Pressure Regulator

(Main Rifle) (007-029)
Preparatory Steps
WARNING
WARNING
oil.
NOTE: The oil pump does not need to be removed.
• Refer to Procedure 007-026 to remove the oil pan
adapter covers or Procedure 007-025 to remove the
oil pan to gain access to the oil pump.
Remove
WARNING
The threaded plug (1) is under spring-pressure. To
reduce the possibility of personal injury, wear proper
eye protection when removing the threaded plug.
NOTE: The procedures for removing the oil pressure
regulator from the oil pump on the QSK45 and QSK60
engines are the same. The oil pump for the QSK60 is
shown.
Remove threaded plug (1), spring (2), and pressure
regulator plunger (3) from the oil pump (4).
Lubricating Oil Pressure Regulator (Main Rifle) QSK45 and QSK60
WARNING
WARNING
bodily injury.
NOTE: The procedures for cleaning and inspecting the oil
pressure regulator on the QSK45 and QSK60 engines are
the same. The oil pressure regulator for the QSK60 is
shown.
Clean the threaded plug, spring, and pressure regulator
plunger with solvent.
Dry all of the parts with compressed air.
Inspect all of the oil pressure regulator parts for reuse.
Put the plunger in the bore, and move it to check for free
movement. If the bore is damaged, the pump must be
replaced. If the plunger is damaged, it must be replaced.
Check the free length of the spring. The free length is

approximately 127.3 mm [5 in].
Use a valve spring tester, Part Number 3375182, or
equivalent. Measure the spring force at the working
height.
Working Height: 70.1 mm [ 2.76 in ]
Spring Force
N lb
230 MIN 52
255 MAX 57
Install
NOTE: The procedures for installing the oil pressure
regulator in the oil pump of the QSK45 and QSK60
engines are similar. The oil pump for the QSK60 is shown.
Use engine oil to lubricate the regulator plunger and bore.
Install the plunger (3) and spring (2) in oil pump (4) with
threaded plug (1).
QSK45 and QSK60 Lubricating Oil Pressure Regulator (Piston Cooling)
Finishing Steps
• Refer to Procedure 007-025 to install the oil pan or
Procedure 007-026 to install the oil pan adapter
cover which was removed to gain access to the oil
pump.
• Fill the engine with clean 15W-40 oil to the correct
level. Refer to Procedure 007-037.
• Run the engine to check for leaks.
• Check the oil pressure.
Lubricating Oil Pressure Regulator

(Piston Cooling) (007-030)
Remove
WARNING
To reduce the possibility of personal injury, wear the
appropriate eye and face protection when removing
the straight threaded o-ring plug holding in the oil
pressure regulator. The spring is under pressure and
can cause personal injury.
Carefully remove the straight-thread o-ring plug (4).
Remove the plunger (2), and spring (1).
Remove the o-ring (3) from the straight-thread o-ring plug.
WARNING
WARNING
personal injury.
Use solvent to clean the lubricating oil pressure regulator
spool and spring. Dry with compressed air.
Inspect the spring for broken coils.
Inspect the spool for scuffing. Minor scuffs can be
removed with a fine crocus cloth.
The critical area of the spool is the seating area. Polished
areas are normal.
Lubricating Oil Pressure Regulator (Piston Cooling) QSK45 and QSK60
Measure the free length of the spring. The free length of

the spring is 150.96 to 154.96 mm [5.94 to 6.10 in]
Use a spring tester. Measure the force of the spring at
working height. The spring working height is 114.3 mm
[4.50 in].
Lubricating Oil Pressure Regulator (Piston Cooling)

Spring
N lbf
106.87 MIN 24.02
118.12 MAX 26.55
If the spring is not within specifications, it must be
replaced.
Install
Lubricate the spool (2) with clean engine oil.
Install the spring (1) and spool (2) into the flywheel
housing.
Install o-ring (3) onto the straight-thread o-ring plug (4).
Install the straight-thread o-ring plug into the flywheel
housing and tighten.
QSK45 and QSK60 Lubricating Oil Pump
Lubricating Oil Pump (007-031)

Preparatory Steps
WARNING
oil. If not reused dispose of in accordance with local
WARNING
WARNING
or get assistance to lift this assembly.
• Remove the lubricating oil pan. Refer to Procedure
007-025.
• Remove the oil lubricating pan adapter covers. Refer
• Remove the lubricating oil pan adapter. Refer to
Procedure 007-027.
007-013.
Procedure 006-015.
• Remove the lubricating oil suction tube. Refer to
Procedure 007-035.
• Remove the lubricating oil transfer tube. Refer to
Procedure 007-040.
Remove
The procedures for removing the lubricating oil pump on
the QSK45 and QSK60 engines are similar. The oil pump
for the QSK60 is shown.
It is recommended that the oil pump to crankshaft gear
backlash be measured before removing the pump to
check for a worn gear.
Lubricating Oil Pump Idler Gear Backlash

mm in
0.21 MIN 0.008
0.39 MAX 0.015
Lubricating Oil Pump QSK45 and QSK60
WARNING
Loosen all of the mounting capscrews (1).
Support the lubricating oil pump.
Remove the mounting capscrews (1).
Gently lower the lubricating oil pump (2) away from the
engine (3). Note the amount and location of any shims (4).
Disassemble
WARNING
CAUTION
The lubricating oil pump must be properly supported
to prevent falling and damaging the pump.
Remove the four gear cover mounting capscrews and
remove the gear cover from the lubricating oil pump.
Remove the three capscrews securing the idler gear and

shaft to the lubricating oil pump.
Remove the gear retainer, thrust bearing, gear, and shaft.
Remove the main rotor bearing retaining snap ring.

Slide the rotor assembly forward 152 to 203 mm [6 to 8 in].

To reduce the possibility of damage to the rotor assembly
tie a shop towel or wire tie around all three rotors.
Remove the rotor assembly from the lubricating oil pump
housing.
Before removing the high pressure relief valve, perform

the following measurement to determine the spool beat-in
wear.
Use a depth gauge to measure the distance (3) from the
machined face (1) of the lubricating oil pump to the front
of the snap ring (2).
Insert a 5/16 x 254 mm [10 in] threaded rod through the

center of the high pressure relief valve assembly. The
threaded rod must protrude from both sides of the relief
valve and the lubricating oil pump housing.
Install a 32 mm [1.25 in] washer and a nut on the end of
the threaded rod at the rear of the lubricating oil pump.
Install a nut and a washer with a smaller diameter than the
snap-ring at the other end of the threaded rod.
Tighten the nuts until the spring is compressed enough to

allow removal of the snap-ring.
Remove the snap-ring.
Remove the threaded rod, spring retainer, spring, and
high pressure relief valve from the lubricating oil pump.
Remove the spring retainer, spring, and high pressure
relief valve from the threaded rod.
Mark the inlet head and the lubricating oil pump body for
alignment during assembly.
Remove the inlet head mounting capscrews and the inlet
head.
WARNING
To reduce the possibility of personal injury, wear the
appropriate eye and face protection when removing
the straight threaded o-ring plug holding in the oil
pressure regulator. The spring is under pressure and
Remove the straight thread o-ring plug (1), spring (2), and
spool (3) from the lubricating oil pump (4).
WARNING
WARNING
personal injury.
WARNING
Clean the lubricating oil pump components with solvent.
Use a bristle brush to clean the oil drilling in the idler gear
shaft.
Use a steam cleaner to rinse the components and dry with
compressed air.
Inspect the following areas of the lubricating oil pump for

damage or blockage.
• Rotor bore housing
• Inlet and outlet ports
• Internal oil passages
• Lubricating oil pump housing
• Inlet head
• Pressure regulator bore.
If the lubricating oil pump housing is damaged, it must be
replaced.
Apply a coat of clean engine oil to the high pressure relief

valve spool and install it into the bore. Slide and seat the
spool into the bottom of the bore.
Measure and record the distance from the machined front
face of the bore to the top of the spool (2).
Subtract the dimension (1), recorded during disassembly,
from dimension (2). If the calculated distance is not within
the acceptable limit, the lubricating oil pump body must
be replaced.
Valve Beat-in Specification

New Acceptable Limit
18.237 to 19.253 mm [0.718 19.634 to 20.650 mm [0.773
to 0.758 in] to 0.813 in]
Inspect the pressure regulator spool for scuffing.

Minor spool scuff is acceptable. If the scuff can be felt by
a fingernail, the spool will possibly need to be replaced.
Insert the spool in the bore and check for smooth
movement in and out of the bore. If any hesitation is felt,
the spool must be replaced and the bore inspected for
burrs.
Remove any burrs found in the bore before installing a
new spool.
Inspect the pressure regulator spring for a broken coil or

rust.
Measure the free length of the pressure regulator spring.
The free length is approximately 126.8 mm [5 in].
Use spring tester, Part Number 3375182 to measure the
pressure regulator spring at working height, 70.1 mm
[2.76 in].
Lubricating Oil Pump Pressure Regulator Spring

Force at Working Height
N lbf
230 MIN 52
255 MAX 57
Inspect the high pressure relief valve spring, spring

retainer, and snap-ring for damage.
Inspect the pressure relief valve spool for scuffing. Minor
scuffs can be removed with a fine crocus cloth.
The critical area of the pressure relief spool is the seating
area. Polished areas on the pressure relief valve spool are
normal.
Measure the free length of the pressure relief valve spring.

The free length is 108 mm [4.25 in].
Use the spring tester, Part Number 3375182, to measure
the pressure relief valve spring at working height, 60 mm
[2.33 in].
Lubricating Oil Pump Pressure Relief Valve Spring

Force at Working Height
N lbf
658 MIN 148
725 MAX 163
There is a step in the power rotor by design. Do not

mistake this step for abnormal wear.
Inspect the three rotors for any damage or abnormal wear.
Minor damage can be removed with a hand stone.
Inspect the main rotor bearing for damage or restricted
rotation.
Inspect the bearing retainer snap-ring for bending or
twisting.
Replace defective components.
Inspect the idler gear and bushing for wear, signs of

seizure, and splitting.
Inspect the idler shaft for wear, signs of seizure, and

damage.
Use a straight edge to inspect the retaining capscrews for

necking. If necking is observed, do not reuse the
capscrews.
The capscrews must be replaced.
Inspect the idler gear for chipped, broken, or cracked

teeth.
Measure the inside diameter of the idler gear bushing

bore.
Lubricating Oil Pump Idler Gear Bushing Bore Inside

Diameter
mm in
60.045 MIN 2.364
60.100 MAX 2.366
Measure the outside diameter of the idler shaft.
Lubricating Oil Pump Idler Gear Shaft Outside

Diameter
mm in
59.975 MIN 2.361
60.006 MAX 2.363
Measure the outside diameter of the ring dowel.
Lubricating Oil Pump Ring Dowel Outside Diameter

mm in
19.217 MIN 0.757
19.243 MAX 0.758
Measure the thrust washer thickness in three places 120

degrees apart.
Lubricating Oil Pump Idler Thrust Washer Thickness

mm in
2.400 MIN 0.095
2.470 MAX 0.097
Flex the thrust washers approximately 3 to 6 mm [1/8 to

1/4 in] and inspect the surfaces for cracks.
Assemble
Lubricate the oil pressure regulator spool and bore with
clean engine oil.
Install the pressure regulator (3), spring (2), and straight
thread o-ring plug (1) into the lubricating oil pump (4).
Tighten the straight thread o-ring plug.
Apply a light coat of clean engine oil to the high pressure

relief valve spool.
Install washer and nut onto the threaded rod.

Install the spring retainer onto the threaded rod.
Install the spool valve and spring onto the threaded rod.
Insert the assembly into the high pressure relief valve bore
and install the washer and nut.
Tighten the nuts on the threaded rod until the snap-ring

can be installed.
Install the snap-ring.
Remove the threaded rod, nuts, and washers.
Lubricate the idler gear bushing and thrust bearing with

Lubriplate™ 105 or equivalent.
Lubricate the capscrews with clean engine oil.
Place the idler gear shaft on the ring dowel.
Verify the oil drilling in the idler shaft is in the six o'clock
position.
Place the thrust bearing on the gear with the grooved side
of the thrust bearings facing the gear.
Place the idler gear and thrust bearings onto the idler gear
shaft.
Install the idler gear retainer and capscrews.
Use magnetic base, Part Number 3377399, and dial

indicator, Part Number 3376050, to measure the idler gear
end clearance.
Lubricating Oil Pump Idler Gear End Clearance

mm in
0.080 MIN 0.003
0.360 MAX 0.014
If the end clearance is not within specifications check for
foreign material between the components and proper
installation of the thrust bearings.
CAUTION
Do not allow the rotors to drop into the bore. Damage
to the rotors or housing can result.
Lubricate the rotors and lubricating oil pump housing with
clean engine oil.
Set the lubricating oil pump housing upright so the rotor
bores are vertical and the open end facing up.
To avoid damage and aid in the installation of the rotors,
assemble the follower rotors to the power rotor securing
them with wire ties or a lint free rag.
Slide the rotor assembly into the housing bore to a point

where the wire tie or lint free rag can be removed.
Remove the wire tie or lint free rag.
Continue installing the rotor assembly into the pump

housing.
Use care when aligning the power rotor gear with the idler
gear to avoid damage to the gears.
WARNING
Set the pump on its side and install the snap ring into the
snap ring groove.
Rotate the pump gears to check for binding.
Install the pump cover and four mounting capscrews.

Torque Value:
M8 23 N•m [ 17 ft-lb ]
M12 80 N•m [ 60 ft-lb ]
Install a new gasket and the suction head to the lubricating

oil pump body aligning the mark made during assembly.
Install and tighten the suction head capscrews.
Install
WARNING
Install the pump (2) and shims (4) on the engine (3).
Install the mounting capscrews (1).
Torque Value:
M12 80 N•m [ 59 ft-lb ]
M10 45 N•m [ 33 ft-lb ]
CAUTION
Backlash measurement is critical. If not properly
adjusted, lubricating oil pump or engine failure will
occur.
It is required to measure the lubricating oil pump backlash
three times. It must be measured on the inverted engine
when the pump is mounted, after the pump plumbing is
installed, and again after the engine is rotated upright.
Lubricating Oil Pump Idler Gear Backlash

mm in
0.021 MIN 0.008
0.039 MAX 0.015
If the backlash is not within specification adjust the
lubricating oil pump.
Adjust
CAUTION
Backlash measurement is critical. If not properly
adjusted, lubricating oil pump or engine failure will
occur.
It is required to measure the lubricating oil pump backlash
three times. It must be measured on the inverted engine
when the pump is mounted, after the pump plumbing is
installed, and again after the engine is rotated upright.
Use a dial indicator to measure the lubricating oil pump
idler gear to crankshaft gear backlash.
Backlash - Lubricating Oil Pump Idler Gear to

Crankshaft Gear
mm in
0.21 MIN 0.008
0.39 MAX 0.015
If the backlash is less than specifications, remove the
pump and install shims between the pump and the engine.
Shims are available 0.13 mm [0.005 in], Part Number
4015782, and 0.25 mm [0.010 in], Part Number 4015783.
If the backlash is greater than specifications, remove any
shims, and measure the backlash again. If no shims were
used, the pump drive gear or the crankshaft gear is worn
and must be replaced.
An equal amount of shim thickness must be used under
both mounting feet, if shims are required.
WARNING
Position the shims (4) between the pump (2) and the
engine block (3).
Install the pump (2) and shims (4) on the engine with the
six capscrews (1).
Torque Value:
M12 80 N•m [ 59 ft-lb ]
M10 45 N•m [ 33 ft-lb ]
Check the lubricating oil pump backlash.
Lubricating Oil Pump Idler Gear to Crankshaft Gear

Backlash
mm in
0.21 MIN 0.008
0.39 MAX 0.015
Lubricating Oil Suction Tube (Block-Mounted) QSK45 and QSK60
Finishing Steps
WARNING
• Install the lubricating oil suction tube. Refer to
Procedure 007-035.
• Install the lubricating oil transfer tube (2). Refer to
Procedure 007-040.
• Install the oil pan adapter (2). Refer to Procedure
007-027.
• Install the lubricating oil pan. Refer to Procedure
007-025.
• Install the lubricating oil pan adapter covers. Refer
Procedure 007-013.
Procedure 006-015.
Procedure 007-037.
Lubricating Oil Suction Tube (Block-

Mounted) (007-035)
Remove
There are different lubricating oil suction tube
arrangements depending on the oil pan style.
Remove the nuts (5), capscrews (4), and strap (3) from the
vertical support bracket assembly (2).
Remove the capscrews (8) and remove the vertical
support bracket assembly.
Remove the three capscrews (6), and the oil suction tube
(1).
QSK45 and QSK60 Lubricating Oil Suction Tube (Block-Mounted)
WARNING
WARNING
WARNING
compressed air. Fly debris and dirt can cause
personal injury.
The oil suction tube on the engine being serviced can be
different than illustrated. Different oil sump locations and
depths require different oil suction tubes. The type of
screen on the end of the lubricating oil suction tube can
be different.
Remove the sealing ring (1), or the gasket (2) from the
lubricating oil suction tube.
Use solvent or steam to clean the lubricating oil suction
tube and dry with compressed air.
CAUTION
If the lubricating oil suction tube is repaired by
welding, be sure all of the welding slag and any metal
that can break are removed from the inside of tube. If
debris enters the lubricating oil pump and system, the
gears will be damaged and failure will result.
Check the lubricating oil suction tube and brackets for
damage or cracks. Check for wear in the area of the
support brackets.
If the lubricating oil suction tube or the brackets are
cracked or damaged, they must be repaired or replaced.
Lubricating Oil System QSK45 and QSK60
Install
Lubricate seal (10) with clean grease and install on the
lubricating oil suction tube.
Install the lubricating oil suction tube (1) and seal (10) with
the three capscrews (6).
NOTE: If the rear housing has been removed and
reinstalled, it will possibly be necessary to realign it when
installing the lubricating oil suction tube.
Install the lubricating oil suction tube support bracket (2)
with the two capscrews (8).
Install the vertical support bracket straps (3) on the
lubricating oil suction tube bracket (2) with two capscrews
(4) and nuts (5).
Tighten the nuts and capscrews.
Lubricating Oil System (007-037)

Drain
Operate the engine until the water temperature reaches
60°C [140°F].
The QSK45 and QSK60 engines have various lubricating

oil pan configurations. Remove all drain plugs when
draining the oil pan.
QSK45 and QSK60 Lubricating Oil System
WARNING
reproductively toxicity. Avoid inhalation of vapors,
WARNING
Remove the oil drain plugs and drain the oil immediately
to make sure all of the suspended contaminates are
removed from the engine.
Fill
Use a high quality 15W-40 multiviscosity oil that meets the
American Petroleum Institute (API) performance
classification CE or CF4 or better.
Choose the correct oil for the operating climate. Refer to
Procedure 018-003 in the Operation and Maintenance
Manual, QSK45 and QSK60 Series Engines, Bulletin
3666260 correct oil.
Fill the engine to the correct level with clean engine oil.
Refer to Procedure 018-017 for engine sump capacity.
Check the oil level on the dipstick. The level must be to
the high (H) mark on the dipstick.
Do not overfill. Drain off excess oil in a pan.
Lubricating Oil System QSK45 and QSK60
CAUTION
Before starting engines not equipped with a PRELUB™
system, complete the following steps. Engine damage
will occur, because of inadequate lubrication at
startup, if these steps are not followed.
NOTE: Engines that are equipped with a PRELUB™
system are self priming and do not require completion of
this and the next step.
The following steps must be completed after each oil
change or after the engine has been shutdown for more
than five days to make sure the engine receives the
correct oil flow through the lubricating system.
Disconnect the engine position sensor.
Using the starter motor, rotate the engine crankshaft until
oil pressure appears on the gauge or the warning light
goes out.
Connect the engine position sensor.
Operate the engine at idle speed to inspect for leaks at the

filters and drain plug(s).
QSK45 and QSK60 Lubricating Oil Temperature Gauge
Shut off the engine.

Wait approximately 5 minutes to allow the oil to drain from
the upper parts of the engine.
Check the oil level.
Add oil as necessary to bring the oil level to the high (H)
mark on the dipstick.
Lubricating Oil Temperature Gauge

(007-038)
Preparatory Steps
WARNING
WARNING
Inspect for Reuse

Remove one of the pipe plugs on either side of the oil pan.
Use a reference gauge of known accuracy, with a
minimum temperature capacity of 150°C [300°F].
Install the gauge into the oil pan to verify the reading of
the suspect gauge.
Lubricating Oil Temperature Gauge QSK45 and QSK60
Fill the engine with clean engine oil. Refer to Procedure

007-037.
Operate the engine.
Compare the temperature reading of the master gauge to
the suspect gauge.
If the suspect gauge does not read the same temperature

as the reference gauge, check the following for defects:
• Electrical wiring
• Sending unit.
Replace all defective parts.
Remove the reference gauge.

Install and tighten the oil pan plug.
QSK45 and QSK60 Lubricating Oil Transfer Tube
Finishing Steps
Fill the engine with clean engine oil. Refer to Procedure
007-037.
Operate the engine to normal operating temperature.

Check for leaks.
Lubricating Oil Transfer Tube

(007-040)
Preparatory Steps
WARNING
WARNING
WARNING
• Remove the oil pan or oil pan covers. Refer to
Procedure 007-025, or Procedure 007-026.
• Remove the oil pan adapter. Refer to Procedure
007-027.
Lubricating Oil Transfer Tube QSK45 and QSK60
Remove
S-Shape type
NOTE: Arrangement consists of lubricating oil pump
connection (3) and block connection (1), with a steel tube
(2) bridging the connections (1) and (3). Connection (1) has
three mounting capscrews. Steel tube has slight bend in
its section.
Remove the three capscrews (10) from the forward
connector (3).
Remove the three capscrews (7) from the lubricating oil
transfer tube to block connector (1).
Remove the two capscrews (8) from the bracket (4).
Remove capscrews (9) from the lubricating oil transfer
tube clamp and remove the lubricating oil transfer tube.
Remove remaining capscrews (9) from the lubricating oil
transfer tube and connections.
Elbow type
NOTE: Arrangement consists of block connection (1), with
a steel tube (2) which bridges from block connections (1)
directly to lubricating oil pump.
Remove the two capscrews (10) and nuts (12) from the
brackets (4) and (5). Remove tube brace (5).
Remove the four capscrews (7), (8), and (9), from the block
connector (1).
Remove the capscrews (6) from the lubricating oil transfer
tube to lubricating oil pump.
Remove the remaining capscrews (6) from the oil transfer
tube (2) and connection (1).
Remove capscrews (11) and remove bracket (4).
Straight type
four mounting capscrews. Steel tube is straight in section.
Remove the three capscrews (3) from the forward
connector (2).
Remove the four capscrews (7), (8), and (9), from the block
connector (6).
Remove the capscrews (10) from the lubricating oil
transfer clamp tube (4) and remove the lubricating oil
transfer tube.
WARNING
WARNING
WARNING
personal injury.
The oil transfer tubes for the QSK45 and QSK60 engines
are different. The procedure is the same for both
lubricating oil transfer tubes.
Remove the seals (3) from the tube and discard them.
Use solvent or steam to clean the lubricating oil transfer
tube and dry with compressed air.
CAUTION
If the lubricating oil transfer tube is repaired by
welding, be sure all of the welding slag and any metal
that can break are removed the inside. If any debris
enters the lubricating oil pump and system, the gears
will be damaged and failure will result.
Check the lubricating oil transfer tube for cracks or other
damage. If the lubricating oil transfer tube is cracked or
damaged it must be repaired or replaced.
Lubricating Oil Transfer Tube QSK45 and QSK60
Install
S-Shape type
three mounting capscrews. Steel tube has slight bend in
its section.
Lubricate the seals (5) and (6) with clean grease prior to
installation.
Attach connector (1) to engine block with capscrews (10).
Install the lubricating oil transfer tube (2) with seal (5) with
the three capscrews (9) into connector (1).
Attach connector (3) to the lubricating oil transfer tube (2)
with seal (6).
Attach connector (3) with capscrews (10).
Tighten the capscrews except for the two bracket
capscrews (8).
Torque Value:
M10 45 N•m [ 33 ft-lb ]
Capscrews
M12 80 N•m [ 59 ft-lb ]
Capscrews
Loosen the capscrews that attaches bracket (4) to the
cylinder block.
NOTE: Loosen the capscrews only enough to allow the
bracket to move. The bracket must remain flat against the
cylinder block.
Tighten the two capscrews (8) that fasten the bracket (4)
and clamp to connector (1).
Tighten the two capscrews in the bracket to cylinder block
connection.
Elbow type
NOTE: Arrangement consists of block connection (1), with
a steel tube (2) which bridges from block connections (1)
directly to lubricating oil pump.
Lubricate the seals (3) with clean grease prior to
installation.
Install bracket (4) secure with two capscrews (11) to
cylinder block.
Install oil transfer tube (2) to lubricating oil pump and
secure with three off capscrews (6).
Install block connector (1) and secure with capscrews (7),
(8), and (9) to cylinder block.
Install remaining capscrews (6) to transfer tube clamp (2)
and block connector (1).
Install tube brace (5) and secure with capscrews (10) and
nuts (12).
Torque Value:
M10 45 N•m [ 33 ft-lb ]
Capscrews
M12 80 N•m [ 59 ft-lb ]
Capscrews
Straight type
four mounting capscrews. Steel tube is straight in section.
Lubricate seals (5) with clean grease prior to installation.
Install connector (6) with capscrews (7), (8), and (9).
Install the lubricating oil transfer tube (4) with seal (5), with
three capscrews (10) into connector (6).
Install sleeve (1) into bore of lubricating oil pump.
Attach connector (2) to the lubricating oil transfer tube (4),
with seal (5) and three capscrews (10).
Attache connector (2) with capscrews (3).
Torque Value:
M10 45 N•m [ 33 ft-lb ]
Capscrews
M12 80 N•m [ 59 ft-lb ]
Capscrews
Lubricating Oil Contamination QSK45 and QSK60
Finishing Steps
WARNING
• Install the oil pan adapter. Refer to Procedure
007-027.
• Install the oil pan or oil pan covers. Refer to
Procedure 007-025, or Procedure 007-026.
• Fill the lubricating oil. Refer to Procedure 007-037.
Lubricating Oil Contamination

(007-044)
General Information
A used oil analysis can help diagnose internal damage
and determine if it was caused by one of the following:
• Oil diluted with coolant
• Oil diluted with fuel.
Pressure Test
Coolant-Diluted Lubricating Oil
For lubricating oil that is diluted with coolant, Perform the
cooling system pressure test. Refer to Procedure 008-018.

Lubricating Oil Dilution
Perform this test on oil that is diluted with fuel.
This test is not effective on a cold engine, less than 21°C
[70°F] coolant temperature, or with a loose overhead
setting.
Install an isolated fuel supply tank to the inlet and drain
lines. Add fluorescent tracer, Part Number 3376891, to the
fuel supply tank.
QSK45 and QSK60 Lubricating Oil Contamination
Remove the valve cover mounting capscrews, but do

not remove the valve covers.
Start the engine and operate it at high idle for 30 seconds.

Run the engine at low idle.
Complete the next step within 5 minutes.
While the engine is operating at low idle, remove the valve

covers and gaskets. Refer to Procedure 003-011
Injectors normally have a small amount of fuel leakage.

Fuel will be a yellow color.
Use a black light to find fuel leaks from inside or around
the injector.
If there is excess leakage around the outside of the

injector, remove the injector and replace all four o-rings.
If there is excess leakage from inside the injector, replace

the injector. Refer to Procedure 006-026.
Install the rocker lever covers. Refer to Procedure

003-011.

Perform this test on oil that is diluted with fuel.
This test is not effective on a cold engine, less than 21°C
[70°F] coolant temperature, or with a loose overhead
setting.
Install an isolated fuel supply tank to the inlet and drain
lines. Add fluorescent tracer, Part Number 3376891, to the
fuel supply tank.
QSK45 and QSK60 Lubricating Oil Contamination
Remove the aftercooler heat shields. Refer to Procedure

010-129.
Remove the valve cover mounting capscrews, but do
not remove the valve covers.
Start the engine and operate it at high idle for 30 seconds.

Run the engine at low idle.
Complete the next step within 5 minutes.
While the engine is operating at low idle, remove the valve

covers and gaskets. Refer to Procedure 003-011
Injectors normally have a small amount of fuel leakage.

Fuel will be a yellow color.
Use a black light to find fuel leaks from inside or around
the injector.
If there is excess leakage around the outside of the

injector, remove the injector and replace all four o-rings.
If there is excess leakage from inside the injector, replace

the injector. Refer to Procedure 006-026.
Install the rocker lever covers. Refer to Procedure

003-011.
Install the aftercooler heat shields. Refer to Procedure
010-129.
QSK45 and QSK60 Lubricating Oil Cooler Cover
Lubricating Oil Cooler Cover (007-045)

Preparatory Steps
WARNING
WARNING
environmental regulations
008-018.
010-035.
011-007.
WARNING
WARNING
008-018.
• Remove the aftercooler heat shields. Refer to
Procedure 010-129.
Procedure 010-076.
010-035.
Procedure 011-015.
011-007.
Lubricating Oil Cooler Cover QSK45 and QSK60
WARNING
WARNING
008-018.
• Remove the low-pressure turbochargers. Refer to
Procedure 010-035.
• Remove the two-stage turbocharger frame. Refer to
Procedure 010-082.
• Remove the high-pressure turbochargers. Refer to
Procedure 010-034.
011-007.
Remove
The QSK45 engine has three oil cooler covers and the
QSK60 single and two stage have four oil cooler covers.
All covers are removed the same way. Each cover
contains two threaded holes that can be used to aid in the
removal of the cover. Only the QSK60 two-stage engine
has frame support brackets welded on the two center
covers.
Remove two locknuts (1) from the oil cooler element
mounting studs (2).
Remove all twenty capscrews (3).
Install two capscrews (3) in the threaded holes of the cover
(4).
Thread the capscrews in evenly to remove the cover.
Remove the cover (4) and discard the gaskets (5 and 6).
WARNING
WARNING
personal injury.
Clean the covers with solvent and dry with compressed
air.
Inspect the covers for corrosion and other damage.
Replace the covers if corroded or damaged.
QSK45 and QSK60 Lubricating Oil Cooler Cover
Install
The QSK45 engine has three oil cooler covers, and the
QSK60 single- and two-stage engines have four oil cooler
covers. The rear two-stage frame support bracket must be
installed after the rear cover is installed. Only the QSK60
two-stage engine has frame support brackets welded on
the two center covers.
Install one gasket (6) on each of the oil cooler element
mounting studs (2).
Install a new gasket (5) and the oil cooler cover (4).
Position twenty capscrews (3) to secure the cover in
position, but do not tighten the capscrews.

Install and tighten the locking nuts.
Finishing Steps
011-007.
010-034.
• Fill the cooling system Refer to Procedure 008-018.

011-007.
Procedure 011-015.
010-034.
Procedure 010-076.
• Install the aftercooler heat shields. Refer to
Procedure 010-129.
• Fill the cooling system Refer to Procedure 008-018.
Cylinder Smokes (Blue Smoke) QSK45 and QSK60

011-007.
• Install the high-pressure turbochargers. Refer to
Procedure 010-034.
• Install the two-stage turbocharger frame. Refer to
Procedure 010-082.
• Install the low-pressure turbochargers. Refer to
Procedure 010-035.
Cylinder Smokes (Blue Smoke)

(007-050)
Preparatory Steps
Industrial and Power Generation
WARNING
• To check for single-cylinder oil consumption, remove
the exhaust manifold. Refer to Procedure 011-007.
WARNING
Procedure 011-015.
Procedure 010-129.
• To check for single-cylinder oil consumption, remove
the exhaust manifold. Refer to Procedure 011-007.

Add one unit of florescent tracer, Part Number 3376891,
to each 38 liters [10.0 gal] of engine oil.
Idle the engine for 5 to 10 minutes or until normal
operating temperature is reached to allow the dye to
circulate through the lubricating system.
QSK45 and QSK60 Cylinder Smokes (Blue Smoke)
Use a high-intensity black light. Inspect the exhaust ports.

A yellow glow indicates a fuel leak. A dark blue glow
indicates an oil leak.
Check for excessive blue smoke coming out of the faulty

cylinder.
Inspect the cylinder heads. Refer to Procedure 002-004.
Check the pistons and rings. Refer to Procedure 001-054.

Oil Transfer Connection QSK45 and QSK60
Finishing Steps
WARNING
• Install the exhaust manifold. Refer to Procedure
011-007.
WARNING
• Install the exhaust manifold. Refer to Procedure
011-007.
Procedure 011-015.
Procedure 010-129.
Oil Transfer Connection (007-061)

WARNING
WARNING
personal injury.
Clean the oil transfer connection (1) with solvent and dry
with compressed air.
Inspect the oil transfer connection (1) for cracks and
damage.
The oil transfer connection (1) must be repaired or
replaced if cracked or damaged.
QSK45 and QSK60 Pre-Lubricating Oil Pump
Pre-Lubricating Oil Pump (007-063)

Preparatory Steps
WARNING
cable last.
WARNING
Acid is extremely dangerous and can damage the
machinery and can also cause serious burns. Always
provide a tank of strong soda water as a neutralizing
agent when servicing the batteries. Wear goggles and
protective clothing to reduce the possibility of serious
personal injury.
WARNING
On some applications, switches labeled battery
disconnect will not disconnect the battery power from
the engine starters. Make certain that the battery
power has been removed from the engine starters by
checking with a multimeter. There must be zero
voltage at the starter before beginning this procedure.
If there is voltage at the starter, then disconnect the
battery terminals directly, removing the negative (-)
battery cable first. This must be done to reduce the
possibility of personal injury.
Disconnect the battery cables. Refer to Procedure
013-009.
Remove
Remove the post timer relay wire (1) and the ground wire
(2) from the high-volume Prelub™ pump.
Pre-Lubricating Oil Pump QSK45 and QSK60
Disconnect the suction hose from the high-volume

Prelub™ pump.
Disconnect the other end of the suction hose from the
elbow located on the oil pan adapter.
Remove the oil pan capscrew, p-clip, and suction hose.
Remove the suction hose elbow.
Disconnect the supply hose from the high-volume Prelub™

pump.
Disconnect the supply hose from the male adapter in the
in the filter head.
Remove the upper U-shaped pump bracket capscrews.

Loosen the lower U-shaped pump bracket capscrews until
the high-volume Prelub™ pump can be removed.
Remove the capscrews and U-shaped pump brackets.
QSK45 and QSK60 Pre-Lubricating Oil Pump
Remove the high-volume Prelub™ pump bracket mounting

capscrews (located on the cylinder block pan rail) and
remove the bracket.
Install
Install the bracket and tighten the capscrews.
Torque Value:
M12 80 N•m [ 50 ft-lb ]
M10 78 N•m [ 58 ft-lb ]
Apply Loctite™ 641 to the capscrews threads.

Place the high-volume Prelub™ pump into the machined
blocks of the bracket.
Place the two U-shaped brackets over the high-volume
Prelub™ pump.
Install the capscrews and tighten in an alternating
sequence.
Make sure the gap is even under each side of the clamp.
Install the elbow into the oil pan adapter and tighten. The
final position of the elbow after it has been tightened will
be facing toward the rear of the engine.
Pre-Lubricating Oil Pump QSK45 and QSK60
Connect the supply hose to the high-volume Prelub™

pump.
Connect the other end of the hose to the filter head male
adapter.
Tighten the fittings.
Attach the hose to the hose bracket and tighten the
capscrew.
Connect the suction hose to the high-volume Prelub™

pump.
Connect the other end of the suction hose to the elbow in
the oil pan rail.
Attach a p-clip to the hose and secure it to a oil pan
adapter capscrew.
Install the post timer relay wire (1) and the ground wire (2)
to the high-volume Prelub™ pump.
QSK45 and QSK60 Lubricating Oil Fill Tube
Finishing Steps
WARNING
cable last.
WARNING
personal injury.
Connect the battery cables. Refer to Procedure 013-009.
Lubricating Oil Fill Tube (007-065)

Remove
Stand-alone
WARNING
WARNING
For removal instructions, refer to the lubricating oil
dipstick Procedure007-011.
Integral Crankcase Breather

Loosen the two clamps fixing the sleeve (2).
Slide the sleeve away from the filler tube (1).
Loosen the clamp (3) fixing the filler tube to the hand hole
cover.
Remove the filler tube.
Lubricating Oil Fill Tube QSK45 and QSK60
WARNING
WARNING
Loosen the clamps securing the hoses to the oil fill tube
and remove the tube, hoses and clamps.

WARNING
WARNING
personal injury.
Clean all the parts with Cummins® parts cleaner, Part
Number 3824510 or equivalent.
Dry with compressed air to prevent contamination of the
lubrication system with residual cleaning fluid.
Inspect the oil fill tube for damage, cracks, or corrosion.

Replace if damaged.
QSK45 and QSK60 Lubricating Oil Fill Tube
Inspect the hoses for cracks, tears, and damage. Replace

if damaged.
Inspect all the hose clamps for damage, or stripped

threads. Replace if damaged.
Install
Stand-alone
For installation instructions refer to Procedure 007-011,
Lubricating Oil Dipstick Tube.
Integral Crankcase Breather

Slide the filler tube over the hand hole cover tube.
Slide the sleeve (2) onto the filler tube (1).
Tighten all hose clamps.
Eliminator Filter QSK45 and QSK60

Install the two hoses and four clamps on the oil fill tube.
Install the oil fill tube and tighten the hose clamps.
Torque Value:
Hose Clamps 8 N•m [ 71 in-lb ]
Eliminator Filter (007-067)

Remove
WARNING
Remove the mounting capscrews.
Remove the eliminator filter.
Remove the bracket mounting capscrews and the bracket.

QSK45 and QSK60 Eliminator Filter
Remove the eliminator hand hole cover and gasket.
Remove the connection tube from the hand hole cover.

Remove and discard the connection tube o-rings.
Exploded View
Exploded View
0. Top view eliminator filter system
1. Filter body
2. Screw
3. Washer
4. Screw
5. Washer
6. Filter Head
30. Locating pin
31. Flange
32. Screw
33. Washer
34. Drain plug
35. Plug
36A. Nozzle
36B. O-ring
37. Plug
38. O-ring
39. O-ring
40. O-ring
41. O-ring
45. Hydraulic motor
47. Hydraulic motor return pipe assembly
49. Shaft
50. Centrifuge cover
51. Screw and washer
52. Hollow screw handle
53. Circlip
54. Pin
55. Centrifuge
56. O-ring
57. O-ring
58. O-ring
59. Sludge collecting paper
69. O-ring
70. Plug and o-ring
71. Stop
72. Plug and o-ring
73. Valve
74. Spring
75. Gasket
76. Plug
77. Plug and gasket
80. Filter support
82. Connecting pipe
83. O-ring
84. Flange
86. O-ring
87. Pipe support
88. Screw.
Exploded View
Filtering Unit
Exploded View
6. Filter head
8. Assembling rod
9. Sleeve/distributor assembly
11. Ball bearing
12. Circlip
13. Driving pin
15. Spacer assembly
16. Spring
17. Spring guide
18. Cover
19. Cover
21. Companion spacer
22. Filtering element
23. Full-flow cover
24. Column
25. Spring
26. Stainer
27. Cover
28. Washer
29. Screw
40. O-ring
42. O-ring
43. O-ring
44. O-ring.
Exploded View
Centrifuge
55. Centrifuge
57. O-ring
90. Rotor body assembly
92. Distributor
93. Top disc
94. Bowl disc
95. Distributing cone
96. Snap ring

97. Sludge collecting paper.
Exploded View
Parts Available for Service

34B. O-ring
35B. Gasket
39. O-ring
40. O-ring
42. O-ring
43. O-ring
44. O-ring
56. O-ring
57. O-ring
58. O-ring
97. Sludge collecting paper.
86. O-ring
Exploded View
Hydraulic Motor
Exploded View
1000. Hydraulic motor
1001. External flange assembly
1002. Piston/driving shaft assembly
1003. Driving shaft assembly
1004. Internal flange assembly
1012. Slide valve
1014A. Pin
1014B. Pin
1015. O-ring
1016. O-ring
1017. Motor liner
1038. Relay
1039. Spring
1040. Plug
1041. O-ring
1042. Gasket
1043. Inlet column
1044. Gasket
1045. Outlet column
1046. Gasket
1047. Screw
1048. Washer
1049. Motor cover
1050. Screw
1051. Washer
1052. Washer
1053. Operating indicator
1054. Nut
1055. Washer
1056. O-ring
1058. O-ring
1061. Plunger
1062. Gasket.
Exploded View
Piston/Driving Shaft Assembly

Exploded View
1002. Piston/driving shaft assembly
1020. Piston
1022. Driving shaft
1023. Locking pin
1024. Driving pin
1025. Circlip
1026. Ball bearing
1027. Driver
1028. Locking pin
1030. Driven ratchet
1031. Spring
1032. Locking pin
1034. O-ring
1035. O-ring
1036. O-ring
1037. O-ring
1039. Driving ratchet.
Exploded View
Driving Shaft Assembly

Exploded View
1003. Driving shaft assembly
1022. Driving shaft
1025. Circlip
1026. Ball bearing
1027. Driver
1028. Locking pin
1029. Driving ratchet
1030. Driven ratchet
1031. Spring
1032. Locking pin
1033. Locking pin.
Disassemble
WARNING
The bowl can be hot. Use gloves when removing the
rotating bowl to reduce the possibility of burns.
Remove the rotating bowl (55) and place it on a work
bench.
WARNING
The bowl discs can have sharp edges. Use gloves
when handling the discs to reduce the possibility of
personal injury.
Remove the rotor cover nut (59) and the rotor cover (90).
Remove the disc stack (xx) from the rotor (90).
Place the disc stack on a work bench.
WARNING
when handling the discs to reduce the possibility of
personal injury.
Remove the snap-ring (96) and the distributor cone (95).
Remove the disc (94) from the distributor.
Remove the top disc (93) from the distributor (92).
WARNING
WARNING
Place a suitable container under the drain plug (34A).
Remove the drain plug and drain the oil.
Remove the vent plug (35A) to aid in draining the oil.
Install the drain plug (34A) and the vent plug (35A) in the
filter body.
Remove the coupling and the banjo screw on the hydraulic

motor return pipe (47).
Remove the pipe supports and the return pipe (47).
Remove the four capscrews (4) and washers (5) from the
hydraulic motor (1000).
Install two M10 capscrews on opposite sides of the

hydraulic motor and tighten them alternately 1/2 of a turn
at a time.
When the hydraulic motor is raised out of the filter head,
lift it out.
Remove the two M10 capscrews.
Carefully place the hydraulic motor on a workbench.
Rotate the driver (1027) by hand. If it can be rotated in

only one direction, the teeth of the ratchet are acceptable.
If it can be rotated on both directions, both the driving and
driven ratchets must be replaced.
Use a 9/16-inch wrench to loosen the locking nut (1054)

on the operating indicator (1053).
Remove the operating indicator.
Remove two screws (1050) and washers (1051 and 1052).

Remove the motor cover (1049).
Drive out the locking pin (1028) with a pin punch and
remove the pin remove the driver (1027).
Remove the two capscrews (1047).
Tap the driving ratchet (1029) carefully with a mallet to

separate the parts of the motor.
Remove the inlet column (1043), from the outlet column

(1045).
Remove the motor liner (1017) from the external flange
assembly (1001).
Drive out the pin (1014A) from the slide valve (1012) and
separate the remaining part of the piston/driving shaft
assembly from the internal flange assembly (1004).
Remove the bearing (1026) and circlip (1025) from the

piston (1020).
Remove the circlip (1025) and the bearing (1026).
Remove the locking pin (1032). Separate the driving

ratchet (1029), driven ratchet (1030), spring (1031), and
the driving shaft (1022).
NOTE: The driving ratchet drives the distributor. The
driven ratchet is driven by the piston.
Remove the two plugs (1040), gaskets (1042), springs

(1039), relays (1038), and o-rings (1041) from the internal
(1004) and external (1001) flange assemblies.
Drive out the pin (1014B) and remove the slide valve
(1012).
The columns (C1 and C2) can not be dismantled.
Remove the twelve capscrews (2) and washers (3) from

the filter head (6).
Install two 1/2-13 UNC capscrews in opposite holes in the

filter head (6). Alternately tighten them 1/2 of a turn at a
time until the filter head separates from the housing.
WARNING
Install two 1/2-13 UNC eye bolts in opposite holes on the
filter head (6).
Remove the filtering unit and place it on a work bench.
Remove the four capscrews (29) and washers (28) from

the cover (27).
Remove the cover.
Remove the full-flow cover (23), with studs (24), strainer

(26), and springs (25).
Remove the full-flow filtering elements (22) one by one.

Remove the companion spacer (21).
Remove the sleeve/distributor assembly and place it on a

work bench.
Remove the four screws (20) and washers from the cover
(19). Remove the cover and spacer (15).
The springs (16) are kept in place by screws in the spacer.
Do not remove the springs.
Remove the circlips (12) and ball bearings (11).

Inspect the ball bearings for free rotation.
Replace the bearings if they are seized or worn.
Remove the distributor (10) and place it on a work bench.
WARNING
WARNING
personal injury.
WARNING
when handling the bowl discs to reduce the possibility
of personal injury.
CAUTION
If sludge is left, this can create an imbalance when the
filter is started.
Inspect the inside of the rotor cover. Remove the sludge
from the wall without damaging the surface.
If a paper insert is used the sludge is removed by pulling
out the paper insert.
If necessary, put all of the components into a cleaning tray
filled with diesel fuel or mineral spirits.
Remove the last solids retained on the components using
compressed air or the air/water gun.
WARNING
WARNING
personal injury.
Clean all of the components with diesel fuel, using a soft
brush.
Remove any remaining solids using compressed air.
Check the condition of the liner (1017) surface. If
necessary, clean the liner using a fine 600-grit emery
cloth.
Lubricate the ball bearings with grease.

Make sure that they can rotate freely. Replace them if they
are seized or feel rough when rotated.
If the driver was rotated in both directions when checked

during disassembly, the teeth of the ratchet are worn out.
Replace both the driving (1029) and the driven ratchets
(1030).
Inspect the helical grooves in the driven ratchet (1030). If

the surface is damaged, polish it using a smooth emery
cloth.
Replace the driven ratchet (1030) if emery cloth does
not repair it.
Inspect the driving pins (1024) in the piston (1020). If the

pins are damaged at their inner ends, remove them from
the piston.
Drive out the locking pins (1023) with a pin punch. If both
ends of the driving pins are damaged, replace them with
new pins. If only the inner ends are damaged, turn them
around and place them into the piston, and make sure
they rotate.
If necessary polish them with a 600-grit emery cloth.
Insert the locking pins into the piston.
WARNING
Do not clean the filter elements with diesel fuel or mineral
spirits.
Carefully clean all the components (except the filter
elements) with clean diesel fuel or mineral spirits and a
soft brush.
WARNING
personal injury.
Remove the last solids retained on the components using
compressed air.
WARNING
CAUTION
Do not use acid-based cleaning solvents. The can
damage the filter elements.
Keep one full-flow filter element as a guide for assembly
of the filter halves after cleaning.
Put the filter elements into a cleaning tray filled with
cleaning solvent. Soak the filter elements in the tray at
least 15 minutes.
Remove an element from the cleaning tray and separate

it into halves.
WARNING
personal injury.
CAUTION
Rinse thoroughly with water. Engine damage can
result if solvent is left on the filter elements.
Brush the element halves with a soft brush. Rinse the
element halves with water on both sides using a air/water
gun.
WARNING
personal injury.
Dry the element halves with compressed air.
Carefully inspect the filter elements for damage or dirt
Always check the filter screen for cracks.
Replace damaged elements.
If the elements are still dirty, repeat the cleaning
procedure. Increase the time the element halves are in the
cleaning tray.
Assemble the element halves and repeat the cleaning

steps on the remaining elements in the tray.
When all of the elements have been cleaned and
assembled according to the “guide” element, clean the
“guide” element.
Assemble
Lubricate the distributor (10) and install it into the sleeve.
Assemble the ball bearings (11) and circlips (12) on the
distributor.
Assemble the spacer (15) onto the sleeve (9). Make sure
that the four locating pins are in the correct position.
Install the cover (19) and four capscrews and washers
(20).
Place the assembly vertically on a workbench.

Install a new o-ring (40) on the filter head (6).
Lubricate the o-ring with grease.
Install the sleeve/distributor assembly on the filter head (6)
and rods (8).
Assemble the companion spacer (21) and the clean full-

flow filtering elements one by one onto the full-flow rods
(8).
Make sure the same number of elements are installed that
were removed.
Assemble the full-flow cover (23), strainer (26), and

springs (25).
Install a new o-ring (42) in the full-flow cover (23) and
lubricate it.
Install new o-rings (43) and (44) in the cover and lubricate
them.
Secure the cover (27) to the rods, using four capscrews
(29) and washers (28).
Turn the filtering unit upside-down.
WARNING
This component weighs 23 kg [50 lb] or more to
reduce the possibility of personal injury use a hoist or
get assistance to lift this component.
Install a new o-ring (40) in the filter head (6) and lubricate
it.
Install two 1/2-13 UNC eye bolts on opposite sides of the
filter head (6). Install a strap between the eye bolts.
Carefully install the filtering unit into the filtering body.
Make sure the holes in the filter head are facing the guide
rods (30) of the filter body.
Install and tighten the twelve capscrews (2) and washers

(3) into the filter head (6).
Install new o-rings (1041) on the relays (1038).

Install the springs (1039) to the plugs (1040) and install
new gaskets (1042).
Install the plugs into the internal (1004) and external
(1001) flange assemblies.
Tighten the plugs.
Make sure the relays slide under the action of their springs
when they are pressed from inside of the internal (1004)
and external (1001) flanges.
The relays must return to their original positions.
Assemble the shaft parts as follows:

• Driving shaft (1022)
• Driving ratchet (1029)
• Driven ratchet (1030)
• New spring (1031)
• Locking pin (1032).
Install the bearing (1026) and circlip (1025) on the shaft

assembly.
Install new o-rings (1034), (1035), (1036), and (1037) onto

the piston (1020).
Lubricate the o-rings with grease.
Install the piston (1020) over the shaft assembly. Insert the
driving pins (1024) into the helical grooves (C) in the driven
ratchet (1029).
Install the circlip (1025) and bearing (1026) onto the shaft.
Install a new o-ring (1016) onto the internal flange

assembly (1004).
Lubricate the o-ring with grease.
Install a new o-ring (1015) to the slide valve (1012) and

lubricate the o-ring with a light grease that does not
contain additives.
Install the slide valve (1012) column (C2).
Install pin (1014B) into the slide valve (1012). Position the
pin so it extends out the same distance on both sides,
Assemble the piston and shaft assembly with the internal

flange assembly (1004).
Make sure the piston lug (X) is in line with the relay (1038)
in the flange.
Install the pin (1014A) in the slide valve (1012). Position

the pin so it extends out the same distance on both sides.
Install the liner (1017) on the internal flange assembly

(1004).
Install new o-rings (1056) and (1058) on the external flange

assembly (1001).
Lubricate o-rings with grease.
Install the external flange assembly (1001).

Make sure the lug (X) is in line with the relay (1038) in the
external flange assembly (1001).
Install new gaskets (1044) and (1046) on the inlet column

(1043) and outlet column (1045).
Install the columns in the respective slots in the external
flange assembly.
Install the two capscrews (1047).

Install the driver (1027) over the shaft.

Install the locking pin (1033).
Install the cover (1049) with capscrews (1050) and

washers (1051 and 1052).
Install the operating indicator (1053) with nut (1054) and

washer (1055) into the end of the driving ratchet (1029).
Tighten the nut while keeping the operating indicator in

position.
Make sure the hydraulic motor has been assembled

correctly by manually turning the driver (1027).
If the hydraulic motor is assembled correctly it will only
rotate in a clockwise direction.
Supply compressed air at 400 to 500 kPa [58 to 72.5 psi]
to the motor outlet and make sure the operating indicator
(1053) and the driver (1027) rotate in a clockwise
direction.
If the rotation is correct, the motor can be inserted into the
filter.
If the rotation is not correct, motor must be disassembled
and assembled correctly.
Install a new o-ring (39) onto the hydraulic motor (1000).

Lubricate the o-ring.
Install the hydraulic motor into the filter head.
Make sure the driver (1027) is in the correct position,
corresponding to the driving pin of the distributor.
Install and tighten the four capscrews (4) and washers (5)
into the hydraulic motor (1000).
Install the hydraulic motor return pipe (47).

Tighten the banjo screw and coupling on the hydraulic
motor pipe.
WARNING
when handling the bowl discs to reduce the possibility
of personal injury.
Place the distributor (92) onto a work bench.
Install the top disc (93) onto the distributor.
Install the discs (94) onto the distributor.
Assemble the distributing cone (95). The correct number
of discs can vary. The correct number of discs is achieved
when the distributing cone is positioned with the circlip
groove on the distributor completely open.
Add or remove bowl discs to achieve the correct height.
Secure the assembly with the circlip (96).
Install the disc stack (xx) on the rotor shaft (90).

Lubricate the o-ring (57) and install it on the rotor (90).

Install a new sludge collecting paper insert into the rotor
cover (90).
Install the rotor cover (90).
Hand tighten the nut (59).
Mount the rotating bowl (55) on the spindle (49).
Install a new o-ring (56) on the cover (50).

Lubricate the o-ring.
Install the cover (50) on the filter, turn the hollow screw
handle (52) clockwise.
Install the four capscrews (51A) and washer (51B).

Install
CAUTION
The eliminator filter can be installed on either side of
the engine. Check to be sure the lubricating oil
transfer tube has been installed correctly. The filter
must be on the opposite bank from the oil transfer
tube. If the eliminator filter is installed on the wrong
bank, the engine will be severely damaged because of
the lack of lubrication.
Install the support bracket to the engine with two
capscrews.
Install the eliminator filter hand hole cover with a new

gasket.
Lubricate the o-rings with vegetable oil and install on both

ends of the connection tube.
Install the connection tube into the filter housing.
WARNING
Install the four guide studs into the engine block.
The gasket has a rib down the center. This gasket is
installed for the right side of the filter.
Install the gaskets over the guide studs.
Install the filter over the guide studs while guiding the
connection tube into the hand hole cover.
Install the eight capscrews.
Remove the guide studs and install the four remaining
capscrews.
Install two capscrews into the lower support.
Pressure Test
Perform the following steps to measure the pressure drop
across the Eliminator Filter.
Remove one plug from each side at the top of the filter
housing.
Install the pressure gauges in the ports.
Operate the engine to normal operating temperature.
Record the readings from both gauges.
The difference between the two measurements is the
pressure drop across the filter.
The maximum operating pressure drop must not exceed
39.9 kPa [5.8 psi]. If the pressure drop is greater, refer to
Section TS.
Remove the pressure gauges.
Install the plugs.
Tighten the plugs.
Fleetguard® Centrifuge QSK45 and QSK60
Fleetguard® Centrifuge (007-068)

Disassemble
NOTE: Although the illustrations in this procedure show
the Fleetguard® Centrifuge mounted on engine, the
procedure remains the same for on and off the engine.
Remove the band clamp (1) from the centrifuge bell
housing (2) and base (3).
Loose the bell knob (4), and remove the centrifuge bell
housing (2) and o-ring (5).
Discard the o-ring.
Using a flat screwdriver or prying tool to raise the turbine

assembly (6) approximately 25 mm [1 in] above the base
(3), and allow any remaining oil to drain from the turbine
assembly.
Remove the turbine assembly (6) from the base (3).

Set the turbine assembly to one side of the work area.
Using a 3 inch spanner wrench, loosen the cam nut (7)

and invert the assembly to loosen the cone washer (8) and
the turbine can (11).
Carefully separate the cam nut (7), cone washer (8),
turbine can (11), Conestac filter (9), and o-ring (12) from
the rotor turbine (10).
Discard the o-ring and Conestac filter.
QSK45 and QSK60 Fleetguard® Centrifuge

Using a clean rag, clean all gasket surfaces, bell housing,
can, and shafts.
Make sure the nozzles are free from debris and dirt.
Inspect all parts for cracks or other damage. If any of the
parts are damaged they must be replaced.
Assemble
Install the o-ring (12), a new Conestac filter (9), turbine can
(11), cone washer (8), and can nut (7) onto the rotor turbine
(10).
Make sure the Conestac filter and o-ring are fully seated
in the groove of the rotor turbine.
Tighten the cam nut (7) only finger tight.
CAUTION
Use caution when assembling the turbine assembly to
prevent damage to the bushings. Damage to the
bushings will cause premature equipment failure.
Install the turbine assembly (6) onto the base (3).
The turbine assembly must spin freely on the base when
installed.
Fleetguard® Centrifuge QSK45 and QSK60
Install the o-ring (5), and the centrifuge bell housing (2),
onto the base (3) hand tightening the bell knob (4).
Install the band clamp (1) around the centrifuge bell
housing (2) and base (3).
Tighten the band clamp (1).
QSK45 and QSK60
Section 8 — Cooling System — Group 08 Page 8-a
Section 8 — Cooling System — Group 08

Section Contents
Page
Coolant Filter .....................................................................................................................................................8-5
Install................................................................................................................................................................8-6
Remove............................................................................................................................................................8-5
Coolant Filter Head ...........................................................................................................................................8-7
Finishing Steps.................................................................................................................................................8-7
Install................................................................................................................................................................8-7
Remove............................................................................................................................................................8-7
Coolant Temperature Gauge .............................................................................................................................8-5
Inspect for Reuse..............................................................................................................................................8-5
Coolant Thermostat ..........................................................................................................................................8-8
Finishing Steps...............................................................................................................................................8-16
QSK45 Engines............................................................................................................................................8-16
Install..............................................................................................................................................................8-13
LTA..............................................................................................................................................................8-13
Leak Test........................................................................................................................................................8-14
Engine Coolant Temperature........................................................................................................................8-14
High Coolant Temperature........................................................................................................................... 8-16
QSK45 Engines..............................................................................................................................................8-8
with Electronically Actuated Injector...............................................................................................................8-9
Remove.......................................................................................................................................................... 8-10
LTA..............................................................................................................................................................8-10
Test................................................................................................................................................................ 8-11
Coolant Thermostat Seal ................................................................................................................................ 8-36
Install..............................................................................................................................................................8-36
Remove.......................................................................................................................................................... 8-36
Coolant Vent Lines ..........................................................................................................................................8-37
Aftercooled Engines.....................................................................................................................................8-37
LTA..............................................................................................................................................................8-38
Cooling System ...............................................................................................................................................8-39
Drain...............................................................................................................................................................8-39
LTA..............................................................................................................................................................8-40
Fill...................................................................................................................................................................8-49
Flush...............................................................................................................................................................8-40
Pressure Test..................................................................................................................................................8-43
Internal.........................................................................................................................................................8-43
External....................................................................................................................................................... 8-48
Cooling System Diagnostics ...........................................................................................................................8-55
Pressure Test..................................................................................................................................................8-55
Cooling System Service Requirements ..........................................................................................................8-57
Water...........................................................................................................................................................8-57
Supplemental Coolant Additive (SCA)...........................................................................................................8-58
QSK45 and QSK60
Page 8-b Section 8 — Cooling System — Group 08
Cooling System - Air or Combustion Gas Test ..............................................................................................8-51

Test................................................................................................................................................................ 8-51
Overflow Method..........................................................................................................................................8-51
Sight Glass Method......................................................................................................................................8-52
Air Compressor............................................................................................................................................8-53
Cylinder Head and Cylinder Liner.................................................................................................................8-53
Drive Belt, Cooling Fan .....................................................................................................................................8-3
Adjust...............................................................................................................................................................8-4
Finishing Steps.................................................................................................................................................8-5
Install................................................................................................................................................................8-4
Remove............................................................................................................................................................8-3
ECM Cooling Plate .........................................................................................................................................8-146
Assemble......................................................................................................................................................8-151
Disassemble..................................................................................................................................................8-147
Finishing Steps.............................................................................................................................................8-153
Install............................................................................................................................................................8-152
Preparatory Steps.........................................................................................................................................8-146
Remove.........................................................................................................................................................8-146
ECM Cooling Plate Lines ...............................................................................................................................8-153
Finishing Steps.............................................................................................................................................8-156
Inspect for Reuse..........................................................................................................................................8-154
Install............................................................................................................................................................8-155
Remove.........................................................................................................................................................8-153
Expansion Tank ...............................................................................................................................................8-90
Finishing Steps...............................................................................................................................................8-94
Install..............................................................................................................................................................8-92
....................................................................................................................................................................8-90
Remove.......................................................................................................................................................... 8-90
Fan Drive Idler Arm Assembly ........................................................................................................................8-58
Assemble........................................................................................................................................................8-61
Disassemble................................................................................................................................................... 8-60
Finishing Steps...............................................................................................................................................8-64
Install..............................................................................................................................................................8-63
Remove.......................................................................................................................................................... 8-58
Fan Drive Idler Pulley Assembly .....................................................................................................................8-64
Assemble........................................................................................................................................................8-66
Turnbuckle Idler System...............................................................................................................................8-66
Shock Absorber System...............................................................................................................................8-64
Disassemble................................................................................................................................................... 8-64
Fan Hub Bracket ..............................................................................................................................................8-67
Fan Hub, Belt Driven .......................................................................................................................................8-68
Finishing Steps...............................................................................................................................................8-75
Standard......................................................................................................................................................8-71
Install..............................................................................................................................................................8-72
Standard......................................................................................................................................................8-72
Rockford......................................................................................................................................................8-72
Remove.......................................................................................................................................................... 8-68
Standard......................................................................................................................................................8-68
Rockford......................................................................................................................................................8-68
QSK45 and QSK60
Section 8 — Cooling System — Group 08 Page 8-c
Fan Shroud Assembly .....................................................................................................................................8-75

Fan, Cooling ....................................................................................................................................................8-75
Finishing Steps...............................................................................................................................................8-78
Install..............................................................................................................................................................8-77
Remove..........................................................................................................................................................8-76
Rotation Check...............................................................................................................................................8-77
Heat Exchanger ...............................................................................................................................................8-95
Assemble......................................................................................................................................................8-102
Disassemble...................................................................................................................................................8-98
Exploded View................................................................................................................................................8-95
Finishing Steps.............................................................................................................................................8-105
Install............................................................................................................................................................8-104
Remove..........................................................................................................................................................8-97
Low-Temperature Aftercooler (LTA) Water Pump ........................................................................................8-133
Assemble......................................................................................................................................................8-139
with Mechanically Actuated Injector............................................................................................................8-139
Disassemble..................................................................................................................................................8-135
Finishing Steps.............................................................................................................................................8-142
General Information.......................................................................................................................................8-133
Install............................................................................................................................................................8-142
Remove.........................................................................................................................................................8-134
Marine Gear Oil Cooler ....................................................................................................................................8-79
Finishing Steps...............................................................................................................................................8-82
Install..............................................................................................................................................................8-81
Pressure Test..................................................................................................................................................8-80
Remove..........................................................................................................................................................8-79
Radiator ...........................................................................................................................................................8-82
Finishing Steps...............................................................................................................................................8-84
Test................................................................................................................................................................8-82
Radiator Hoses ................................................................................................................................................8-85
Finishing Steps...............................................................................................................................................8-88
Install..............................................................................................................................................................8-87
LTA..............................................................................................................................................................8-87
Remove..........................................................................................................................................................8-85
LTA..............................................................................................................................................................8-86
Radiator Pressure Cap ....................................................................................................................................8-88
Pressure Test..................................................................................................................................................8-89
Radiator Top Tank ...........................................................................................................................................8-89
Leak Test........................................................................................................................................................8-89
Right Bank Number 8 Coolant Loop .............................................................................................................8-143
Finishing Steps.............................................................................................................................................8-146
QSK45 and QSK60
Page 8-d Section 8 — Cooling System — Group 08
Install............................................................................................................................................................8-145
QSK60 Two Stage......................................................................................................................................8-143
Remove.........................................................................................................................................................8-143
Sea Water Pump ............................................................................................................................................8-105
Install............................................................................................................................................................8-107
Remove.........................................................................................................................................................8-105
Service Tools ....................................................................................................................................................8-1
Cooling System.................................................................................................................................................8-1
Supplemental Coolant Additive (SCA) ..........................................................................................................8-108
Maintenance Check.......................................................................................................................................8-108
Coolant Thermostat Housing Support ............................................................................................................8-18
Finishing Steps...............................................................................................................................................8-33
LTA..............................................................................................................................................................8-34
Install..............................................................................................................................................................8-26
LTA..............................................................................................................................................................8-28
LTA..............................................................................................................................................................8-19
Remove..........................................................................................................................................................8-20
LTA..............................................................................................................................................................8-21
Water Pump ...................................................................................................................................................8-113
Assemble......................................................................................................................................................8-124
Disassemble..................................................................................................................................................8-118
New...........................................................................................................................................................8-120
Finishing Steps.............................................................................................................................................8-133
with Electronically Actuated Injector............................................................................................................8-133
Install............................................................................................................................................................8-129
Machine........................................................................................................................................................8-123
Measure........................................................................................................................................................8-121
Remove.........................................................................................................................................................8-114
Water Manifold ..............................................................................................................................................8-109
QSK60 Marine Applications........................................................................................................................8-111
Finishing Steps.............................................................................................................................................8-113
Install............................................................................................................................................................8-111
Remove.........................................................................................................................................................8-110
Section 8 — Cooling System — Group 08 Page 8-1
Service Tools
Cooling System
Repair Location.

Gear Puller
Used to remove the water pump pulley and impeller.
ST-647
Water Pump Seal Driver

Used to install the ceramic seal on the water pump driveshaft.
3377260
Water Pump Seal Driver

Used to install the ceramic seal on the water pump driveshaft.
3824836
Water Pump Bearing Mandrel

Used to press the bearing and shaft into the water pump body.
3375318
Bearing Separator
Used to hold the bearing when removing it from the shaft.
3375326
Thermostat Seal Driver

Used to install the thermostat seals.
3375411
Page 8-2 Section 8 — Cooling System — Group 08

Digital Optical Tachometer
Used to measure the rpm of the fan.
3377462
Reflective Tape
Used with optical tachometer, Part Number 3377462, to measure the
3377464 rpm of the fan.
Cooling System Test Kit - Fleetguard®

Used to measure supplemental cooling additive (SCA) concentration.
CC-2602
Snap-On Pry Bar

Used to remove the thermostat seals.
1650
QSK45 and QSK60 Drive Belt, Cooling Fan
Drive Belt, Cooling Fan (008-002)

Preparatory Steps
WARNING
Remove the cooling fan. Refer to Procedure 008-040.
Remove
WARNING
The fan belt idler is under tension. Do not allow your
hands to get between the idler and the belt or the fan
hub. Personal injury can result.
Loosen the six capscrews (1) and the three capscrews (2)
and the center capscrew (4). Turn the hexagon nut (3)
counterclockwise to relieve tension on the belt.
Remove the fan belt.
Inspect for Reuse

Inspect the belt for:
• Cracks
• Glazing
• Tears or cuts.
Replace the belt if damaged.
Drive Belt, Cooling Fan QSK45 and QSK60
Install
Install the belt.
Adjust
Install the belt tension gauge, Part Number 3163569.
Turn the control rod (1) clockwise to tighten the belt
tension.
Reposition the idler lever clamping screws only if correct

tension can not be obtained using the control rod.
Loosen the three capscrews (4), the six capscrews (5), and
the center capscrew on the belt tensioner.
Turn the control rod (1) counterclockwise until the idler
lever pulley (2) is off the belt (3) completely.
Position the idler lever pulley (2) against the belt (3).
Reposition clamping capscrews if necessary.
Turn the control rod (1) clockwise to increase the belt
tension.
Set the belt initially to 4893 N [1100 lbf].
Run the engine for a minimum of 1 hour and a maximum
of 24 hours. Check and reset, if necessary, to 4893 N
[1100 lbf].
After the belt tension has relaxed to a minimum of 3559 N
[800 lbf], reset it to 4893 N [1100 lbf].
Tighten the three capscrews (4), six capscrews (5), and
the center capscrew on belt tensioner.
QSK45 and QSK60 Coolant Filter
Finishing Steps
WARNING
Install the fan. Refer to Procedure 008-040.
Coolant Temperature Gauge (008-004)

Inspect for Reuse
Check for a blown fuse.
Check the wiring from the gauge to the sending unit for
broken connection(s).
Use a temperature gauge of known accuracy to check the

existing gauge.
Replace the gauge or sending unit if faulty.
Coolant Filter (008-006)

Remove
WARNING
Remove the pressure cap from the radiator.
Coolant Filter QSK45 and QSK60
WARNING
Turn valve (1) on the coolant filter head to the OFF position
to prevent water loss.
Remove the coolant filters.
Install
Clean the area around the coolant filter head. Clean the
gasket surface of the coolant filter head.
The o-ring can stick on the coolant filter head. Make sure
the o-ring is removed.
Discard the coolant filters.
CAUTION
When lubricating the seal on the coolant filter do not
allow oil to get into the coolant filter. It will adversely
affect the SCA.
Lubricate the seal on the coolant filter with clean engine
oil.
Install the coolant filter.

Turn the coolant filter clockwise until the seal touches the
coolant filter head.
Turn the coolant filter an additional ½ to ¾ of a turn after
contact.
Turn the valve (1) on the coolant filter head to the ON
position.
QSK45 and QSK60 Coolant Filter Head
Coolant Filter Head (008-007)

Preparatory Steps
WARNING
Remove the coolant filters. Refer to Procedure 008-006.
Remove
Remove the two coolant filter head mounting capscrews,
and the coolant filter head (4).
Install
Install the coolant filter head on the thermostat housing
with two capscrews.
Finishing Steps
Install the coolant filters. Refer to Procedure 008-006.
Coolant Thermostat QSK45 and QSK60
Coolant Thermostat (008-013)

Preparatory Steps
QSK45 Engines
WARNING
WARNING
WARNING
008-018.
• Remove the coolant filter head. Refer to Procedure
008-007.
• Remove the thermostat housing. Refer to Procedure
008-015.
WARNING
WARNING
WARNING
008-018.
• Remove the front intercooler. Refer to Procedure
010-083.
008-007.
008-015.
QSK45 and QSK60 Coolant Thermostat
WARNING
WARNING
WARNING
008-018.
WARNING
WARNING
WARNING
008-018.
• Remove the water outlet manifold. Refer to
Procedure 008-061.
• Remove the front intercooler. Refer to Procedure
010-083.
• Remove the sea water expansion tank. Refer to
Procedure 008-052.
• Remove the sea water heat exchanger. Refer to
Procedure 008-053.
008-007.
008-015.
Remove
Remove the upper radiator and aftercooler hoses on the
thermostat housing.
Remove the 20 capscrews holding the thermostat housing

covers on the right and left side of the thermostat housing.
Remove both thermostat housing covers and discard both
thermostat housing cover gaskets.
NOTE: With the thermostat housing covers removed, it
exposes three thermostats on the left and three
thermostats on the right. One thermostat on the left side
is mounted upright for the LTA cooling system.
Remove the thermostats.
LTA
The low temperature aftercooler (LTA) thermostat is
accessed by removing the hose and outlet connection
from the left thermostat housing.
Remove the low temperature aftercooler (LTA) thermostat.

Remove the thermostat cover plates. Each cover plate has
ten capscrews.
Remove the two capscrews in each clamping plate and

remove the spacers and clamping plates.
Remove the thermostats and seals from the housing.
Inspect for Reuse

The two center thermostats are low temperature
aftercooling thermostats and have a different temperature
range than the engine thermostats. They are knurled on
the upper diameter.
Check the thermostats for wear or damage. If the barrel of
a thermostat is worn or fretted, it must be replaced.
Test
Check the thermostat marking to see when the thermostat
is designed to open.
The rated nominal temperature is marked on the side of
the thermostat.
The design temperature of the thermostat is 82°C [180°
F].
Suspend the thermostat and thermometer in a container

of water. Do not allow the thermostat or thermometer to
touch the side of the container.
Heat the water to check the temperature when the
thermostat begins to open.
Thermostat Initial Opening Temperature

°C °F
74.4 MIN 166
48.3 MAX 173
Continue to apply heat to check the temperature when the

thermostat is completely open.
Minimum Open Distance at Full Open Temperature

mm in
10.0 MIN 0.40
Full-Open Temperature
°C °F
90 MIN 194
Remove the container from the heat.
With the thermostat open, check for wear or damage.

If the seat of the thermostat is worn or fretted, it must be
replaced.
Make sure the thermostat closes when the temperature is
below 74.4°C [166°F].
Install
Install the thermostat seals. Refer to Procedure 008-016.
Install the thermostat by pushing on the outer rim.
Install the thermostat housing cover gasket, right and left

covers, and capscrews.
Install the upper radiator and aftercooler hoses on the

thermostat housing.
LTA
Install the LTA thermostat.
Install the outlet hose and connection.

Install the thermostat seals. Refer to Procedure 008-016.
Install the thermostat by pushing on the outer rim.
Install the clamping plates, spacers and capscrews.
Install the thermostat housing cover gaskets, covers, and

capscrews.
Leak Test
The engine thermostat and thermostat seal must operate
properly in order for the engine to operate in the most
efficient heat range. Overheating or overcooling will
shorten engine life.
With a low temperature aftercooling thermostat, the intake
air temperature is monitored by the electronic system and
will generate a fault code when the intake air temperature
exceeds the maximum temperature limits.
Engine Coolant Temperature
WARNING
before removing the pressure cap. Heated coolant
spray or steam can cause personal injury.
NOTE: If the engine being tested has low temperature
aftercooling, leave the low-temperature aftercooling
radiator hoses connected to the thermostat housing.
Remove the upper engine radiator hoses from the
thermostat housing.
Install two hoses of the same size on the thermostat

housing outlets. The hoses must be long enough to reach
a remote, dry container.
Install and tighten hose clamps on the housing outlets.
Put the end of the hoses in the two dry containers.
Operate the engine at rated rpm for 1 minute.

Measure the amount of coolant collected in each
container.
The amount of coolant collected must not be more than
100 cc [3.3 fl oz].
If more than 100 cc [3.3 fl oz] of coolant is collected, the

thermostat or the thermostat seal is leaking.
Remove the thermostats and replace the seals. Refer to

Procedure 008-015.
Test the thermostats for proper operation.
High Coolant Temperature

Restrict the radiator airflow. Operate the engine until the
coolant temperature reaches 90 to 93°C [195 to 200°F].
Use a contact pyrometer (shown), or install a temperature

gauge in the desired locations.
Record the temperature of the coolant outlet hoses. An
increase in temperature indicates the thermostats have
started to open.
Record the temperature of the radiator bottom tank or
coolant out tube.
If the difference in temperature is more than 8°C [15°F],

either the thermostats are not fully open or the radiator
core is plugged.
Check the radiator; refer to Procedure 008-042. If the
radiator is in good working order, replace the thermostats.
Finishing Steps
QSK45 Engines
WARNING
• Install the thermostat housing. Refer to Procedure
008-015.
• Install the coolant filter head. Refer to Procedure
008-007.
• Operate the engine until the coolant temperature
reaches 70°C [158°F]. Check for leaks.
WARNING
008-015.
008-007.
• Install the front intercooler. Refer to Procedure
010-083.
WARNING
WARNING
008-015.
008-007.
• Install the sea water heat exchanger. Refer to
Procedure 008-053.
• Install the sea water expansion tank. Refer to
Procedure 008-052.
• Install the front intercooler. Refer to Procedure
010-083.
• Install the water outlet manifold. Refer to Procedure
008-061.
Coolant Thermostat Housing Support QSK45 and QSK60
Coolant Thermostat Housing Support

(008-015)
Preparatory Steps
Aftercooled Engines
WARNING
WARNING
If the engine is equipped with a fan, remove the fan and
the fan hub. Refer to Procedure 008-036.
Drain the cooling system. Refer to Procedure 008-018.
Disconnect the coolant temperature sensor wire.
Disconnect the coolant pressure sensor wire.

QSK45 and QSK60 Coolant Thermostat Housing Support
LTA
WARNING
WARNING
If the engine is equipped with a fan, remove the fan hub.
WARNING
On the two-stage QSK60 engine, the front intercooler
must be removed for access to the thermostat and
support housings.
Remove the front intercooler. Refer to Procedure 010-083.
Disconnect the coolant temperature sensor wire.
Disconnect the coolant pressure sensor wire.

WARNING
WARNING
WARNING
• If the engine is equipped with a fan, remove the fan
hub. Refer to Procedure 008-036.
008-018.
• Remove the sea water expansion tank. Refer to
Procedure 010-052.
• Remove the sea water heat exchanger. Refer to
Procedure 010-053.
• Disconnect the coolant temperature sensor wire.
• Disconnect the coolant pressure sensor wire.
Remove
Aftercooled Engines
Remove the upper radiator hoses from the thermostat
housing.
Remove the turbocharger coolant return line (1) from the
rear of the thermostat housing.
Remove the bypass tube (2) and gasket (3) from
thermostat housing.
Remove the four capscrews (4) and the two retainer clips
(5).
Remove the aftercooler coolant return tube (6), aftercooler
coolant supply tube (7), o-rings (8), and hoses (9) from the
thermostat housing support.
Remove the two water transfer tubes. Remove and

discard the o-rings.
WARNING
If the engine is equipped with an air compressor,
disconnect the air compressor water outlet tube from the
Remove the four front mounting capscrews (12), the 10
top mounting capscrews (13), and the thermostat housing
support.
LTA
Remove the vent hoses from the thermostat housing.

housing.
Remove the upper low temperature aftercooling radiator
hoses from the thermostat housing.
Remove the turbocharger return lines (1) from the
thermostat housing.
Remove the three capscrews, gasket (3), and bypass tube
(2) from the thermostat housing.
Right Bank
• Remove the capscrews (2)
• Remove the P-clips (1).
The mounting hardware attaches the upper and lower
tubes to the brackets on number 5 rocker housing.

• Capscrew (1)
• P-clips (2)
• Spacer (3)
• Washer (4)
• Nut (5).
The above listed mounting hardware attaches the upper
and lower water tubes to the support bracket mounted on
rocker housing number 2.

• Capscrew (1)
• P-clip (2)
• Washer (3)
• Nut (4).
The above listed mounting hardware attaches the lower
water tube to the bracket mounted on the thermostat
housing support.
Remove the lower and upper water transfer tube from the
rubber tee.
NOTE: The circled area of the graphic is for location

purposes only.
Remove the upper water transfer tube from the thermostat
housing.
Remove the lower tube from the junction block.

Left Bank
water transfer tubes to the brackets on rocker housing
number 5.

water transfer tubes to the bracket mounted on rocker
housing number 2.

purposes only.
Remove the upper water transfer tube from the thermostat
housing.
Remove and discard the o-ring.
Remove the upper and lower water tubes from the rubber
tee.
Remove the lower tube from the junction block.
Remove the six capscrews, two gaskets, and two tubes

from the thermostat housing to the low temperature
aftercooling water pump.
Remove the four capscrews (4) and the two retainer clips
(5).
Remove the aftercooler coolant return tube (6), aftercooler
coolant supply tube (7), o-rings (8), and hoses (9) from the
Remove the two water transfer tubes.

Remove and discard the four o-rings.
WARNING
If the engine is equipped with an air compressor,
disconnect the air compressor water outlet tube from the
Remove the four front mounting capscrews (12), the 10
top mounting capscrews (13), and the thermostat housing
support.
Install
Aftercooled Engines
CAUTION
The thermostat housing mounting gaskets used on
aftercooled engines and low temperature aftercooled
engines are different. Use of the incorrect gasket on
aftercooled engines will restrict coolant flow and
cause high intake manifold temperatures.
On aftercooled engines the main water pump supplies
both the aftercooling and water jacket circuits.
The thermostat housing gasket on aftercooled engines,
illustrated in the graphic, is identified with 2 open ports (1).
NOTE: Thermostat housing mounting gaskets used on
low temperature aftercooled engines have only open port.
Install the thermostat housing mounting gasket between
the cylinder block and the thermostat housing.
WARNING
Position thermostat housing support on engine.
Install the four capscrews (12) from the front and 10
capscrews (13) from the top.
If the engine is equipped with an air compressor, connect
the air compressor water outlet tube to the thermostat
housing support.
Tighten the top capscrews in the pattern shown.

Tighten the front capscrews in the pattern shown.

Torque Value: Step1 195 N•m [ 144 ft-lb ]
Step2 550 N•m [ 406 ft-lb ]
The front alignment plate is only used on engines without
fan drives.
Use vegetable oil to lubricate the o-rings.

Install the two o-rings on the two water transfer tubes.
Install the two water transfer tubes into the thermostat
housing.
Use vegetable oil to lubricate the four o-rings (8).

Install four new o-rings (8) on the aftercooler coolant
supply tubes (7) and the aftercooler coolant return tubes
(6).
Install the two aftercooler coolant supply tubes (7) and the
two aftercooler coolant return tubes (6) in the thermostat
housing support. Install the retainer clip (5) and capscrews
(4). Tighten the capscrews.
Install the bypass tube (2) and gasket (3) with three
capscrews.
Install the upper radiator hoses onto the thermostat

housing.
Tighten the hose clamps.
Install the vent lines onto the thermostat housing.

Install the turbocharger coolant return line (1) onto the
thermostat housing.
LTA
CAUTION
The thermostat housing mounting gaskets used on
aftercooled engines and low temperature aftercooled
engines are different. Use of the incorrect gasket on
low temperature aftercooled engines will cause
excessive pressure in the low temperature
aftercooled system resulting in coolant loss from an
low temperature aftercooled system surge tank
overflow.
On low temperature engines, the low temperature
aftercooling circuit has a separate water pump mounted
on the front cover of the engine.
The thermostat housing mounting gasket used on low
temperature aftercooled systems, illustrated in the
graphic, is identified with only open port (2).
NOTE: The thermostat housing mounting gasket used on
aftercooled engines has two open ports.
Install the thermostat housing mounting gasket between
the cylinder block and thermostat housing
WARNING
Position thermostat housing support on the engine.
Install the four capscrews (12) from the front and 10
capscrews (13) from the top.
If the engine is equipped with an air compressor, connect
the air compressor water outlet tube to the thermostat
housing support.
Tighten the top capscrews in the pattern shown.

Tighten the front capscrews in the pattern shown.

Step2 550 N•m [ 406 ft-lb ]
NOTE: Front alignment plate is only used on engines
without fan drives.
Use vegetable oil to lubricate the o-rings.

Install the o-rings on the two water transfer tubes.
Install the two water transfer tubes on the thermostat
housing.
Use vegetable oil to lubricate the four o-rings (8).

Install two new o-rings (8) on the aftercooler coolant supply
tubes (7) and the aftercooler coolant return tubes (6).
Install the vent lines (9).
Install the two aftercooler coolant supply tubes (7) and the
two aftercooler coolant return tubes (6) in the thermostat
housing support. Install the retainer clip (5) and capscrews
(4). Tighten the capscrews.
Install the two low temperature aftercooling coolant pump

tubes, with six capscrews, into thermostat housing.
CAUTION
Do not use petroleum based oil. Use of petroleum
based oil will cause the o-ring to swell.
Right Bank
• Lubricate the o-ring with vegetable oil.
• Install the o-ring onto the lower water tube.
• Fit lower water tube into junction block.
CAUTION
purposes only.
• Install the o-ring onto the tube.
• Fit the upper tube into the thermostat housing.
Fit the upper and lower water tubes into the rubber tee.
Do not fully tighten the p-clip capscrews until the tube is

assembled onto all brackets.
Secure upper and lower tubes on the number 5 rocker
housing using the following:
• P-clips (1)
• Capscrews (2).
Do not fully tighten the p-clip capscrews until the tube is

assembled onto all brackets.
Secure the upper and lower tube on the number 2 rocker
housing using the following:
• Capscrews (1)
• P-clips (2)
• Spacer (3)
• Washers (4).
Secure the lower water pipe to the bracket on the

thermostat housing using the following:
• Capscrews (1)
• P-clip (2)
• Washers (3)
• Nuts (4).
CAUTION
Left Bank
• Fit the lower tube into the junction block.
CAUTION
purposes only.
• Fit the upper tube into the thermostat housing.
Fit the upper and lower water tubes into the rubber tee.
Secure both the upper and lower tubes to the brackets on

the number 5 rocker housing using the following:
• P-clips (1)
• Capscrews (2).
Secure the upper and lower tubes to the brackets on the

number 2 rocker housing using the following:
• P-clips (1)
• Capscrews (2).
Install the bypass tube (2) and gasket (3) with three
capscrews onto thermostat housing. Tighten the
capscrews.
Install the upper radiator hoses on the thermostat housing.
Install the turbocharger coolant return line (1) on the
thermostat housing.
Finishing Steps
Aftercooled Engines
Connect the coolant temperature sensor wire.
Connect the coolant pressure sensor wire.

If the fan hub was removed, install fan hub. Refer to

Procedure 008-036.
Fill the cooling system. Refer to Procedure 008-018.

Operate the engine to 70°C [158°F] coolant temperature
LTA
Connect the coolant temperature sensor wire.
Connect the coolant pressure sensor wire.

Install the front intercooler. Refer to Procedure 010-083.
If the fan hub was removed, install the fan hub. Refer to
Procedure 008-036.

Operate the engine to 70°C [158°F] coolant temperature

• Connect the coolant temperature sensor wire.
• Connect the coolant pressure sensor wire.
• Install the sea water heat exchanger. Refer to
Procedure 008-053.
• Install the sea water expansion tank. Refer to
Procedure 008-052.
• If the fan hub was removed, install the fan hub. Refer
• Operate the engine to 70°C [158°F] coolant
temperature and check for leaks.
Coolant Thermostat Seal QSK45 and QSK60
Coolant Thermostat Seal (008-016)

Remove
NOTE: The procedures used to replace the thermostat
seal in the jacket water aftercooling system and the low-
temperature aftercooling system are similar.
Remove the thermostats (9) from the thermostat housing.
CAUTION
Use care when removing the seal. The thermostat
housing can be damaged during removal.
The thermostat housing has a machined counterbore to
locate the seals.
The two center thermostats are for LTA cooling and the
other four thermostats control engine cooling.
Use a Snap-On® pry bar, Part Number 1650, or equivalent,
to remove the thermostat seals. Position the pry bar tip
under the top flange of the seal and pry upward. Remove
the seals from the housing.
Install
The seal must be installed with the part number
positioned upward (facing seal driver).
Use a mallet and a mandrel, or a socket with a diameter
the same as the seal case.
Install the seals.
Be sure the seals seat in the bottom of the counterbore.
Install the thermostats (9) in the thermostat housing. Refer

QSK45 and QSK60 Coolant Vent Lines
Coolant Vent Lines (008-017)

General Information
Aftercooled Engines
The cooling system must be designed to allow the air to
escape while filling the radiator.
The aftercooler vent line (number 4 hose) is routed from

the top of the aftercooler to the top of the thermostat
housing.
The number 6 hose engine vent line (7) is routed from the
top of the thermostat housing to the radiator top tank
expansion space above the water level.
CAUTION
Do not route the fill or vent line in a manner that will
allow air to be trapped in the system. Air trapped in
the system can cause water pump cavitation and
inadequate coolant level.
Route the vent line away from the makeup or fill line.
The vent line must have a continuous rise to prevent air
lock and inadequate venting.
Coolant Vent Lines QSK45 and QSK60
LTA
The engine vent line and the aftercooler vent line are
routed from the top of the thermostat housing to the
radiator top tank expansion space above the water level.
CAUTION
the coolant system can cause water pump cavitation
and inadequate coolant level.

QSK45 and QSK60 Cooling System
The engine vent line and the aftercooler vent line are
routed from the top of the thermostat housing to the
radiator top tank expansion space above the water level.
CAUTION
the coolant system can cause water pump cavitation
and inadequate coolant level.
Route the exhaust manifold heat shield vent line away
from the makeup or fill line.
The exhaust manifold heat shield vent line must have a
continuous rise to prevent air lock and inadequate
venting.
Cooling System (008-018)

Drain
WARNING
The QSK45 and QSK60 industrial engines use a two-
pump/two-loop cooling system. The primary radiator
provides cooling for the engine using the water pump
mounted on the right-bank side of the engine. An LTA
water pump is mounted on the left-bank side of the engine
on the front gear cover. The LTA water pump circulates
coolant through the two-pass core of the LTA radiator and
back through the aftercoolers. The two center thermostats
control temperature as the coolant passes through the
thermostat housing.
Remove the radiator cap after the engine is cool.
Open the petcocks on each turbocharger.
Cooling System QSK45 and QSK60
Aftercooled Engines
WARNING
This cooling system uses the same radiator to cool the
aftercoolers as is used to cool the engine. Refer to
Procedure 200-003.
Open the draincock at the bottom of the radiator.
Remove the lower radiator hose.
Drain the cooling system.
Do not allow the cooling system to dry out.
LTA
WARNING
This system cools the aftercoolers using a radiator
separate from that used to cool the engine. Refer to
Procedure 200-003.
Drain the coolant.
The low-temperature aftercooling (LTA) cooling system is
drained by opening the draincock in the LTA radiator or
disconnecting the piping.
Do not allow the cooling system to dry out.
Flush
WARNING
The performance of Restore™ depends on time,

temperature, and concentration levels. An extremely
scaled or flow-restricted system, for example, can require
higher concentrations of cleaners, higher temperatures,
or longer cleaning time. Restore™ can be safely used up
to twice the recommended concentration levels.
Extremely scaled or fouled systems can require more than
one cleaning.
Do not remove the coolant filters.
CAUTION
Fleetguard® Restore™ contains no antifreeze. Do not
allow the cooling system to freeze during the cleaning
operation.
Close all petcocks to avoid air entrapment in the cooling
system.
Immediately add 3.8 liters [1 gal] of Fleetguard® Restore™,
or equivalent, for each 38 to 57 liters [10 to 15 gal] of
cooling system capacity, and fill the system with plain
water.
Turn the heater temperature switch to HIGH to allow
maximum coolant flow through the heater core. The
blower does not have to be on.
Operate the engine at a coolant temperature of at least

85°C [185°F] for 1 to 1-½ hours.
Fill the cooling system with clean water.
Operate the engine at high idle for 5 minutes with the

coolant temperature above 85°C [185°F].
If the water drained is still dirty, the system must be
flushed again until the water is clean.
Install a new coolant filter.

Fill the cooling system with fully formulated coolant.
Use additional SCA to bring the coolant to the correct SCA
concentration level. Refer to Procedure 018-018.
Install the pressure cap. Operate the engine until the

coolant reaches a temperature of 70°C [158°F] and check
for coolant leaks.
Minimum Cooling System Pressure Cap Capacity 76
kPa [ 11 psi ]
Pressure Test
Internal
Check the oil cooler covers for coolant leakage. Remove
the cooler covers, and perform an inspection and pressure
test as required. Refer to Procedure 007-045.
WARNING
If the oil cooler cores are not leaking, drain the oil. Refer
to Procedure 007-037. Check for coolant in the oil.
If the oil does not contain coolant, check the aftercooler.
WARNING
Remove the oil pan. Refer to Procedure 007-025.
WARNING
Remove the oil pan adapter. Refer to 007-027.
Remove the oil suction and transfer tubes. Refer to

Procedures 007-035 and 007-040.
WARNING
Remove the oil pump Refer to Procedure 007-031.
Remove the lubricating oil filters. Refer to Procedure

007-013.
Discard the filters if they are not required for failure
analysis.
Check for leakage on the inside and outside of the cylinder

liner.
If coolant is leaking on the inside of the cylinder liner,
remove the cylinder head and pressure test the cooling
system before removing the cylinder liner.
Remove all cylinder liners that are leaking externally.
If the cylinder liners are not leaking, check the aftercooler
element.
Disconnect the aftercooler coolant lines. Plug one

connector, and apply air pressure to the other connector.
If the air pressure decreases, replace the aftercooler
element Refer to 010-008.
If the aftercooler element is not leaking, check the

intercooler elements.
Disconnect the intercooler coolant connectors. Plug one

connector and apply air pressure to the other connector.
If the air pressure decreases, replace the intercooler
element. Refer to Procedure 010-084.
If the intercooler element is not leaking, check the cylinder

heads.
Inspect the cylinder heads. Refer to Procedure 002-004.
Check the cylinder head intake ports for coolant.

If coolant is found in the intake ports, remove the cylinder
head and test for defects. Replace if defective. Refer to
Procedure 002-004.
Remove the test equipment from the aftercooler. Connect

coolant lines.
Remove the test equipment from the intercooler. Remove

the plug from the outlet tube.
Replace the pressure cap.
WARNING
Install the lubricating oil pump. Refer to Procedure
007-031.
Install the oil transfer and suction tubes. Refer to

Procedures 007-035 and 007-040.
WARNING
Install the oil pan adapter. Refer to Procedure 007-027.
Install the oil pan. Refer Procedure 007-025. Install the oil
pan adapter cover plate. Refer to 007-026.

Install the new lubricating oil filters. Refer to Procedure

007-013.
Fill the engine with clean engine oil to the correct level.
Refer to Procedure 007-037 for the oil capacity of the
engine.
External
To confirm and locate external coolant leaks, it is not
necessary to warm the engine.
WARNING
Check the coolant level and fill if necessary.
Add heavy-duty coolant. Refer to Procedure 018-018 for
specifications.
To confirm and locate external coolant leaks that occur
during normal engine operation, complete this test while
the engine is warm.
CAUTION
Do not apply more than 140 kPa [20 psi] of air
pressure to the cooling system. Excessive air
pressure can damage the water pump seal.
If the radiator is equipped with a pressure relief valve,
install a plug in the overflow tube (1).
Install the pressure tester on the radiator fill neck or surge
tank (if equipped).
Apply maximum air pressure.
Maximum Air Pressure: 140 kPa [ 20 psi ]
Maintain the air pressure for a minimum of 5 minutes.

Check for leaks. Any leaks must be repaired.
Remove the pressure test equipment and the plug from
the pressure relief valve overflow tube (if equipped).
Install the coolant system pressure cap.

Install the lower radiator hose(s).
Fill
Make sure the radiator draincocks are closed.
Open the cooling system venting petcocks.
Use fully formulated coolant to fill the cooling system.

Use the correct units of SCA to obtain the correct cooling
system protection. Refer to Procedure 018-018.
CAUTION
Fill the cooling system slowly to avoid trapping air in
the cooling system. Air trapped in the system can
cause water pump cavitation and inadequate coolant
level.
Begin filling the cooling system with coolant.
Fill until a continuous stream of coolant begins to flow from
each opened petcock in the coolant system.
Close each petcock as the continuous stream of coolant
begins to flow from that petcock.
Fill the system with the coolant to the bottom of the
radiator fill neck.
Install the cooling system pressure cap.

Operate the engine until the coolant reaches a
temperature of 85°C [185°F]. Check for leaks.
WARNING
Shut the engine off, and allow it to cool.
Check the coolant level.
QSK45 and QSK60 Cooling System - Air or Combustion Gas Test
Cooling System - Air or Combustion

Gas Test (008-019)
Test
Overflow Method
WARNING
Remove the cooling system pressure cap.
Install a radiator pressure cap that has had the spring and
pressure relief valve removed.
The pressure cap must make a tight seal.
Attach a rubber hose to the radiator overflow connection.
Put the free end of the hose in a container of water.
Operate the engine at rated rpm until it reaches a

temperature of 85°C [185°F] with the thermostat open.
Check for a continuous flow of air bubbles from the hose
in the water container.
A continuous flow of bubbles can be the result of:
• Air compressor cylinder head leak
• Cylinder head combustion gas leak
• Incorrect cylinder protrusion
• Cracked or broken cylinder liners.
If air is not in the system, perform the following:

• Remove the test equipment.
• Check the coolant level and fill if necessary.
• Install the correct radiator pressure cap.
• Operate the engine to a temperature of 80°C [180°
F].
• Check for coolant leaks.
Cooling System - Air or Combustion Gas Test QSK45 and QSK60
Sight Glass Method

Install a clear Pyrex® tube in the water connection
between the engine radiator and the thermostat housing.
If desired, the Pyrex® tube can be installed in the vent line
between the thermostat housing and the radiator.
WARNING
Use wire lace to cover the tube and hose. Personal
injury can result if the Pyrex® tube separates from the
hoses.
Cover the tube and hose with a wire lace.
Operate the engine at 75 percent of rated rpm until it

reaches an operating temperature of 85°C [185°F].
Check for a continuous flow of air bubbles in the hose.
A continuous flow of air bubbles indicates excessive air in

the system. Continue to operate the engine for 25 minutes.
If the flow of bubbles does not stop, check for the
following:
• Air compressor cylinder head leak
• Cylinder head combustion gas leak
• Incorrect cylinder protrusion
• Cracked or broken cylinder liners.
QSK45 and QSK60 Cooling System - Air or Combustion Gas Test
If no air is found in the system or if the flow of bubbles

stops within 25 minutes, perform the following:
Check the coolant level and fill if necessary.
Install the correct radiator pressure cap.
Operate the engine until it reaches a temperature of 85°
C [185°F], and check for coolant leaks.
Air Compressor
CAUTION
The air compressor discharge must be disconnected
at the compressor. This will allow the compressor to
discharge air to the atmosphere to prevent the
compressor from overheating during this test.
CAUTION
Do not operate the engine over 5 minutes with the
components isolated from the cooling system.
Component damage can result.
Disconnect the air compressor discharge line.
Disconnect and plug the coolant supply and coolant drain

lines, from the air compressor.
Repeat the sight glass method or overflow method test.
If air is not found in the cooling system with the air
compressor isolated, replace the air compressor cylinder
head gasket. Refer to the Holset Master Repair Manual,
Bulletin 3666121.
Cylinder Head and Cylinder Liner

A cracked or defective cylinder head will pressurize the
cooling system and force the coolant out the overflow
tube.
Check the cylinder head gasket. Refer to Procedure
002-004.
Cooling System - Air or Combustion Gas Test QSK45 and QSK60
A cracked or porous cylinder liner will pressurize the

cooling system and force coolant out the overflow tube.
To determine the cylinder liner that is leaking, perform the

following:
• Remove the water pump. Refer to Procedure
008-062.
• Remove the collar.
• Install the water pump without the collar (20).
WARNING
WARNING
Drain the coolant down to where coolant is level with the
water manifold tubes.
Slide the water manifold tubes into the rocker lever
housing.
Operate the engine at low idle for a maximum of 4

minutes. Check inside the water passage of each rocker
lever housing for air bubbles. Air bubbles in the coolant
indicate a porous or cracked cylinder liner.
A defective cylinder liner must be replaced. Refer to
Procedure 001-028.
QSK45 and QSK60 Cooling System Diagnostics
If bubbles are not detected, install the water tubes and

water pump collar.
Cooling System Diagnostics (008-020)

Pressure Test
Use a pressure gauge with a minimum capacity of 275 kPa
[40 psi]. Measure the coolant pressure at the thermostat
housing.
Operate the engine until the coolant temperature reaches
85°C [185°F].
The thermostats must be open.
Operate the engine at rated rpm. Compare the pressure

readings to the following specifications.
Coolant Pressure-at-Water Manifold

kPa psi
1800 rpm 75 MIN 11
1900 rpm 82 MIN 12
2100 rpm 89 MIN 13
Coolant Pressure Cap Removed:

kPa psi
241 MAX 35
Cooling System Diagnostics QSK45 and QSK60
If the above measurement location is not accessible,

install the gauge in the engine block in place of the
draincock.
Coolant Pressure - At the Oil Cooler Housing

kPa psi
1800 rpm 103 MIN 15
1900 rpm 117 MIN 17
2100 rpm 131 MIN 19
Coolant Pressure Cap Removed:

kPa psi
241 MAX 35
If the coolant pressure is high, make sure the thermostats

are operating correctly. Refer to Procedure 008-013.
If the thermostats are OK, inspect the radiator for
restriction. Refer to Procedure 008-042.
If the cooling system pressure is low, install a gauge (with

a maximum capacity of 69 kPa [10 psi]) at the water pump
inlet.
Operate the engine at rated rpm. If the gauge reads more

than 35 kPa [5 psi], check the radiator for restriction. Refer
QSK45 and QSK60 Cooling System Service Requirements
Cooling System Service Requirements

(008-022)
General Information
Water
Always use good-quality soft water in the coolant mixture.
Water added to the cooling system must meet the
specifications given in the accompanying chart.
Mineral Problem Caused Maximum

Limits
Calclum Deposits on Liners/ 170 ppm
Magnesium Heads/Coolers
(hardness)
Chloride General Corrosion 40 ppm
Sulfate General Corrosion 100 ppm
CAUTION
Antifreeze over concentration reduces protection. Do
not use more than 68-percent antifreeze or
overheating can result. A mixture of 50-percent
antifreeze and 50-percent water is sufficient for freeze
protection to -37°C [-35°F]
CAUTION
Do not use a high-silicate antifreeze. A silicate-gel
(hydro-gel) formation can occur when a cooling
system contains an over concentration of high-silicate
antifreeze and/or supplemental coolant additives.
Engine damage will result.
Use ethylene-glycol or propylene-glycol antifreeze year-
round to provide freezing and boil-over protection.
• Buildup in coolant low-flow areas

• Clogged coolant filters
• Plugged radiator.
Fan Drive Idler Arm Assembly QSK45 and QSK60
Do not use soluble oils in the cooling system. The use of

soluble oil will:
• Allow cylinder liner pitting
• Corrode brass and copper
• Damage heat-transfer surfaces
• Damage seals and hoses.
Supplemental Coolant Additive (SCA)

Supplemental coolant additives, SCA, or equivalent, are
required to protect the cooling system from fouling, solder
blooming, liner pitting, and general corrosion. The coolant
filter is required to protect the cooling system from
abrasive material, debris, and precipitated coolant
additives.
Fan Drive Idler Arm Assembly

(008-029)
Preparatory Steps
WARNING
The fan belt idler is under tension. Do not allow hands
to get between the idler and the belt or the fan hub.
Personal injury can result.
• Remove the fan. Refer to Procedure 008-040.
• Remove the fan belt. Refer to Procedure 008-002.
Remove
Revised idler design
WARNING
Remove the four capscrews from the adjusting bracket.
Remove the fan idler assembly and adjusting bracket (as
an assembly).
QSK45 and QSK60 Fan Drive Idler Arm Assembly
Old idler design
WARNING
The belt tensioner and the pivot arm assembly will
rotate during removal. Personal injury can result. To
or get assistance to lift the component.
Loosen the belt control rod (1) to release the idler arm
assembly (2).
Remove the three capscrews (3) from the idler arm
assembly (2).
WARNING
Remove the two capscrews (4), retainer plug (5), washer
(6), and the control rod (7).
Remove six capscrews (8).
Remove capscrew (9), plain washer (10), and idler arm
assembly (2).
For engines that use a Rockford fan clutch, the actuator

bracket (1) has a solenoid bracket (2) attached by using
the actuator bracket mounting capscrews. Both the
solenoid bracket and actuator bracket are removed at the
same time.
Remove the actuator bracket capscrews.
Remove the actuator bracket (1) and the solenoid bracket
(2).
WARNING
Use the correct lifting equipment to remove idler pulley
support bracket.
Remove the lower nuts from the idler pulley support
bracket.
Remove the capscrews (1) from the idler pulley support
bracket.
Remove the idler pulley support bracket.
Remove the spacers (3) and studs (2).
Disassemble
Remove the capscrews.
Remove the pulley assembly from the pivot arm assembly.
Rotate the cap until the pins (1) align with the slots (2) in
the cap.
Remove the cap.
Using a vise, support the pivot arm assembly.

Remove the following parts:
Capscrew (3)
Plain washer (4)
Thrust bearing (5)
Pivot Arm (6)
Thrust bearing (7)
Spring (8).
Remove the following parts:

Bushing (9)
O-ring (10).
Discard the o-ring.
The pivot arm (6) contains an external wear sleeve to
prevent the spring from contacting the arm and can be
replaced if needed.
WARNING
WARNING
personal injury.
Clean the parts with solvent and dry with compressed air.
Check the shaft for wear. Make sure the shaft is tight in
the support.
If the shaft has grooves in the surface or is loose, the
support and the shaft must be replaced as an assembly.
Measure the shaft outside diameter.
Fan Drive Idler Arm Assembly Outside Diameter

mm in
38.087 MIN 1.500
38.113 MAX 1.501
Assemble
Install and position the bushings (9) evenly into the pivot
arm.
Lubricate the o-ring (10) with vegetable oil.
Install the o-ring onto the pivot arm.
Use a vise to support the pivot arm assembly.

Place the spring onto the support.
The end of the spring must be positioned on the spring
stop on the pivot arm assembly as shown in the
illustration.
Lubricate the thrust bearings (5) and (7) with grease.

Install the parts:
Thrust bearings (7)
Pivot arm (6)
Thrust bearing (5)
Plain washer (4)
Capscrew (3).
Align the pins (1) with the slots (2) in the cap.
Install and rotate the cap.
Lubricate the pivot arm assembly until grease is begins to

flow from under the cap.
Install the pulley assembly onto the pivot arm assembly.

Install
WARNING
Use the correct lifting equipment to install the idler pulley
support bracket.
Make sure the rubber gasket (4) remains in the correct
position during installation.
Install the studs (2) and spacers (3).
Install the Idler support bracket and gasket (4).
Install the 12 mm capscrews (1) into the idler pulley
support bracket and tighten.
Install locknuts onto studs (2) and tighten.
For engines that have a Rockford fan clutch a solenoid

bracket (2) is installed with the actuator bracket (1) using
the same mounting capscrews.
Install the actuator bracket capscrews, actuator bracket
(1) and solenoid bracket (2) on the front gear cover.
Position the idler arm assembly (2) with plate washer (10)
and capscrew (9).
Install six capscrews (8).
Fan Drive Idler Pulley Assembly QSK45 and QSK60
Install the idler arm assembly (7), washer (6), retainer plug
(5), and capscrews (2).
Install three capscrews (3) in the idler arm assembly (2).
Finishing Steps
• Install the fan belt. Refer to Procedure 008-002.
• Install the fan. Refer to Procedure 008-040.
• Adjust the belt tension. Refer to Procedure 008-002.
Fan Drive Idler Pulley Assembly

(008-030)
Disassemble
Turnbuckle Idler System
Remove the two capscrews (3) and retaining plate.
Remove the idler shaft (1), idler pulley (5), bearings (4),
washer (6), and spring (7).
Remove the key (2) from the idler shaft (1) when present
in the idler arm assembly, Part Number 4066540.

Shock Absorber System
WARNING
Use solvent to clean the pulley assembly.
QSK45 and QSK60 Fan Drive Idler Pulley Assembly
Check the end clearance of the fan drive idler pulley

assembly.
Fan Drive Idler Pulley Assembly End Clearance

mm in
0.08 MIN 0.003
0.25 MAX 0.010
Rotate the pulley and check for rough or damaged
bearings.
The bearings must be replaced if any of the above
conditions are found.
Check the shock absorber for cracks and fluid leakage.

Push the shock absorber up and down to check the
vibration absorption.
The shock absorber must be replaced if the above
conditions exist.

Check the shaft for wear. Make sure the shaft is tight in
the support.
If the shaft has grooves in the surface or is loose, the
support and the shaft must be replaced as an assembly.
Use idler shaft, Part Number 4001567 or 4066386, and
idler bearings, Part Number 4016800, when replacement
is necessary.
Shaft Outside Diameter

mm in
59.97 MIN 2.3610
59.98 MAX 2.3614
CAUTION
If disassembly is required after the Loctite has been
applied and the bearings are locked onto the idler
shaft, the assembly must be heated to 176.7°C [350°
F] to disassemble. The bearings must be replaced
after disassembly because this exceeds the
approximate rated bearing temperature of 121.1°C
[250°F].
Use Loctite primer, Primer T - Loctite 7471, Part Number
3824715, to clean the idler shaft and the inside race of the
bearings.
Fan Drive Idler Pulley Assembly QSK45 and QSK60
Assemble
Install both idler bearings into the idler pulley.
Apply grease in the cavity of the dust shields.

Assemble the dust shields with the greased cavity towards
the bearings.
The dust shields must align properly with the ball bearing
bores.
Install the bearing spacer and spring washer on top of the
dust shield.
The components must be properly aligned.
Apply Loctite to the inside of the bearing races and idler

shaft. Use either of the following bottle sizes of Loctite
products:
• Loctite Threadlocker 242 (Blue) 24221, Part Number
3824041.
• Loctite Threadlocker 242 (Blue) 24231, Part Number
3824040.
Install the pulley assembly into the idler lever with the
bearing spacer and spring washer facing the smaller bore
in the idler lever.
The dust shields, bearing spacer, and spring washer
must be properly aligned.
QSK45 and QSK60 Fan Hub Bracket
Assemble the idler lever, pulley assembly, and idler shaft.

NOTE: The idler shaft key is not needed.
Specific care must be taken when inserting the idler shaft
so the dust shield next to the bearing spacer remains
properly aligned.
Secure the idler shaft into the idler lever and install the
retaining plate and capscrews.
Fan Hub Bracket (008-035)

WARNING
WARNING
WARNING
personal injury.
Clean the fan hub bracket using solvent and steam.
Dry the fan hub bracket with compressed air.
Fan Hub, Belt Driven QSK45 and QSK60
Check the fan hub bracket support areas for cracking or

fretting.
Replace the fan hub bracket support if damaged.
If the fan hub bracket is replaced, make sure to install the
correct bracket. All fan hub brackets are not the same.
The center location and spacing from the center of the
block can be different.
Fan Hub, Belt Driven (008-036)

Preparatory Steps
Remove the fan. Refer to Procedure 008-040.
Remove the fan belt. Refer to Procedure 008-002.
Remove
Standard
WARNING
This assembly weighs 23 kg [50 lb.] or more. To avoid
personal injury, use a hoist or get assistance to lift
this assembly.
Remove the eight capscrews and the fan hub.
Rockford
Remove the wire tie that secures the number 12 drain
hose (1) to the number 8 supply hose.
Disconnect the drain hose from the port in the side of the
fan clutch.
Disconnect the drain hose from the large tee in the front
gear housing and remove the hose.
QSK45 and QSK60 Fan Hub, Belt Driven
Remove the wire tie that secures the number 4 solenoid-

to-clutch supply hose (1) to the number 8 fan hub supply
hose.
Disconnect the solenoid-to-clutch supply hose from the
top of the fan clutch.
Disconnect the solenoid-to-clutch supply hose from the
solenoid and remove the hose.
Remove the capscrew and P-clip located on the side of

the actuator.
Disconnect the solenoid drain hose from the sump port (1)
of the solenoid (2).
Disconnect the solenoid drain hose from the lower port of
the large tee (3) and remove the hose.
Remove the wire tie that secures the number 8 fan hub
supply hose.
Disconnect the fan clutch supply hose from the rear side
of the lower tee.
Disconnect the fan clutch supply hose from the top of the
fan clutch and remove the hose.
Remove the wire tie that secures the solenoid supply to

the fuel hose.
Remove the three capscrews and P-clips that secure the
solenoid supply hose to the front of the engine.
Disconnect the solenoid supply hose from the supply port

of the solenoid valve.
Disconnect the solenoid supply hose from the from the
lower tee and remove the hose.
Remove the tee located in the lower left bank port in the
front gear cover.
Remove the tee located in the top left bank of the front
gear cover.

Sump port male union (1)
Supply port 90 degree elbow (2)
Control port 90 degree elbow (3)
Solenoid.
WARNING
This assembly weighs 23 kg [50 lb.] or more. To avoid
personal injury, use a hoist or get assistance to lift
this assembly.
For fan clutches equipped with speed sensors, remove the
speed sensor from the center of the fan clutch hub.
Remove the capscrews and the fan hub.
Inspect for Reuse

Standard
Check the seal for leaks.
Check the shaft (1) for damage. Check the fan hub exterior
(2) for damage.
If the shaft or fan hub is damaged, the fan hub must be
rebuilt.
Check the fan hub end clearance.
Bearing End Clearance

mm in
0.03 MIN 0.001
0.25 MAX 0.010
If the clearance is not within the specifications, the fan
hub must be rebuilt.
Rotate the fan hub to check for rough or damaged
bearings.
If the fan hub does not rotate freely, the fan hub must be
rebuilt.
If applicable, remove the pipe plugs (3). Install a grease

fitting in one of the holes.
Use a grease gun and water pump type grease. Pump
grease into the hub until it begins to come out of the open
plug hole.
Remove the grease fitting. Install the pipe plugs (3).
Install
Standard
WARNING
This assembly weighs more than 23 kg [50 lb]. To
lift this assembly.
Install the fan hub, the eight washers, and the capscrews.
Tighten the fan hub capscrews.
Rockford
WARNING
lift this assembly.
Install the fan hub and capscrews.
For fan clutches equipped with speed sensors, install the
speed sensor and tighten.
Install the solenoid onto the solenoid bracket with

capscrews and tighten the capscrews.
Install the o-rings onto the three male connections and
lubricate with clean engine oil.
Install the following and tighten:
Straight male union into sump port (1).
Elbow into supply port (2)
Elbow into control port (3).
Install the o-ring onto the tee and lubricate with clean
engine oil.
Install the tee into the top left bank of gear cover and
tighten the tee.
The final position of the center hose port is facing down.
Install the o-ring onto the tee and lubricate with clean
engine oil.
Install the tee into the lower left bank port in the front gear
cover and tighten the tee.
The final position of tee is with the number 4 hose
connection facing forward and the number 8 hose
connection facing to the rear.
Connect the number 4 solenoid supply hose to the supply

port of the solenoid valve.
Route the supply hose to the lower tee in the front gear
cover and connect it to the tee.
Tighten the hose nuts.
Attach the hose with two P-clips to the lower front gear
cover capscrews located behind the accessory drive
pulley.
Install a third P-clip under the front trunnion remote grease
nipple bracket.
Secure the solenoid supply hose to the fuel hose using
wire ties.
Tighten the P-clip capscrews.
The lower hose elbow faces slightly outboard, and the top
elbow faces slightly to the rear to allow the number 4 hose
elbow to clear the number 8 supply hose.
Connect the number 8 fan hub supply hose to the top port
of the fan clutch.
Route the hose to the lower tee on the front gear cover
and connect the hose.
For engines equipped with an air compressor, secure the

number 8 fan hub supply hose to the water tube with a
wire tie.
For engines that are not equipped with an air compressor,
secure the fan hub supply hose at a higher location with
a wire tie.
Secure the hose with a P-clip installed to the front lower
air intake manifold capscrew.
Connect the number 4 solenoid drain hose to the straight

male connector in the sump port (1) of the solenoid (2).
Route the drain hose to the lower port in the upper front
gear cover tee (3) and connect the hose.
Secure the hose with a P-clip connected to the actuator
bracket.
Connect the number 4 solenoid-to-clutch drain hose to the

control port (1) in the solenoid.
Route the hose to the top of the fan clutch and connect
the hose.
Secure the hose to the number 8 fan supply hose with a
wire tie.
Connect the number 12 drain hose (1) to the connector in

the side of the fan clutch.
Route the hose to the upper tee in the front gear cover and
connect the hose.
Secure the hose to the fan hub supply hose with wire ties.
QSK45 and QSK60 Fan, Cooling
Secure the three hoses connected to the fan clutch to

together to provide a neat routing.
Make sure all the hoses are routed so they are clear of any
rotating parts.
Finishing Steps
Install the fan belt. Refer to Procedure 008-002.
Install the fan. Refer to 008-040.
Fan Shroud Assembly (008-038)

Inspect for Reuse
Inspect the fan shroud for the correct fan clearance. Refer
to the vehicle manufacturer's specifications and the
appropriate installation recommendations bulletin.
Inspect the fan shroud for cracks, air leaks, or other
damage. Replace the part if damaged. Refer to the
manufacturer's instructions.
Fan, Cooling (008-040)

Preparatory Steps
WARNING
cable last.
Disconnect the batteries or air supply line to the air starter
to prevent accidental starting.
Fan, Cooling QSK45 and QSK60
Remove
CAUTION
Do not pry or pull on the cooling fan. The cooling fan
blades can be damaged.
WARNING
Remove the cooling fan capscrews.
Remove the cooling fan and cooling fan spacer.
Inspect for Reuse

Check the cooling fan for cracks, loose rivets, and bent or
loose blades.
WARNING
Do not straighten a bent cooling fan blade or continue
to use a damaged cooling fan. A bent or damaged
cooling fan blade can fail during operation and cause
personal injury or property damage.
If damage is found, replace the cooling fan.
QSK45 and QSK60 Fan, Cooling
Install
Replace the original equipment cooling fan with a cooling
fan of the identical part number. Cummins Inc. must
approve any cooling fan changes.
WARNING
Install the cooling fan, applicable spacer, and capscrews.
Tighten the cooling fan capscrews. Refer to the OEM
service manual for correct capscrew torque.
Rotation Check
Use an optical tachometer, Part Number 3377462, or a
strobe light to measure the cooling fan rpm.
When using Cummins optical tachometer, use a piece of

reflective tape, Part Number 3377464, for marking
purposes.
Mark a spot on the cooling fan so the fan rpm can be
measured.
Mark a spot on the vibration damper or accessory drive
pulley to measure engine rpm.
Fan, Cooling QSK45 and QSK60
Measure the diameter of the cooling fan belt pulley to

determine the drive ratio.
Fan Pulley Diameter Ratio
513 mm [20.20 in] 0.42
450 mm [17.72 in] 0.42
431 mm [0.50 in] 0.50
Operate the engine.

Compare the cooling fan rpm to the engine rpm.
Compare the cooling fan rpm to the specification.
If the cooling fan rpm is not correct, check the belt tension.
Finishing Steps
WARNING
cable last.
Connect the batteries or air starter supply line.
QSK45 and QSK60 Marine Gear Oil Cooler
Marine Gear Oil Cooler (008-041)

Preparatory Steps
WARNING
cable last.
WARNING
WARNING
WARNING
Disconnect the batteries or air supply line to the air starter
to prevent accidental engine starting.
Drain the coolant. Refer to Procedure 008-018.
Drain the oil from the marine gear oil cooler. Refer to the
marine gear manufacturers instructions for draining the
oil.
Remove
Disconnect marine gear oil lines from the marine gear oil
cooler.
Remove the oil line connectors from the marine gear oil
cooler.
Marine Gear Oil Cooler QSK45 and QSK60
Disconnect the coolant lines from the rear of the marine

gear oil cooler.
Remove the coolant line connectors from the marine gear
oil cooler.
Remove the six capscrews, three front brackets and

spacers that hold the marine gear oil cooler to the rear
bracket.
Remove the marine gear oil cooler.
Inspect for Reuse

Inspect the marine gear oil cooler plates and shell for
damage. If the plates or shell is damaged the marine gear
oil cooler must be replaced.
Inspect the marine gear oil cooler coolant and oil ports for
thread damage. If the threads are damaged beyond repair
the marine gear oil cooler must be replaced.
Pressure Test
Install the coolant and oil connectors into the marine gear
oil cooler.
Place a Joint Industry Counsel 20 (15/8-12) threaded cap
onto one of the oil connectors of the marine gear oil cooler.
Place a Joint Industry Counsel 20 (15/8-12) threaded cap
with an air fitting onto the remaining oil connector of the
marine gear oil connector.
QSK45 and QSK60 Marine Gear Oil Cooler
Install a pressure regulator onto the cap and air fitting.

Connect shop air to the pressure regulator.
Adjust the pressure regulator to 170 kPa [25 psi].
CAUTION
To reduce the possibility of damage to the marine
gear oil cooler, the water in the test tank must be
treated with a noncorrosive additive.
Submerge the marine gear oil cooler in a tank of treated
water for 10 minutes.
If air bubbles escape from the fuel side of the marine gear
oil cooler in the last two minutes of the test, the marine
gear oil cooler must be replaced.
Remove the marine gear oil cooler from the tank of treated
water.
WARNING
personal injury.
Remove the pressure regulator from the air fitting.
Remove the caps from the fuel connectors of the marine
gear oil cooler.
Drain the treated water out of the marine gear oil cooler.
Use compressed air to dry the coolant side of the marine
gear oil cooler.
Install
Place the marine gear oil cooler onto the rear bracket and
install the front brackets, spacers and capscrews.
Radiator QSK45 and QSK60
Connect the coolant and gear oil lines to the marine gear
oil cooler connectors.
Tighten the coolant and gear oil lines.
Finishing Steps
WARNING
cable last.
Connect the batteries or air starter air supply line.
Add gear oil to the marine gear. Refer to the
Radiator (008-042)
Test
To check for a radiator obstruction perform the following
steps.
Use a pressure gauge designed to measure 0 to 100 kPa
[0 to 15 psi]. Install a valve on each side of the gauge.
Install one line into the water pump inlet connection and
the other into the thermostat return line on top of the
radiator core.
Bleed the air from the gauge lines.
QSK45 and QSK60 Radiator
Restrict the radiator airflow. Operate the engine until the

coolant temperature reaches 88 to 90°C [190 to 195°F].
Operate the engine at rated rpm.

Close valve (1), and open valve (2).
Record the pressure at the top of the radiator.
Close valve (2) and open valve (1).

Record the pressure at the water pump inlet.
Compare the two pressure readings. If they differ by more
than 35 kPa [5 psi], the radiator core or piping is
obstructed.
To perform a reverse flow test perform the following steps.

This test must be performed with the cooling system
completely full and the coolant at ambient temperature.
Operate the engine at medium to high idle. Since the
thermostats are closed, coolant flow is through the bypass
line (1) and the engine (2).
Radiator QSK45 and QSK60
As the engine is warming up, use a contact pyrometer to

check the temperature of the radiator top and bottom
tanks.
If the bottom tank begins to warm and the top tank remains
cold, the radiator has reverse flow. Refer to the
manufacturer's instructions for repair procedures.
Check the piping to be sure it is the correct size and routed
according to specifications. Refer to the appropriate
installation recommendation bulletin.
Finishing Steps
WARNING
personal injury.
Check for plugged radiator fins.
Use compressed air to blow out the dirt and debris.
Blow the compressed air opposite the direction of the fan
airflow.
Check for bent or broken fins. Check for radiator core and
gasket leaks.
If the radiator must be replaced, refer to the OEM's
replacement procedures.
QSK45 and QSK60 Radiator Hoses
Radiator Hoses (008-045)

Preparatory Steps
WARNING
WARNING
Remove
Aftercooled Engines
Disconnect the lower radiator hose from the water pump
inlet.
Disconnect the lower radiator hose from the radiator
bottom tank.

housing.
Remove the upper radiator hoses from the top tank of the
radiator.
Radiator Hoses QSK45 and QSK60
LTA
Disconnect the lower radiator hose from the water pump
inlet.
Disconnect the lower radiator hose from the radiator
bottom tank.
Remove the low temperature aftercooling hoses from the

thermostat housing.
Remove the low temperature aftercooling radiator hoses

from the top tank of the radiator.
Inspect for Reuse

CAUTION
Do not bend or deform the hoses during inspection.
This can cause the hoses to crack.
Check all hoses for cracks, cuts, or collapsing.
The silicone engine coolant hose will exhibit swelling due
to the elasticity of the hose.
QSK45 and QSK60 Radiator Hoses
Install
Aftercooled Engines
Install the upper radiator hoses to the thermostat housing.
Tighten the clamps.
Torque Value:
Worm Clamp 5 N•m [ 44 in-lb ]
T-Bolt Clamp 8 N•m [ 71 in-lb ]
Install the upper radiator hoses to the top tank of the

radiator. Tighten the clamps.
Torque Value:
Install the lower radiator hose to the radiator bottom tank.

Tighten the clamps.
Torque Value:
LTA
Install the upper low temperature aftercooling radiator
hoses to the thermostat housing. Tighten the clamps.
Torque Value:
Radiator Pressure Cap QSK45 and QSK60
Install the low temperature aftercooling radiator hoses to

the top tank of the radiator.
Tighten the clamps.
Torque Value:
Install the lower radiator hose to the water pump inlet.

Tighten the clamp.
Torque Value:
Install the lower radiator hose to the radiator bottom tank.
Tighten the clamps.
Torque Value:
Finishing Steps
Operate the engine to 70°C [160°F] coolant temperature.
Check for leaks.
Radiator Pressure Cap (008-047)

Inspect for Reuse
Inspect the rubber seal of the pressure cap for damage.
Inspect the radiator fill neck for cracks or other damage.
Refer to the radiator manufacturer's instructions if the fill
neck is damaged.
Make sure the correct radiator cap is being used. The
pressure rating must be 48 kPa [11 psi] or greater.
QSK45 and QSK60 Radiator Top Tank
Pressure Test
Pressure-test the radiator cap.
The pressure cap must seal within 14 kPa [2 psi] of the
value printed on the cap, or it must be replaced.
Radiator Top Tank (008-051)

Leak Test
Aftercooled Engines
WARNING
WARNING
Plug the radiator fill line outlet.

Fill the top tank within 25 mm [1 in] from the top with water.
If the level drops and leakage is observed from the
draincock and the lower radiator outlet, the baffle is
leaking. The radiator must be repaired or replaced.
Expansion Tank QSK45 and QSK60
Expansion Tank (008-052)

Preparatory Steps
WARNING
cable last.
WARNING
Wait until the coolant temperature is below 50° [120°
F] before removing the pressure cap. Heated coolant
WARNING
not reused, dispose in accordance with local
• Disconnect the batteries or air supply to the air
starter to prevent accidental starting.
008-018.
Remove
Disconnect the connector harness for the coolant level
switch.
Disconnect the jacket water make up line (1) from the

expansion tank.
Disconnect the LTA coolant make up line (2) from the
expansion tank.
QSK45 and QSK60 Expansion Tank
Disconnect all of the vent lines from the expansion tank.
WARNING
The expansion tank is mounted onto a support bracket
which is mounted onto the engine. The support bracket
has two capscrews on each side which attach from
underneath the tank.
Remove the four capscrews from the expansion tank
support bracket.
Remove the expansion tank from the support bracket.
Remove the rubber vibration isolators.
WARNING
Remove the 10 support bracket capscrews.
Remove the support bracket.

Clean the expansion tank by flushing it with warm water.
Inspect the expansion tank for cracks or dents.

If the expansion tank is damaged it must be replaced.
Inspect the rubber vibration isolators for cracks in the

rubber.
If the rubber vibration isolators are cracked they must be
replaced.
Install
WARNING
Place the support bracket on the engine and install the
capscrews.
A vibration isolator consists of two pieces.

Insert the T-piece into the support bracket hole for all four
isolators.
QSK45 and QSK60 Expansion Tank
WARNING
Place the expansion tank on top of the vibration isolators.
Align the expansion tank mounting holes with the vibration
isolators.
Place the second half of the vibration isolators onto the

capscrews.
Thread each of the four capscrews in finger tight.
Connect all of the vent lines.
Connect the jacket water make up line (1) to the expansion

tank.
Connect the LTA coolant make up line (2) to the expansion
tank.
Connect the coolant level switch to the harness.
Finishing Steps
WARNING
cable last.
• Connect the batteries or the air supply line to the air
starter.
QSK45 and QSK60 Heat Exchanger
Heat Exchanger (008-053)

Exploded View
Heat Exchanger QSK45 and QSK60

Exploded View
A. Pressure plate B. Frame plate.
Preparatory Steps
WARNING
cable last.
WARNING
WARNING
• Disconnect batteries or air supply to air starter to
prevent accidental engine starting.
008-018.
• Remove the expansion tank. Refer to Procedure
008-052.
Remove
Disconnect all plumbing for the front and rear of the heat
exchanger:
• Seawater tube
• Jacket water tube
• LTA tube.
Install a lifting eye into the heat exchanger front plate at

location (11).
Install a lifting eye into the heat exchanger rear plate at
location (12).
The nylon strap used to remove the heat exchanger

must have a capacity of 140 kg [300 lb].
Insert a nylon strap through the lifting eyes.
WARNING
Remove the capscrews from the heat exchanger bracket.
Remove the heat exchanger.
Disassemble
Remove the eight capscrews that hold the shroud to the
heat exchanger assembly.
The ends of the shroud will possibly have to be bent
outwards to clear it from the sides of the heat exchanger.
Remove the shroud from the heat exchanger.
Draw a diagonal line across the top of the plate pack with
a paint marker or a wide marker.
The diagonal line will aid in assembly.
Remove spacer capscrews (9) and (10).

Remove the inserts the spacer capscrews were routed
through.
Remove the service spacers from the front cover.
Thread the service spacers into the side alignment

spacers until they bottom out.
The plate pack clamping capscrews must be loosened in

sequence and in small increments to keep the front and
back covers within 12 mm [½ in] variance from parallel.
Loosen the plate pack clamping capscrews in sequence
and small increments until they can be removed from the
assembly.
Remove the plate clamping capscrews and front cover.
WARNING
The plates can have sharp edges. To reduce the
possibility of cuts, wear gloves when handling the
plates.
Keep the plates in the order they were removed in when
disassembling the plates. This will aid in the assembly of
the heat exchanger.
Remove the plates from the assembly.

CAUTION
Incorrect orientation of the gaskets can cause
overheating and sea water to enter the cooling
system.
Observe the orientation of the gasket for assembly
accuracy.
Remove each gasket from the plate one at a time.
Clean the plate with a soft brush and running water.

If deposits are present that are difficult to remove, spray

the plate with a high pressure water hose.
If brushing and high pressure water does not properly
clean the plates, the deposits on the plates can be
evaluated.
Use the information in the following lists to determine what
solvents to use.
Incrustation
• Calcuim carbonate (corrosion products - clean with
nitric acid).
• Calicum sulphate (metal ozides - clean with sulfamic
acid).
• Silicates (silt - clean with citric acid, alumina - clean
with phosphric acid, diatomic organisms and their
excrement of various colors - clean with complexing
agents EDT, A, and NTA).
Biological Growth
• Slime - Clean with alkaline cleaning agents.
• Bacteria - clean with sodium hydroxide.
• Nematodes - Clean with sodium hydroxide.
• Protozoa - Cleaning effect can be considerably
increased by the addition of small quantities of
hypochlorite or agents for the formation of
complexes and surfactants.
Concentration maximum: Four Percent.
Temperature maximum: 60°C [140° F].
Solvents That Can Not be Used
• Ketones (acetone, methyletylketone,
methylisobutylketone)
• Esters (ethylacetate, butylacetate)
• Halogenated hydrocarbons (chloro-thene, carbon
tetrachloride, freons)
• Aromatics (benzene, toluene).
Inspect the gaskets for swelling, cracks, and deformation.

Replace the gaskets swollen, cracked or deformed.
Assemble
Insert the service spacers into the side alignment spacers.
WARNING
plates.
CAUTION
Incorrect orientation of the gaskets can cause over
heating and sea water to enter to the cooling system.
Place the gaskets back onto the plates one at a time.
Make sure the tabs are locked into the slots and orientated
correctly.
WARNING
plates.
Insert cleaned plates against the rear cover in the correct
order.
Refer to the exploded view for the plate installation order.
After the plates are assembled in the engine, make sure

the profile shows a honey comb pattern and the gasket
tabs alternate position.
If the pattern is not a honey comb pattern throughout the
entire plate pack, the plates must be rearranged.
Install the front plate making sure the aligning shroud

groove is on the same side (top) as the alignment groove
on the rear cover.
Install capscrews (1) through (8).

When tightening the capscrews, keep the front and back
covers within 12 mm [½ in] variance from parallel.
Tighten the capscrews in the sequence shown in the
graphic.
Once the cover is completely against the eight spacers,
tighten the capscrews in the sequence shown in the
graphic.
Remove the service spacers.

Install the inserts and the side alignment capscrews into
locations (9) and (10).
Install the service spacers into the locations shown in the

graphic.
The ends of the shroud will possibly need to be bent to fit

over the heat exchanger.
Install the shroud onto the heat exchanger.
Install the eight shroud capscrews.
Install
Install a lifting eye into the front plate at location (11).
Install a lifting eye into the rear plate at location (12).
The nylon strap used to install the heat exchanger must

have a capacity of 140 kg [300 lb].
Insert a nylon strap through the lifting eyes.
WARNING
Place the heat exchanger onto the bracket.
Insert the bracket capscrews that attach the bracket to the
heat exchanger.
Remove the nylon strap.
QSK45 and QSK60 Sea Water Pump
Connect all plumbing for the front and rear of the heat
exchanger:
• Seawater tube
• Jacket water tube
• LTA tube.
Tighten all capscrews.
Finishing Steps
WARNING
cable last.
• Install the expansion tank. Refer to Procedure
008-052.
• Connect the batteries or air starter supply line.
• Fill the cooling system. Refer to Procedure 008-018
Sea Water Pump (008-057)

Remove
Close the sea water inlet valve.
Disconnect the sea water inlet tube.

Disconnect the sea water outlet tube.
Remove the clamping devices that secure the sea water
inlet and outlet tubes to the mounting brackets.
Sea Water Pump QSK45 and QSK60
Disconnect the sea water pump priming hose.
Remove the four sea water pump to front accessory drive

adapter capscrews.
WARNING
Remove the pump from the accessory drive adapter.
Inspect for Reuse

Inspect the sea water pump housings for damage.
Inspect the sea water pump for signs of oil or water leaks.
If the sea water pump housings are damaged or shows
signs of leaks, the sea water pump must be replaced.
QSK45 and QSK60 Sea Water Pump
Inspect the sea water pump shaft splines for any damage.
If the sea water pump shaft splines are damaged, the sea
water pump must be replaced.
Install
WARNING
Carefully install the sea water pump into the front
accessory drive adapter.
Install the four sea water pump to front accessory drive

adaptor capscrews.
Connect the sea water pump priming hose.

Supplemental Coolant Additive (SCA) QSK45 and QSK60
Connect the sea water inlet tube.

Connect the sea water outlet tube.
Install the clamping devices that secure the sea water inlet
and outlet tubes to the mounting brackets.
Open the sea water inlet valve.
Supplemental Coolant Additive (SCA)

(008-060)
Maintenance Check
Supplemental coolant additives, or equivalent, are used to
prevent the buildup of corrosion and scale deposits in the
cooling system.
CAUTION
Inadequate concentration of coolant additives can
result in major corrosive damage to cooling system
components. Over-concentration can cause the
formation of gelatin (gel) that can cause restrictions
and plugging.
The SCA concentration must not fall below 1.2 units per
3.8 liters [1 gal] or exceed 3 units per 3.8 liters [1 gal].
When changing the coolant, the initial SCA, or equivalent
concentration, must be between 1.2 and 3 units per 3.8
liters [1 gal] of coolant (initial charge).
The cooling system must be clean before adding SCA, or
equivalent. Refer to Procedure 008-018.
QSK45 and QSK60 Water Manifold
DCA4 is compatible with all permanent-type antifreeze

except methoxy propanol. If methoxy propanol antifreeze
is used, reduce the amount of DCA4 by one-third. This will
prevent inhibitor loss due to precipitation caused by
chemical incompatibility.
If coolant is added between drain intervals, additional

SCA, or equivalent, will be required.
Check the coolant just before changing the coolant filter.
Use only coolant test kit, Fleetguard® Part Number
CC2602, to check the coolant additive concentration when
SCA is used.
Use the correct Fleetguard® coolant filter to maintain the

correct SCA concentration in the system.
Maintain the correct concentration by changing the
maintenance coolant filter at each oil drain interval.
Water Manifold (008-061)

Preparatory Steps
• Drain the coolant. Refer to Procedure 008-018.
Procedure 010-129.
Water Manifold QSK45 and QSK60
Remove
Remove any vessel plumbing, such as a Mercer connector
and vent lines, from the water manifold. Refer to the
proper vessel manufacturer's service manual for
instructions.
Remove the three capscrews securing the jacket water

bypass line to the water manifold.
Remove the three capscrews in each of the two outlet

pipes.
Discard the gaskets.
WARNING
Remove the four capscrews securing the water manifold
to the support bracket.
Remove the water manifold.
QSK45 and QSK60 Water Manifold
Remove the capscrews securing the support bracket to

the engine.

Clean the water manifold.
Inspect the water manifold for cracks and visible leaks.

Replace the water manifold, if necessary.
Install
The bottom four capscrews securing the support bracket
require a round spacer under the capscrew head.
Install the capscrews securing the support bracket to the
engine. Do not tighten the capscrews at this time.
Water Manifold QSK45 and QSK60
WARNING
Fit the water manifold onto the support bracket.
Install the new gaskets for the water outlet pipes.
Install the three capscrews securing each of the two water
manifold outlet pipes to the thermostat housing.
Install the four capscrews securing the water manifold to

the support bracket.
Install the three capscrews securing the jacket water

bypass line to the water manifold.
Tighten the six capscrews securing the support bracket to

the engine.
QSK45 and QSK60 Water Pump
Install any vessel plumbing, such as a Mercer connector

and vent lines, to the water manifold.
Refer to the proper vessel manufacturer's service manual
for torque specifications.
Finishing Steps
Procedure 010-129.
• Add coolant to engine and check for leaks. Refer to
Procedure 008-018.
Water Pump (008-062)

Preparatory Steps
WARNING
compartment before servicing the batteries. To avoid
arcing, remove the negative (-) battery cable first, and
attach the negative (-) battery last.
WARNING
WARNING
• Disconnect the batteries or air supply line to the air
starter to prevent accidental engine starting. Refer to
Procedure 013-009.
008-018.
Water Pump QSK45 and QSK60
WARNING
attach the negative (-) battery cable last.
WARNING
WARNING
013-009.
008-018.
• Remove the alternator drive belt. Refer to Procedure
013-005.
• Remove the alternator drive pulley. Refer to
Procedure 009-010.
Remove
NOTE: The procedure for the QSK45 engine is shown.
The procedure for the QSK60 engine is similar.
Open the draincock on the engine (1) and on the water
pump (2).
Remove the bypass tube hose clamp (3).

Remove the four capscrews (4), the bypass tube (5), and
the gasket (6).
Remove the four capscrews (7), the inlet tube (8), and the
gasket (9) from the water pump inlet.
Discard the gasket.
Remove the two capscrews (10) from the engine (1) and
the water pump support bracket (11).
Remove the two capscrews (12) from the water pump (2)
and the water pump support bracket (11).
Remove the capscrew (13), two spacers (14), and the
water pump support bracket (11) from the water pump (2),
and the engine (1).
WARNING
Remove the four capscrews (15) from the water pump
adapter (16) and the engine (1).
Remove the four capscrews (17) from the water pump and
the water pump drive assembly (18).
Remove the water pump, gasket (19), and the collar (20)
from the water pump drive assembly (18).
Discard the gasket.

NOTE: The procedure for the QSK60 Tier II engine is
shown. The procedure for the QSK50 Tier II is similar.
Open the drain cock on the engine block (1) and the water
pump (2).
Remove the two brackets and U clamps (1) from the low
temperature aftercooler outlet (2) and jacket water bypass
pipes (3).
1. Remove the hose clamps (1) from the low

temperature aftercooler outlet (2) and the jacket
water bypass pipe (3).
2. Remove the U clamp (4) from the jacket water
bypass pipe (3).
3. Remove the four capscrews (5), low temperature
aftercooler outlet (2), and the gaskets.
4. Remove the four capscrews (6), the jacket water
bypass pipe (3), and the gaskets.
Remove the bracket/clamp (1) from the low temperature

aftercooler bypass pipe (2).
Remove the hose clamp (3) from the low temperature
Remove the bypass pipe (2).
Remove the four capscrews and jacket water radiator inlet

connection.
Remove the capscrews and jacket water inlet connection.

Remove the two capscrews (2) from the engine block (1)
Remove the two capscrews (2) from the water pump (4),
Remove the capscrews (2) and the water pump support
bracket (3) from the water pump (4), and the engine block
(1).
WARNING
Remove the six capscrews (1) from the water pump (2) and
the gear housing (3).
Remove the four capscrews (4) from the engine block (5).
Remove the water pump from the front gear housing.
Inspect for Reuse

A minor chemical buildup or streaking at the water pump
weep hole (1) is normal. Do not repair or replace the
water pump (2) unless an actual leak is confirmed. If a leak
is confirmed, contact Cummins Authorized Repair Facility
for replacement.
NOTE: QSK45 and QSK60 engines have two-pump, two-
loop systems. Check both pumps. Procedures for both
pumps are similar.
Inspect the water pump and bypass tube for coolant or oil
leakage. Check the water pump weep hole for excessive
leakage.

A minor chemical buildup or streaking at the water pump
weep hole (1) is normal. Do not repair or replace the water
pump unless an actual leak is confirmed. If a leak is
confirmed, contact a Cummins Authorized Repair Facility
for replacement.
Disassemble
Remove the:
Splined coupling (1)
Mounting gasket (2)
Adapter plate (3)
O-ring (4)
Adapter plate gasket (5).
Discard the o-ring and gaskets.
Remove the:
Water inlet connection (6)
Gasket (7)
Support bracket (8)
Draincock (9).
Discard the gasket.
Remove the:
Capscrews (10)
Water pump inlet housing (11)
O-ring seal (12).
Discard the o-ring.
NOTE: New water pumps and rebuilt water pumps with

new shafts and impellers do not contain the drive key and
capscrew.
Remove the:
Self-locking capscrews (12)
Drive key (13).
CAUTION
The puller screw must pass easily through the
impeller bore to prevent damage to the impeller.
Install a short capscrew in the shaft to protect the threads.
Remove the impeller using a standard puller, Part Number
ST-647 or equivalent.
Remove the large snap ring (14).
Set the water pump in a arbor press with the impeller end
of the shaft up.
Press the bearing and shaft assembly out of the water
pump housing.
Remove the:
Oil seal (15)
Mechanical water seal (16).
Discard the seals.
The bearing and shaft assembly can be one of two

different designs. The disassembly and assembly
procedures are different for the two designs.
The new design bearing and shaft assembly (1) positions
the snap ring (2) nearest the impeller end of the shaft.
The previous design bearing and shaft assembly (3)
positions the snap ring (2) nearest the end of the shaft.
The new design bearing shaft assembly can have either a
double or single row bearing (4). If a single row bearing is
used a longer spacer (5) is required.
The previous design bearing and shaft assembly must
use the double row bearing.
The following disassembly procedure is for the previous

design.
Remove the snap ring (1).
Use water pump bearing separator, Part Number
3375326, or equivalent to remove bearings (2) and (3) from
the shaft.
New
Remove the snap ring (2).
Place the bearing and shaft assembly (1) onto supports

with the large bearing (4) setting on the supports.
Use a hydraulic press to press the shaft (7) through
bearing (4), spacer (5) and bearing (6).
Measure
A new shaft, Part Number 3634049, has been released for
the QSK45 and QSK60 engines. The new shaft can be
used with the old impeller. The previous shaft, Part
Number 3626952, can be used in the new and existing
pump bodies.
Three different shafts have been used. The outside
diameter in the bearing area is the same on all three
shafts.
Measure the water pump shaft bearing area diameter.
Water Pump Shaft Diameter (bearing area)

mm in
30.010 MIN 1.181
30.020 MAX 1.812
Measure the diameter of the impeller end of the water

pump shaft.
Water Pump Shaft Diameter (impeller end)

mm in
24.999 MIN 0.984
25.009 MAX 0.985
Measure the inside diameter (17) of the water pump

impeller.
Water Pump Impeller Inside Diameter, Part Numbers

3050453, 3050454 and 3050455
mm in
24.919 MIN 0.981
25.945 MAX 0.982
Water Pump Impeller Inside Diameter, Part Numbers

3001711, 3002106, and 3175069
mm in
24.932 MIN 0.982
25.958 MAX 0.983
The outside diameter (18) of the water pump impeller is
given for parts identification only. It is not necessary to
measure the part.
Water Pump Impeller Outside Diameter

Engine mm in
QSK45 146 5.75
QSK60 171 6.75
Water pump impellers with a 74 degree (19) angle can

only be installed with a water pump connection that has
a 16 degree angle.
Water pump impellers with a 67 degree angle (19) can
only be installed with a water pump connection that has
a 23 degree angle.
QSK45 Water Pump Impeller Angle

Part Number Angle
3050455 74 degrees
3175069 74 degrees
3050453 67 degrees
3001711 67 degrees
All QSK60 impellers have a 78 degree angle (19).
The water pump inlet housing angle (20) is measured at

the location illustrated.
QSK45 Water Pump Inlet Housing Angle

Part Number Angle
2006456 16 degrees
3001712 23 degrees
All QSK60 water pump inlet housings have a 12 degree

angle (20).
Measure the water pump housing mechanical water seal

bore (21), oil seal bore (22), rear bearing bore (23), and
front bearing bore (24).
Water Pump Housing Mechanical Water Seal Bore

mm in
53.60 MIN 2.110
54.10 MAX 2.130
Water Pump Housing Oil Seal Bore

mm in
38.05 MIN 1.498
38.10 MAX 1.500
Water Pump Housing Rear Bearing Bore

mm in
61.997 MIN 2.440
62.009 MAX 2.441
Water Pump Housing Front Bearing Bore

mm in
71.996 MIN 2.834
72.012 MAX 2.835
The depth of the water pump housing front bearing bore

(25) is different for single row bearing and double row
bearings.
Water Pump Housing Front Bearing Bore Depth

Bearing Style mm in
Single row bearing 25.4 1.00
Double row bearing 36.8 1.45
The water pump housing impeller counterbore diameter

(26) is different between engines.
Water Pump Housing Impeller Counterbore Diameter

Engine mm in
QSK45 (new) 147 5.80
QSK45 (previous) 160 6.30
QSK60 173 6.80
Machine
CAUTION
Do not install a new mechanical water seal in an
existing water pump housing without machining the
pump housing. Doing so can cause rapid mechanical
water seal failure.
A new mechanical water seal has been released that
replaces the previous mechanical water seal. The new
mechanical water seal is 2 mm [0.788 in] longer than the
previous seal.
The distance from the rear face to the mechanical water
seal ledge on the existing water pump is 134.87 mm ±
0.25 mm [5.31 in ± 0.009 in].
Machine the water pump housing to 136.88 mm ± 0.25
mm [5.39 in ± 0.009 in].
Assemble
CAUTION
Make sure to install the correct bearing if the wrong
bearing is installed the pump will fail.
CAUTION
To prevent damage to the bearing the mandrel must
contact the inner race of the bearing during
installation.
NOTE: The following three steps are for the new shaft
assembly.
Support the shaft on the splined end as shown in the
illustration.
Using a hydraulic press and the appropriate mandrel (8)
press the bearing onto the shaft until it rests against the
step on the shaft (9).
On new shafts, the bearing will not fit tightly in the area of
the shaft (10) that has been machined to a smaller
diameter.
If a single row bearing is used (11) the long spacer (12)

must be used.
If a double row bearing is used (13) a short spacer (14)
must be used.
Slide the correct spacer (5) onto the shaft until it touches
the inner race of the bearing.
CAUTION
To prevent damage to the bearing the mandrel must
contact the inner race of the bearing during
installation.
NOTE: The following bearing and shaft assembly steps
are for the previous design. The remainder of the
assembly procedures are the same for the new and
previous designs.
Only double row bearings can be used for the front
bearing on the previous design.
Support the shaft as shown in the illustration.
Using an arbor press and the appropriate mandrel (4) and
(5) press each bearing onto the shaft until it rests against
the step on the shaft.
Install the retaining ring.
Using water pump seal driver, Part Number 3377260 or

3824836, install the seal with the part number facing
down.
The seal must not be more than 0.51 mm [0.020 in] below
the top step in the water pump housing.
Support the water pump housing on a arbor press.

Using the arbor press and water pump bearing driver, Part
Number 3375318, or equivalent press the bearing and
shaft assembly into the water pump housing.
The beveled edge of the snap ring must be positioned up

as shown in the illustration.
Install the snap ring.
The specifications for making a water pump seal driver are

listed below.
Reference mm in
Tool length (29) 102.0 4.00
Outside diameter (30) 51.0 2.00
Radius (36) 0.51 0.20
Inside Diameter (31)

mm in
25.07 MIN 0.997
25.12 MAX 0.989
Depth (32)
mm in
20.80 MIN 0.819
20.90 MAX 0.823
Length (33)
mm in
5.41 MIN 0.213
5.51 MAX 0.217
Inside Diameter (34)

mm in
41.40 MIN 1.630
41.53 MAX 1.635
Outside Diameter (35)

mm in
30.20 MIN 1.182
30.28 MAX 1.192
CAUTION
To prevent damage to the bearings during mechanical
water seal installation support the water pump
housing not the shaft.
Support the water pump housing.
Using the mechanical water pump seal driver (27), Part
Number 3377260, or equivalent press the water pump
seal (16) into the water pump housing until it rests on the
shoulder.
The installed height of the mechanical seal must be 21.36
to 21.87 mm [0.841 to 0.861 in].
CAUTION
The mechanical water seal will fail if the spring
tension is not correct. Use Loctite to keep the seal in
place. If Loctite contacts the sealing surfaces the seal
will fail.
Apply only one drop of Loctite 290 or equivalent, to the
seal at the parting line of the shaft.
Apply a light coat of Loctite 609 or equivalent to the inside

of area of the impeller shaft bore.
CAUTION
If the incorrect impeller or water pump inlet
connection are installed, the water pump will be
damaged from contact or performance of the pump
will be decreased.
For water pumps that have impeller and shaft slots for a
drive key, the slots must be aligned before the impeller is
pressed onto the shaft.
Support the water pump on the shaft as shown in the

illustration.
Place a small piece of flat steel on the impeller.
Press the impeller onto the shaft until it is even with the
end of the shaft using an arbor press.
For impellers that have slots for a drive key, install the
drive key (13) and self-locking capscrews (12).
Torque Value:
Water Pump 20 N•m [ 177 in-lb ]
Impeller Drive
Key Capscrews
Lubricate the o-ring with vegetable oil.

Install the o-ring (12) onto the water pump inlet housing
(11).
Install the water pump inlet housing into the water pump
housing.
Install and tighten the capscrews.
Torque Value:
Water Pump 45 N•m [ 33 ft-lb ]
Inlet Housing
Capscrews
Install the gasket (7), water pump inlet connection (6), and
capscrews.
Torque Value:
Inlet
Connection
Capscrews
Install the draincock and tighten.
Torque Value:
Draincock
Lubricate the o-ring (4) with vegetable oil.

Install the o-ring in the groove of the adapter plate (3).
Install the adapter plate with the o-ring side toward the
housing.
While rotating the shaft, lubricate the bearing with clean

engine oil.
Lubricate the splines on the shaft and install the spline
coupling.
Install
WARNING
Position the collar (20) on the water pump drive assembly
(18).
The collar can be installed on the water pump shaft or the
water pump drive assembly shaft. It is usually easier to
install on the water pump drive assembly.
Install the water pump and gasket (19) on water pump
drive assembly (18) with four capscrews (17).
Torque Value:
Mounting
Capscrews
Install the water pump adapter (16) on the engine (1) with
four capscrews (15).
Torque Value:
Adapter
Mounting
Capscrews
Install the water pump support bracket (11) on the water

pump (2) and the engine (1) with two spacers (14), one
screw (13), two screws (12), and two screws (10).
Torque Value:
Support
Bracket
Capscrews
Install the inlet tube (8) and gasket (9) on the water pump
inlet with four capscrews (7).
Torque Value:
Inlet Mounting
Capscrews
Install the bypass tube (5) and gasket (6) on the water
pump inlet with four capscrews (4).
Torque Value:
Bypass Tube
Mounting
Capscrews
Install the bypass tube hose clamp (3).
Tighten the clamp.
Torque Value:
Bypass Tube
Hose Clamp
Close the draincock on the engine (1) and on the water

pump (2).
WARNING
Install the water pump (2) into the gear housing (3) using
the six capscrews (1) and a new gasket.
Install the four capscrews (4) to the engine block (5) using
a new gasket.
Torque Value:
Mounting
Capscrews
Install the capscrews (2) and the water pump support

bracket (3) to the water pump (4), and the engine block (1).
Install the two capscrews (2) to the water pump (4), and
Install the two capscrews (2) to the engine block (1) and
Torque Value:
Support 45 N•m [ 33 ft-lb ]
Bracket
Capscrews
Lubricate the new o-ring on the jacket water inlet.

Install jacket water inlet and capscrews onto the water
pump.
Torque Value:
Jacket Water 45 N•m [ 33 ft-lb ]
Inlet
Capscrews
Install the jacket water radiator inlet connection, gasket

and four capscrews.
Torque Value:
Jacket Water 45 N•m [ 33 ft-lb ]
Radiator Inlet
Capscrews
Install the bypass pipe (2).

Install the hose clamp (3) on the low temperature
Install the bracket/clamp (1) to the low temperature
aftercooler bypass Pipe (2).
Install the jacket water bypass pipe (3), gaskets and four
capscrews (6).
Install the low temperature outlet pipe (2), gasket and four
capscrews (5).
Install the U clamp (4) to the jacket water bypass pipe (3).
Install the hose clamps (1) to the low temperature
aftercooler outlet (2) and the jacket water bypass pipe (3).
Install the bracket and U clamps (1) to the low temperature

aftercooler outlet (2) and jacket water bypass pipe (3)
Tighten the U clamps.
Close the draincock on the engine block (1) and on the

water pump (2).
QSK45 and QSK60 Low-Temperature Aftercooler (LTA) Water Pump
Finishing Steps
013-009.

013-009.
• Fill the cooling system. Refer to Procedure 008-018
• Install the alternator drive pulley. Refer to Procedure
009-010.
• Install the alternator drive belt. Refer to Procedure
013-005.
Low-Temperature Aftercooler (LTA)

General Information
Engines with electronically actuated injectors do not have
a separate low temperature aftercooler water pump.
Instead, the low temperature aftercooler water pump
element is located forward of the jacket water pump. More
information about this pump can be found in Procedure
008-062, Water Pump.
Low-Temperature Aftercooler (LTA) Water Pump QSK45 and QSK60
Preparatory Steps
WARNING
cable last.
WARNING
Wait until the temperature is below 50° C [120° F]
WARNING
• Disconnect the batteries or air supply line to the
starter to prevent accidental engine starting.
008-018.
Remove
NOTE: The procedure for the QSK45 is shown. The
procedure for the QSK60 engine is similar.
Remove the plug (1) on the low temperature aftercooling
water pump (2) to drain the remaining or trapped coolant
from the engine (3).
WARNING
CAUTION
Do not support the weight of the water pump on the
shaft end. Damage to the coupling or shaft can occur.
Remove the four nuts (4), capscrews (5), and the two
clamps (6) from the inlet pipe (7) and bypass pipe (8).
Position the inlet pipe (7) and bypass pipe (8) aside to
remove the three gaskets (9). Discard the old gaskets.
Remove the four capscrews (10), the low temperature

aftercooling pump (2), and the o-ring (11) from the engine
(3).
Inspect the o-ring for damage.
Discard the o-ring if damaged.
Disassemble
Remove the four capscrews (1) and separate the pump
end body (2) from the drive end body.
Turn the pump over to expose the splined shaft and

remove the lipseal from the bearing housing.
Remove the beveled retaining ring using snap ring pliers.

Remove the spring washer located under the snap ring.
There are two types of impellers. One impeller has three

equally spaced threaded holes in the hub. This is the old
style impeller. The new style has no holes in the impeller
hub and the use of a hydraulic press is required to remove
the impeller. The old style impeller can also be removed
using an hydraulic press.
Support the bearing housing and press the shaft out of the
impeller.
While removing the impeller, the drive end bearing will be
pressed out of the bearing housing.
Once the impeller is free of the shaft, remove it from the
press.
Continue to press the shaft to remove the drive end
bearing out of the bearing housing.
Remove the rotating half of the mechanical seal (1) from

the impeller end of the drive end body.
Press the drive end bearing off the shaft.
Remove the four capscrews (1) and separate the bearing

housing (2) from the drive end body (3).
Remove the beveled retaining ring using snap ring pliers.
Remove the stationary half of the mechanical seal from

the drive end body.
Press out the lipseal and bearing from the drive end body.

WARNING
WARNING
personal injury.
The mechanical seals, lipseals, o-rings, spring washers
(lock washers), and bearings are not serviceable and
must be replaced.
Clean all the disassembled parts with solvent and dry with
compressed air.
The impeller must be replaced if the performance has

deteriorated below an acceptable level. If the shaft has
not suffered mechanical damage, it can be used again.
Inspect the impeller for damage or erosion. Replace if
necessary.
Inspect the shaft for abnormal wear, pitting, or damage.

Replace if necessary.
Inspect the pump housing and drive end housing for

cracks or other damage. Replace if necessary.
Assemble
Install the lipseal (1) into the drive end housing (2) with the
cup side of the seal toward the impeller.
Apply grease to the lip and upper face of the lipseal.
Press the bearing into the drive end housing.

Install the beveled retaining ring with the bevel facing
away from the bearing.
To operate correctly and effectively, the seal faces must

be clean and dry.
Apply a soapy solution to the stationary half of the
mechanical seal and install the seal into the drive end
housing from the impeller side.
Clean and dry the face of the seal using a lint free cloth.
Install the bearing housing (2), using a new o-ring (4), to

the drive end body (3), and tighten the capscrews (1).
Press a new bearing onto the splined end of the shaft.
Install the shaft from the bearing housing end and press
the shaft into the assembly until the bearing on the splined
end bottoms out in the bearing housing.
Install the spring washer and beveled retaining ring, with

the bevel up, into the bearing housing.
Apply grease to the bearing face and to the lipseal.

Install the lipseal into the bearing housing with the cup
side of the seal toward the splined shaft.
To operate correctly and effectively, the seal faces must

be clean and dry.
Using a soapy solution on the inside of the rotating half of
the mechanical seal, press the seal over the shaft until it
seats against the stationary half of the seal in the housing.
Support the splined shaft end of the pump and bearing

housing and press the impeller onto the shaft.
Install a new o-ring (3) on the drive end housing.

Install the end housing (2), capscrews, and spring washers
(1).
Tighten the capscrews in a crisscross pattern.
Install
WARNING
Do not support the weight of the pump on the shaft end.
Install the low temperature aftercooled water pump (2),
and o-ring (11), onto the engine (3) with the four capscrews
(10).
Position the two gaskets (9) on the low temperature

aftercooled water pump and bypass pipe (8) and inlet pipe
(7).
Install the two clamps (6) on the bypass (8) and inlet (7)
pipes with the four capscrews (5) and nuts (4).
Tighten the nuts.
NOTE: Do not cause undue loading on the pump with the
piping.
Finishing Steps
WARNING
cable last.
• Connect the batteries or air line to the starter.
temperature and check for coolant leaks.
QSK45 and QSK60 Right Bank Number 8 Coolant Loop
Right Bank Number 8 Coolant Loop

(008-116)
Preparatory Steps
QSK60 Two Stage
WARNING
WARNING
Remove
Remove the p-clips (1), capscrews (2), and nuts (3) that
mount the water transfer tubes assembly to the 2-stage
frame.
Remove the p-clip (1), capscrew (2), and spacer (3) that
tube.
Right Bank Number 8 Coolant Loop QSK45 and QSK60
Loosen the hose clamps (1).

Remove the water transfer tubes assembly (2) from the 4-
way water manifold (3) behind the thermostat housing
near the number 1 cylinder.
Remove the capscrew (1) and retaining clamp (2) that hold
the water transfer tube (3) into the water manifold.
Disconnect the water transfer tubes assembly (3) from the
water manifold near to the number 8 cylinder.
Remove the complete water transfer tubes assembly from
the engine.

Flush the tubes with water to make sure the water tubes
are internally clean and free of debris before refitting.
Check that the tubes are free from dents, cracks, and
other damage.
The o-rings must always be replaced following removal
of the water transfer tubes.
QSK45 and QSK60 Right Bank Number 8 Coolant Loop
Install
Use vegetable oil to lubricate the o-ring (4). Do not use
petroleum-based oil as this will cause swelling of the o-
rings.
Install the water tube (3) into the water manifold.
Install the retaining clamp (2) and capscrew (1).
Install the water transfer tubes assembly (2) into the 4-way
water manifold (3) behind the thermostat housing near the
number 1 cylinder.
Tighten the hose clamps (1).
Install the p-clip (1), capscrew (2), and spacer (3) that
frame.
Install the p-clips (1), capscrews (2), and nuts (3) that
frame.
ECM Cooling Plate QSK45 and QSK60
Finishing Steps
ECM Cooling Plate (008-128)

Preparatory Steps
• Remove the ECMs. Refer to Procedure 019-031 in
the Troubleshooting and Repair Manual Electronic
Control System QSK50 and QSK60 Modular
Common Rail System Series Engines, Bulletin
4021533.
008-018.
Remove
Remove the p-clamp capscrews to the ECM cooling lines.
Disconnect the ECM Supply and Return coolant lines from

the ECM.
QSK45 and QSK60 ECM Cooling Plate
Remove the nuts and washers from the ECM cooling plate
mounting studs and remove the ECM cooling plate.
Remove the ECM mounting studs.

The upper stud is in the fuel junction block, with the bottom
studs in the cylinder block.
Disassemble
Remove the vibration isolators from the ECM cooling
plate.
Remove the tee adapter from the ECM cooling plate

coolant return port (lower).
Remove the drain cock from the return tee.
Remove the elbow adapter from the ECM cooling plate

coolant supply port (upper).
WARNING
WARNING
Clean the ECM cooling plate, fittings and attaching
hardware with cleaning solvent, Cummins Part Number
3824510 or equivalent.
Inspect the ECM cooling plate for any signs of damage,

cracks, corrosion, and leaks. Replace if damaged.
Inspect the threaded holes which mount the ECMs for any
signs of damage.
If damage is found, it can be repaired with a screw thread
insert, Cummins Part Number 3822699 or equivalent
(M8x1.25).
Inspect the threaded ports where the coolant lines attach

for damage or stripped threads,
Replace the ECM cooling plate if ports are damaged or
stripped.
Inspect the tee fitting for signs of damage or stripped

threads. Replace the tee fitting if damaged.
Inspect the elbow for cracks, damage, and stripped

threads. Replace the elbow if damaged.
Inspect the drain cock for damage, seizure, and stripped

threads. Replace if damaged or seized.
Inspect the ECM mounting studs for corrosion and

stripped threads. Replace as necessary.
Inspect the vibration isolators for cracks, wear, or

damage. Replace if necessary.
Inspect the ECM coolant supply and return lines for

cracks, damage, age wear, or leakage.
Inspect the fitting on each end of the cooling lines for
damage and stripped threads.
Replace damaged coolant lines.
Assemble
If reusing the drain cock, apply thread sealer, Part Number
3375066 or equivalent to the threads. If a new draincock
is to be used, the threads will already have sealant
applied.
Install the drain cock into the tee. Hand tighten.
Install new o-rings on the return tee and install it in the

ECM cooling plate return port.
Torque Value:
Coolant Return 25 N•m [ 18 ft-lb ]
Tee
Install new o-rings on the supply elbow and install it in the

ECM cooling plate supply port.
Torque Value:
Coolant Supply 25 N•m [ 18 ft-lb ]
Elbow
Install the vibration isolators on the ECM cooling plate.

Install
Install the cooling plate mounting studs onto the fuel
injection block and cylinder block.
Torque Value:
ECM Mounting 80 N•m [ 60 ft-lb ]
Studs
Install the ECM cooling plate and mounting nuts onto the
mounting studs.
Torque Value:
ECM Cooling 23 N•m [ 17 ft-lb ]
Plate Nuts
Install the ECM Supply and Return coolant lines to the

ECM.
Torque Value:
Coolant Lines 15 N•m [ 89 in-lb ]
Install the p-clamp capscrews to the ECM cooling lines.

Torque Value:
P-Clamps 45 N•m [ 35 ft-lb ]
QSK45 and QSK60 ECM Cooling Plate Lines
Finishing Steps
• Install the ECMs. Refer to Procedure 019-031 in the
Troubleshooting and Repair Manual Electronic
Control System QSK50 and QSK60 Modular
Common Rail System Series Engines, Bulletin
4021533.
ECM Cooling Plate Lines (008-130)

Preparatory Steps
WARNING
WARNING
coolant spray or steam can cause serious personal
injury.
008-018.
Remove
Remove the capscrews securing the clips which hold the
electronic control module (ECM) cooling plate lines to the
cam follower covers and the air compressor housing.
ECM Cooling Plate Lines QSK45 and QSK60
Remove the electronic control module (ECM) cooling plate

supply and return lines.
Remove the brackets from the coolant lines.
Remove the male connectors and adapters from the Low

Temperature Aftercooler lines. Discard the o-rings.
Inspect for Reuse

Inspect the coolant lines for cracks, damage, age wear, or
leakage.
Inspect the fittings on both ends of the coolant lines for
damage and stripped fittings. Replace if damage is found.
QSK45 and QSK60 ECM Cooling Plate Lines
Inspect the connectors and adapters for cracks, damaged

and stripped threads. Replace if damage is found.
Install
If the adapters are being reused, apply sealant, Cummins®
Part Number 3375066, or equivalent, to the threads of the
adapter. If installing new adapters, sealant is already
applied to the threads.
If the male connectors are being reused, apply sealant,

Cummins® Part Number 3375066, or equivalent, to the
threads of the connectors. If installing new male
connectors, sealant is already applied to the threads.
Install the male connectors into each of the adapters.
Install the electronic control module (ECM) coolant plate

supply and return lines.
ECM Cooling Plate Lines QSK45 and QSK60
Install the electronic control module (ECM) coolant line

brackets.
Attach the bracket to the cam follower cover and air

compressor housing.
Finishing Steps
QSK45 and QSK60
Section 9 — Drive Units — Group 09 Page 9-a
Section 9 — Drive Units — Group 09

Section Contents
Page
Accessory Drive ................................................................................................................................................9-3
Assemble..........................................................................................................................................................9-8
Disassemble.....................................................................................................................................................9-4
Finishing Steps...............................................................................................................................................9-11
Initial Check......................................................................................................................................................9-3
Install..............................................................................................................................................................9-10
Remove............................................................................................................................................................9-3
Accessory Drive Cover ....................................................................................................................................9-29
Install..............................................................................................................................................................9-30
Remove.......................................................................................................................................................... 9-29
Accessory Drive Pulley ...................................................................................................................................9-11
Install..............................................................................................................................................................9-13
Remove.......................................................................................................................................................... 9-11
Alternator Drive Pulley ....................................................................................................................................9-13
Finishing Steps...............................................................................................................................................9-14
Install..............................................................................................................................................................9-14
Remove.......................................................................................................................................................... 9-13
Engine Barring Device .................................................................................................................................... 9-29
Install..............................................................................................................................................................9-29
Remove.......................................................................................................................................................... 9-29
Fuel Pump Drive ..............................................................................................................................................9-14
Assemble........................................................................................................................................................9-19
Disassemble................................................................................................................................................... 9-15
Initial Check....................................................................................................................................................9-14
Hydraulic Pump Drive ..................................................................................................................................... 9-21
Install..............................................................................................................................................................9-22
Remove.......................................................................................................................................................... 9-21
Service Tools ....................................................................................................................................................9-1
Drive Units........................................................................................................................................................9-1
Water Pump Drive ...........................................................................................................................................9-23
Assemble........................................................................................................................................................9-27
Disassemble................................................................................................................................................... 9-24
Finishing Steps...............................................................................................................................................9-28
Initial Check....................................................................................................................................................9-23
Install..............................................................................................................................................................9-28
QSK45 and QSK60
Page 9-b Section 9 — Drive Units — Group 09

Remove.......................................................................................................................................................... 9-24
Section 9 — Drive Units — Group 09 Page 9-1
Service Tools
Drive Units
Repair Location.

Gear Puller
Used to remove the drive pulleys and impellers.
ST-647
Coupling Puller
Used to remove the splined coupling gear from the compressor drive,
3376663 fuel pump, and air compressor.
Adapter Kit
Contains most adapters for removing accessory drive pulleys.
3823765
Sealant (RTV)
Applied to the portion of the cover that will be in the bore of the front
3377132 cover.
Pulley Adaptor Kit

Used with pulley installation tool, Part Number 3376326, to assemble
3824502 pulleys onto shafts.
Accessory Drive Oil Seal Installer

Used to assemble accessory drive oil seals into the front cover.
3824922
Page 9-2 Section 9 — Drive Units — Group 09

Pulley Installation Tool
Contains a variety of adaptors to assemble pulleys onto shafts.
3376326
QSK45 and QSK60 Accessory Drive
Accessory Drive (009-001)

Preparatory Steps
WARNING
WARNING
If an air compressor is not mounted on the engine, it is
not necessary to drain the cooling system.
• Drain the cooling system, if applicable. Refer to
Procedure 008-018.
• Remove the fuel pump. Refer to Procedure 005-016.
• Remove the air compressor, if applicable. Refer to
Procedure 012-014.
• Remove the accessory drive pulley, if applicable.
• Remove the accessory drive cover, if applicable.
• Remove the accessory drive seal, if applicable.
Remove
Remove the six capscrews.
Remove the accessory drive assembly.
Remove and inspect gasket.
Initial Check
WARNING
Use solvent to clean the outer housing of the accessory
drive.
Accessory Drive QSK45 and QSK60
Use a dial indicator to measure the accessory drive shaft

end clearance.
Accessory Shaft End Clearance

mm in
0.05 MIN 0.002
0.30 MAX 0.012
Disassemble
CAUTION
To prevent damage to the shaft, the capscrew must
be installed into the drive shaft without the washer.
Remove the capscrew and washer.
Install the capscrew into the shaft.
Use a jaw puller to remove the lovejoy type coupling.

Remove the capscrew from the shaft.
WARNING
Remove the clamping washer (2).
Remove the gear and shaft assembly.
Remove the pipe plug from the housing.
Use solvent to clean the parts.
Measure the inside diameter of the busings.
Accessory Drive Bushing Inside Diameter

mm in
49.95 MIN 1.967
50.03 MAX 1.970
If the inside diameter of either bushing is not within
specification, both bushings must be replaced.
Check the grooved surfaces of the bushings (1) for

damage.
Measure the distance from the outside of the thrust faces
of the two bushings.
Accessory Drive Busing Thrust Face Distance

mm in
45.370 MIN 1.786
45.450 MAX 1.789
If the distance between the two thrust faces is not within
Remove the flanged bushing from the drive housing using

a brass drift (1), taking care not to damage the bushing
bore.
Only remove the gear from the shaft when the gear or the
shaft must be replaced.
Use an arbor press to remove the gear.
Inspect for Reuse

Check the inner diameter of the coupling for damage.
If damage is found the coupling must be replaced.
Measure the inside diameter of the coupling.
Accessory Drive Lovejoy Coupling Inside Diameter

mm in
25.377 MIN 0.999
25.407 MAX 1.000
Accessory Drive Spline Coupling Inside Diameter

mm in
25.255 MIN 0.994
25.278 MAX 0.996
If the inner diameter of the coupling is not within
specification the coupling must be replaced.
If the bushing was removed, inspect the housing for

scoring and other damage.
Replace the housing if damaged.
If the bushing was removed, measure the inside diameter

of the bushing bore.
Accessory Drive Bushing Bore Inside Diameter

mm in
60.00 MIN 2.362
60.05 MAX 2.364
Replace the housing if the bushing bore is not within
specifications.
Inspect the shaft in the gear fit area for fretting or burrs.
Clean burrs with emery cloth.
Accessory Drive Shaft Outside Diameter

Measurements
mm in
(1) 34.964 MIN 1.376
34.976 MAX 1.377
(2) 43.928 MIN 1.729
43.940 MAX 1.730
(3) 44.370 MIN 1.747
44.630 MAX 1.757
(4) 45.070 MIN 1.774
45.082 MAX 1.775
(5) 49.820 MIN 1.961
49.832 MAX 1.962
(6) 25.424 MIN 1.001
25.436 MAX 1.001
If the outside diameter is not within specification, the
Check the gear teeth and gear bore for damage.

Replace the gear if damaged.
Measure the gear inside diameter.
Accessory Drive Gear Inside Diameter

mm in
44.98 MIN 1.771
45.02 MAX 1.772
If the gear is not within specification, the gear must be
replaced.
Assemble
WARNING
Wear protective clothing to reduce the possibility of
personal injury from burns.
CAUTION
Do not exceed the specified time or temperature.
Damage to the gear teeth will result.
If an adequate press is not available, an oven can be
used.
Heat the gear at 235°C [450°F] for not less than one hour,
and not more than six hours.
WARNING
Support the gear.
Slide the shaft into the gear until the shoulder of the shaft
touches the gear.
If an arbor press is available, support the gear.

Lubricate the shaft with clean engine oil.
Press the shaft through the gear until the shoulder of the
shaft touches the gear.
CAUTION
If the heat method was used to install the gear, allow
the gear to air cool. Do not use water or oil to reduce
cooling time. Damage to the gear can result.
Use a feeler gauge to measure the distance between the
shoulder of the shaft and the gear.
Accessory Drive Gear to Shaft Distance

mm in
0.05 MAX 0.002
If the distance between the gear and the shaft is not within
specification, press the gear on until the specification is
met.
CAUTION
The bushings must be pressed in square to the bores
of the housing. The thrust faces of the two bushings
must be parallel and concentric. The bushing with the
center counterbored must have the pressure applied
to the counterbore face and not on the thrust bearing
face. Failure to comply can result in distortion of the
thrust face.
Support the housing.
The bushing with the smaller outside diameter is pressed
into the output side.
Using an arbor press and the shaft as a mandrel, press
the bushing into the housing.
Turn the housing over and press the remaining bushing
into place.
Lubricate the grooved surface of the thrust bearing with

Install the gear and shaft assembly into the housing.
Install the clamping washer (1) with the beveled edge up.
Support the assembly on the gear or the shaft.

Use an arbor press and a mandrel to press the coupling
onto the shaft until it touches the clamping washer.
The clamping washer must be positioned tightly between
the coupling and the shoulder of the shaft.
Install the pipe plug into the housing.
Tighten the pipe plug.
The capscrew must contain an oil drilling if an air

compressor is to be mounted on the engine.
Install the washer and capscrew.
Torque Value:
9.525 mm 45 N•m [ 35 ft-lb ]
[0.375 in]
Capscrew
Length
12.7 mm [0.50 100 N•m [ 75 ft-lb ]
in] Capscrew
Length
Rotate the shaft, checking for correct assembly.

Use a dial indicator to measure the accessory drive shaft
end clearance.
Accessory Drive Shaft End Clearance

mm in
0.05 MIN 0.002
0.30 MAX 0.012
If the end clearance is not within specifications, make sure
the coupling is positioned tightly against the clamping
washer.
Install
CAUTION
Do not use sealants on the gasket. The gasket is
manufactured from material that sealants will
damage.
Lubricate the bushing in the front gear housing cover with
Lubriplate™ 105.
Install the gasket onto the pilot of the drive housing cover.
QSK45 and QSK60 Accessory Drive Pulley
There is not a requirement to align the index on the drive

gear with the marks on the camshaft gear on QSK45 and
QSK60 engines.
Install the accessory drive assembly, turning the shaft as
necessary to engage the gears.
Install and tighten the six capscrews.
With the accessory drive installed, measure the end

clearance.
Accessory Drive End Clearance

mm in
0.13 MIN 0.005
0.29 MAX 0.011
Finishing Steps
• Install the accessory drive seal, if applicable. Refer
• Install the accessory drive pulley, if applicable. Refer
• Install the accessory drive cover, if applicable. Refer
• Install the air compressor, if applicable. Refer to
Procedure 012-014.
• Install the fuel pump. Refer to Procedure 005-016.
• Fill the cooling system, if applicable. Refer to
Procedure 008-018.
reaches 71°C [160°F]. Check for coolant leaks.
Accessory Drive Pulley (009-004)

Remove
CAUTION
Improper use of the standard puller, Part Number
ST-647, will damage the internal threads of the
accessory driveshaft.
Use a standard puller, Part Number ST-647, or equivalent
to remove the accessory drive pulley.
Accessory Drive Pulley QSK45 and QSK60
WARNING
cleaning, follow the manufacturers recommendations
Use solvent and a clean shop towel to clean the pulley
wear sleeve.
Inspect the pulley for cracks, wear in the belt grooves, or

other damage.
Inspect the mating surface and the bore of the pulley for
damage.
Measure the inside diameter of the pulley.
Accessory Drive Pulley Inside Diameter

mm in
34.912 MIN 1.375
34.938 MAX 1.376
QSK45 and QSK60 Alternator Drive Pulley
Install
CAUTION
Do not lubricate the drive seal. The seal must be clean
and dry or the seal will leak.
CAUTION
Do not use a hammer to drive the pulley into position.
Damage to the thrust bearing will result.
Lubricate the outside of the shaft and the inside of the
pulley with clean engine oil.
Insert the adapter, Part Number 31163372, into the pulley
installation tool, Part Number 3376326.
Using the pulley installation tool, install the pulley on the
shaft until it touches the step on the shaft.
Remove the tool and adapter.
Alternator Drive Pulley (009-010)

Preparatory Steps
Remove the alternator belt. Refer to Procedure 013-005.
Remove
Using puller, Part Number ST-647, remove the pulley from
the alternator drive pulley shaft.
Remove the puller.
Fuel Pump Drive QSK45 and QSK60
Inspect for Reuse

Inspect the pulley for nicks, cracks, excessive wear, or
other damage in the belt grooves.
Install
CAUTION
Do not use a hammer to drive the pulley into position.
The thrust washers will be damaged.
Use the pulley pusher kit, Part Number 3376085, and
adapter, Part Number 3163272.
Install the correct adapter in the pusher.
Install the pulley on the shaft.
Remove the tool and adapter.
Finishing Steps
Install and adjust the alternator belt. Refer to Procedure
013-005.
Fuel Pump Drive (009-011)

Initial Check
WARNING
Use solvent to clean the outer housing of the fuel pump
drive.
QSK45 and QSK60 Fuel Pump Drive
Use a dial indicator to measure the fuel pump drive shaft

end clearance.
Fuel Pump Shaft End Clearance

mm in
0.05 MIN 0.002
0.30 MAX 0.012
Disassemble
CAUTION
To prevent damage to the shaft, the capscrew must
be installed into the drive shaft without the washer.
Remove the capscrew and washer.
Install the capscrew into the shaft.
Use a jaw puller to remove the lovejoy type coupling.

Remove the capscrew from the shaft.
WARNING
Remove the clamping washer (2).
Remove the gear and shaft assembly.
Use solvent to clean the parts.
Measure the inside diameter of the busings.
Fuel Pump Drive Bushing Inside Diameter

mm in
49.95 MIN 1.967
50.03 MAX 1.970
If the inside diameter of either bushing is not within
Check the grooved surfaces of the busings (1) for damage.

Measure the distance from the outside of the thrust faces
of the two bushings.
Fuel Pump Drive Busing Thrust Face Distance

mm in
45.370 MIN 1.786
45.450 MAX 1.789
If the distance between the two thrust faces is not within

a brass drift (1), taking care not to damage the bushing
bore.
Only remove the gear from the shaft when the gear or the
Use an arbor press to remove the gear.
Inspect for Reuse

Check the inner diameter of the coupling for damage.
If damage is found the coupling must be replaced.
Measure the inside diameter of the coupling.
Fuel Pump Drive Lovejoy Coupling Inside Diameter

mm in
25.377 MIN 0.999
25.407 MAX 1.000
Fuel Pump Drive Spline Coupling Inside Diameter

mm in
25.255 MIN 0.994
25.278 MAX 0.996
If the inner diameter of the coupling is not within
specification the coupling must be replaced.
If the bushing was removed, inspect the housing for

scoring and other damage.
Replace the housing if damaged.
If the bushing was removed, measure the inside diameter

of the bushing bore.
Fuel Pump Drive Bushing Bore Inside Diameter

mm in
60.00 MIN 2.362
60.05 MAX 2.364
Replace the housing if bushing bore is not within
specifications.
Inspect the shaft in the gear fit area for fretting or burrs.
Clean burrs with emery cloth.
Fuel Pump Drive Shaft Outside Diameter

Measurements
mm in
(1) 34.964 MIN 1.376
34.976 MAX 1.377
(2) 43.928 MIN 1.729
43.940 MAX 1.730
(3) 44.370 MIN 1.747
44.630 MAX 1.757
(4) 45.070 MIN 1.774
45.082 MAX 1.775
(5) 49.820 MIN 1.961
49.832 MAX 1.962
(6) 25.424 MIN 1.001
25.436 MAX 1.001
If the outside diameter is not within specification, the
Check the gear teeth and gear bore for damage.

Replace the gear if damaged.
Measure the gear inside diameter.
Fuel Pump Drive Gear Inside Diameter

mm in
44.98 MIN 1.771
45.02 MAX 1.772
If the gear is not within specification, the gear must be
replaced.
Assemble
WARNING
CAUTION
Damage to the gear teeth will result.
If an adequate press is not available, an oven can be
used.
Heat the gear 235°C [450°F] for not less than one hour,
and not more than six hours.
WARNING
Support the gear.
Slide the shaft into the gear until the shoulder of the shaft
touches the gear.
If an arbor press is available, support the gear.

Press the shaft through the gear until the shoulder of the
shaft touches the gear.
CAUTION
If the heat method was used to install the gear, allow
the gear to air cool. Do not use water or oil to reduce
cooling time. Damage to the gear can result.
Use a feeler gauge to measure the distance between the
shoulder of the shaft and the gear.
Fuel Pump Drive Gear to Shaft Distance

mm in
0.05 MAX 0.002
If the distance between the gear and the shaft is not within
specification, press the gear on until the specification is
met.
CAUTION
must be parallel and concentric. The bushing with the
center counterbored must have the pressure applied
to the counterbore face and not on the thrust bearing
face. Failure to comply can result in distortion of the
thrust face.
Support the housing.
The bushing with the smaller outside diameter is pressed
into the output side.
Using an arbor press and the shaft as a mandrel, press
the bushing into the housing.
Turn the housing over and press the remaining bushing
into place.
Lubricate the grooved surface of the thrust bearing with

Install the gear and shaft assembly into the housing.
Install the clamping washer (1) with the beveled edge up.
QSK45 and QSK60 Hydraulic Pump Drive
Support the assembly on the gear or the shaft.

Use an arbor press and a mandrel to press the coupling
onto the shaft until it touches the clamping washer.
The clamping washer must be positioned tightly between
the coupling and the shoulder of the shaft.
Install the pipe plug into the housing.
The capscrew must contain an oil drilling if an air

compressor is to be mounted on the engine.
Install the washer and capscrew.
Torque Value:
9.525 mm 45 N•m [ 35 ft-lb ]
[0.375 in]
Capscrew
Length
12.7 mm [0.50 100 N•m [ 75 ft-lb ]
in] Capscrew
Length
Rotate the shaft, checking for correct assembly.

Use a dial indicator to measure the fuel pump drive shaft
end clearance.
Fuel Pump Drive Shaft End Clearance

mm in
0.05 MIN 0.002
0.30 MAX 0.012
If the end clearance is not within specifications, make sure
the coupling is positioned tightly against the clamping
washer.
Hydraulic Pump Drive (009-016)

Remove
Remove the mounting capscrews and the hydraulic pump,
if equipped, or the cover plate.
Hydraulic Pump Drive QSK45 and QSK60
Remove the hydraulic pump drive mounting capscrews.

Remove the hydraulic drive assembly, allowing the gear
to turn freely as it disengages from the idler gear.
Remove and inspect gasket, if damaged, discard.
Inspect for Reuse

Measure the end clearance.
Hydraulic Pump Drive End Clearance

mm in
0.125 MIN 0.005
0.285 MAX 0.011
If the end clearance is not within specifications, the
assembly must be rebuilt.
Install
Lubricate gasket with Lubriplate™ 105. Install gasket.
Install the pump drive, allowing the gear to turn as it
meshes with the idler gear.
Align the capscrew holes.
Install and tighten the hydraulic pump drive mounting
capscrews.
Measure the hydraulic pump drive end clearance after

installing the drive.
Hydraulic Pump Drive End Clearance - Installed

mm in
0.125 MIN 0.005
0.285 MAX 0.011
QSK45 and QSK60 Water Pump Drive
Install the mounting capscrews and the hydraulic pump, if

equipped, or the cover plate.
Water Pump Drive (009-029)

Preparatory Steps
WARNING
WARNING
• Remove the water pump. Refer to Procedure
008-062.
• Remove the alternator drive pulley. Refer to
Procedure 009-010.
• Remove the alternator drive seal. Refer to Procedure
001-001.
Initial Check
Measure the water pump drive end clearance after the
drive has been installed.
Water Pump Drive End Clearance - Installed

mm in
0.05 MIN 0.002
0.21 MAX 0.008
Water Pump Drive QSK45 and QSK60
Remove
Remove the six capscrews.
Lightly tap on the end of the shaft with a rubber mallet,
and remove the water pump drive assembly.
Remove, inspect, and discard the gasket, if damaged.
Disassemble
Support the housing and press the shaft through the gear
until the gear is free from the shaft.

Use a light to inspect the main oil passage. The passage
must be clean and open.
Remove the shaft.

Check the housing for an orifice expansion plug.
Check the shaft for an orifice pipe plug.
The plugs must be removed to clean the oil drillings if dirt
or debris is found in the main oil passage.
Do not remove the expansion plugs if the main oil passage
is clean.
Measure the inside diameter of the housing bushings.
Water Pump Drive Bushing Diameter

mm in
Flanged Bushings 49.95 MIN 1.967
50.03 MAX 1.970
Standard Bushings 44.48 MIN 1.751
44.58 MAX 1.755
If the bushings are not within specifications, the
bushings must be replaced.
Check the grooved surface of the thrust faces for damage.

Measure the distance from the thrust bearing faces (2).
Water Pump Drive Thrust Bearing Face Distance

mm in
45.370 MIN 1.786
45.450 MAX 1.789
If the thrust bearing face distance is not within
specifications, the bushings must be replaced.

a brass drift (1), taking care not to damage the bushing.

WARNING
Clean the parts with solvent.
Measure the inside diameter of the housing bushing bore.
Water Pump Drive Housing Bushing Bore

mm in
60.000 MIN 2.362
60.050 MAX 2.364
If the housing bushing bore is not within specifications,
the housing must be replaced.
Check the shaft at the seal area for wear.

Check the shaft splined area for wear or damage.
Measure the outside diameter of the shaft.
Water Pump Drive Shaft Outside Diameter

mm in
(1) 35.084 MIN 1.381
35.096 MAX 1.382
(2) 43.928 MIN 1.729
43.940 MAX 1.730
(3) 44.370 MIN 1.747
44.630 MAX 1.757
(4) 45.070 MIN 1.774
45.082 MAX 1.775
(5) 49.820 MIN 1.961
49.832 MAX 1.962
(6) 39.994 MIN 1.574
40.006 MAX 1.575
If the shaft is not within specifications, the shaft must be
replaced.
Check the gear teeth for wear or pitting.

Measure the inside diameter of the gear.
Water Pump Drive Gear Inside Diameter

mm in
44.98 MIN 1.771
45.02 MAX 1.772
If the gear is not within specifications, the gear must be
replaced.
Assemble
CAUTION
must be parallel and concentric. Failure to comply can
result in distortion of the thrust face.
Support the housing (5).
Using an arbor press (1), spacer (3), and shaft (2), press
the bushing (4) into the housing.
Repeat the process for the remaining bushing.
Lubricate the bushing bores and thrust faces with

Lubriplate™ 105, or equivalent.
Support the housing and shaft assembly in a hydraulic

press.
Clean any Lubriplate™ from the shaft and apply an even
coat of Loctite 609, or equivalent, to the inside diameter
of the gear.
Install shaft into housing.
Press the gear onto the shaft until the gear touches the
shoulder of the shaft.
Measure the water pump drive end clearance.
Water Pump Drive End Clearance

mm in
0.05 MIN 0.002
0.33 MAX 0.013
If the end clearance is not within specifications, Make sure
that both thrust bearings are correctly positioned in the
water pump drive housing counterbores.
If the bearings are correctly positioned and the end
clearance is not within specifications, the drive must be
completely disassembled and individual component
dimensions checked.
Install
Lubricate the bushing in the front gear housing cover with
Lubriplate™ 105, Part Number 3163086, 3163087, or
equivalent.
Install the gasket on the drive pilot.
Install the pump drive, allowing the gear to turn as it
meshes with the idler gear.
Align the capscrew holes, and install the six water pump
drive mounting capscrews.
Tighten the six capscrews.
Measure the water pump drive end clearance after the

drive has been installed.
Water Pump Drive End Clearance - Installed

mm in
0.05 MIN 0.002
0.21 MAX 0.008
Finishing Steps
• Install the alternator drive seal. Refer to Procedure
001-001.
• Install the alternator drive pulley. Refer to Procedure
009-010.
• Install the water pump. Refer to Procedure 008-062.
QSK45 and QSK60 Accessory Drive Cover
Engine Barring Device (009-035)

Remove
NOTE: Only engines equipped with wet type flywheel
housings have the gaskets (5).
Remove the starter cover capscrews (7) and lock washers
(8).
Remove the starter cover (6) and gasket (5).
Remove the access hole cover capscrew (4) and lock
washer (3).
Remove the access hole cover (2), and remove the o-ring
(1) from the access cover.
Remove the engine barring device capscrews (10) and
lock washers (7).
Remove the engine barring device (9), and gasket (5).
Discard the gaskets and o-ring.
Install
Install the o-ring seal (1) onto the access hole cover (2).
Lubricate the o-ring seal with vegetable oil.
Install the access hole cover (2) in the bore in the flywheel
housing.
Install the lock washer (3) and capscrew (4) and tighten
the capscrew.
NOTE: Gaskets are not required on a dry type flywheel
housing.
Install the gasket (5), cover plate (6), lock washers (7), and
capscrews (8).
Install the gasket (5), engine barring device (9), lock
washers (7), and capscrews (10).
Accessory Drive Cover (009-039)

Remove
Remove the accessory drive cover using a rubber mallet.
Accessory Drive Cover QSK45 and QSK60
WARNING
WARNING
personal injury.
Clean the cover with solvent and dry with compressed air.
Inspect the cover for cracks and damage.
Replace the cover if cracked or damaged.
Install
The cover is installed only if the accessory drive does
not have a pulley.
Use sealant, Part Number 3377132. Apply a bead of
sealant to the portion of the cover that will be in the bore
of the front cover. Position the cover in the bore.
Do not bend the cover when pushing it into the bore. If the
cover is bent, an oil leak will result.
Use a mallet. Push the cover into the bore until the step
on the cover touches the front gear housing. Check to
make sure the cover is straight in the bore.
QSK45 and QSK60
Section 10 - Air Intake System - Group 10 Page 10-a
Section 10 - Air Intake System - Group 10

Section Contents
Page
Aftercooler Assembly ......................................................................................................................................10-3
Assemble......................................................................................................................................................10-11
QSK45 Engines..........................................................................................................................................10-11
QSK60 Engines..........................................................................................................................................10-12
Disassemble...................................................................................................................................................10-6
Finishing Steps............................................................................................................................................. 10-18
Industrial and Power Generation.................................................................................................................10-18
Install............................................................................................................................................................10-14
QSK45 Engines..........................................................................................................................................10-14
QSK60 Engines..........................................................................................................................................10-16
Machine..........................................................................................................................................................10-7
QSK60 Engines............................................................................................................................................10-7
Pressure Test..................................................................................................................................................10-7
Remove..........................................................................................................................................................10-3
QSK45 Engines............................................................................................................................................10-3
QSK60 Engines............................................................................................................................................10-5
Aftercooler Coolant Tube ..............................................................................................................................10-19
Clean and Inspect for Reuse......................................................................................................................... 10-19
Aftercooler Element ...................................................................................................................................... 10-19
Finishing Steps............................................................................................................................................. 10-32
QSK45 Engines..........................................................................................................................................10-32
QSK60 Industrial and Power Generation.....................................................................................................10-33
Install............................................................................................................................................................10-29
QSK45 Engines..........................................................................................................................................10-29
QSK60 Engines..........................................................................................................................................10-31
Machine........................................................................................................................................................10-24
QSK60 Engines..........................................................................................................................................10-24
Preparatory Steps......................................................................................................................................... 10-19
QSK45 Engines..........................................................................................................................................10-19
QSK60 Industrial and Power Generation.....................................................................................................10-20
Pressure Test................................................................................................................................................10-24
Remove.........................................................................................................................................................10-21
QSK45 Engines..........................................................................................................................................10-21
QSK60 Engines..........................................................................................................................................10-22
Aftercooler Heat Shield ...............................................................................................................................10-172
Install..........................................................................................................................................................10-172
Remove.......................................................................................................................................................10-172
Air Cleaner Assembly (Engine-Mounted) ......................................................................................................10-34
Finishing Steps............................................................................................................................................. 10-37
Install............................................................................................................................................................10-35
Remove.........................................................................................................................................................10-34
Air Intake Restriction .................................................................................................................................... 10-44
Measure........................................................................................................................................................10-44
Air Leaks, Air Intake and Exhaust Systems .................................................................................................10-38
Pressure Test................................................................................................................................................10-40
On-Engine Repair.......................................................................................................................................10-40
Pressure Test................................................................................................................................................10-42
Off-Engine Repair.......................................................................................................................................10-42
QSK45 and QSK60
Page 10-b Section 10 - Air Intake System - Group 10
Frame, Two-Stage Turbocharger ................................................................................................................10-141

Clean and Inspect for Reuse........................................................................................................................10-149
Two Stage................................................................................................................................................10-149
Finishing Steps............................................................................................................................................10-157
with Mechanically Actuated Injector..........................................................................................................10-157
with Electronically Actuated Injector..........................................................................................................10-157
Install..........................................................................................................................................................10-150
Preparatory Steps........................................................................................................................................10-141
Remove.......................................................................................................................................................10-142
Intercooler Assembly ..................................................................................................................................10-157
Assemble....................................................................................................................................................10-162
Disassemble................................................................................................................................................10-160
Finishing Steps............................................................................................................................................10-166
Inspect for Reuse........................................................................................................................................10-159
Install..........................................................................................................................................................10-164
Pressure Test..............................................................................................................................................10-161
Remove.......................................................................................................................................................10-157
Intercooler Element .....................................................................................................................................10-166
Finishing Steps............................................................................................................................................10-172
Install..........................................................................................................................................................10-169
................................................................................................................................................................10-169
Pressure Test..............................................................................................................................................10-169
Remove.......................................................................................................................................................10-166
CELECT™ or Centry™................................................................................................................................10-166
Service Tools ...................................................................................................................................................10-1
Cylinder Block.................................................................................................................................................10-1
Turbocharger .................................................................................................................................................10-46
Assemble......................................................................................................................................................10-73
HX60 Turbocharger....................................................................................................................................10-73
HX82 Turbocharger....................................................................................................................................10-80
HX83 Turbocharger....................................................................................................................................10-86
HX60 Turbocharger....................................................................................................................................10-70
HX82 Turbocharger....................................................................................................................................10-72
Disassemble..................................................................................................................................................10-56
HX60 Turbocharger....................................................................................................................................10-56
HX82 Turbocharger....................................................................................................................................10-60
HX83 Turbocharger....................................................................................................................................10-65
Fluorescent Dye Tracer.................................................................................................................................10-46
Turbocharger Coolant Hoses ......................................................................................................................10-109
Finishing Steps............................................................................................................................................10-116
Inspect for Reuse........................................................................................................................................10-112
Install..........................................................................................................................................................10-113
Single Stage.............................................................................................................................................10-113
Two Stage................................................................................................................................................10-114
Remove.......................................................................................................................................................10-109
Single Stage.............................................................................................................................................10-109
Two Stage................................................................................................................................................10-111
Turbocharger Heat Shield ...........................................................................................................................10-137
Finishing Steps............................................................................................................................................10-140
Install..........................................................................................................................................................10-139
QSK45 and QSK60
Section 10 - Air Intake System - Group 10 Page 10-c
Remove.......................................................................................................................................................10-137
Turbocharger Inlet Connections .................................................................................................................10-173
Finishing Steps............................................................................................................................................10-174
Install..........................................................................................................................................................10-173
Remove.......................................................................................................................................................10-173
Turbocharger Oil Drain Line ........................................................................................................................10-117
Install..........................................................................................................................................................10-119
QSK45 and QSK60 Single Stage..............................................................................................................10-119
QSK60 Two Stage....................................................................................................................................10-119
Remove.......................................................................................................................................................10-117
QSK60 Two Stage....................................................................................................................................10-117
Turbocharger Oil Supply Line .....................................................................................................................10-120
Install..........................................................................................................................................................10-127
QSK60 Two Stage....................................................................................................................................10-129
Remove.......................................................................................................................................................10-120
QSK60 Two Stage....................................................................................................................................10-123
Turbocharger, High Pressure ........................................................................................................................10-88
Finishing Steps............................................................................................................................................10-104
Industrial and Power Generation...............................................................................................................10-104
QSK60 Marine Applications......................................................................................................................10-104
Install............................................................................................................................................................10-94
Check for Correct Component....................................................................................................................10-94
QSK45 and QSK60 Single Stage................................................................................................................10-95
Bearing Housing Adjustment......................................................................................................................10-95
QSK60 Two Stage......................................................................................................................................10-98
Bearing Housing Adjustment......................................................................................................................10-99
Left-Bank Rear or Right-Bank Front..........................................................................................................10-101
Left-Bank Front or Right-Bank Rear..........................................................................................................10-102
Remove.........................................................................................................................................................10-88
QSK45 and QSK60 Single Stage................................................................................................................10-88
QSK60 Two Stage......................................................................................................................................10-89
Left-Bank Rear or Right-Bank Front............................................................................................................10-89
QSK45 Single Stage...................................................................................................................................10-91
QSK60 Two Stage......................................................................................................................................10-91
Left-Bank Front or Right-Bank Rear............................................................................................................10-91
Turbocharger, Low Pressure ......................................................................................................................10-104
Check for Correct Component.....................................................................................................................10-106
Finishing Steps............................................................................................................................................10-109
Install..........................................................................................................................................................10-107
Remove.......................................................................................................................................................10-105
QSK45 and QSK60
Page 10-d Section 10 - Air Intake System - Group 10
This Page Left Intentionally Blank

Section 10 - Air Intake System - Group 10 Page 10-1
Service Tools
Cylinder Block
Repair Location.

Manometer
Used to measure air inlet restriction.
ST-1111-3
Dial Depth Gauge

This gauge is used to check for proper nozzle ring crush or end
ST-537 clearance checks on turbochargers.
Black Light Assembly High Intensity

Used to help find the source for leaks in the lubricating and/or cooling
3824524 system.
Fluorescent Tracer
Used to help determine the source of oil leaks. It must be used with
3376891 a black light.
Anti-Seize Compound
Used to speed assembly and disassembly of studs, bolts, capscrews,
3824879 flanges, and fittings.
Nylon Lifting Sling (1 in x 6 ft)

Aid in the removal and installation of heavy components.
3375957
Page 10-2 Section 10 - Air Intake System - Group 10

3375958
Exhaust Manifold Leak Tester Kit

Used to pressure test turbocharger gasket, exhaust bellows, exhaust
4918234 manifold gaskets, and exhaust manifold adapter gasket sealing areas
for leaks.
Exhaust Manifold Leak Test Kit

Used to pressure test exhaust bellows, exhaust manifold gaskets,
4918187 and exhaust manifold adapter gasket sealing areas for leaks.
Air Pressure Regulator

Used with the exhaust manifold leak tester.
3164231
QSK45 and QSK60 Aftercooler Assembly
Aftercooler Assembly (010-002)

Preparatory Steps
WARNING
WARNING
WARNING
WARNING
008-018.
Procedure 010-129.
Remove
QSK45 Engines
Loosen the hose clamps (19) between the air crossover
(17) and the turbocharger.
Loosen the hose clamps (15) between the tee-connection
(13) and the aftercooler.
Remove the v-band clamp (18) between the air crossover
and the tee-connection. Pull the air crossover and the
hose (16) from the turbocharger. Push the hose (12) on the
tee-connection (13) as far as possible.
Remove the four capscrews. Remove the tee-connection
and gasket (14). Remove the hose from the connection.
Discard the gasket.
Aftercooler Assembly QSK45 and QSK60
NOTE: Procedures for one side of the engine are shown.

Procedures for the other side are similar.
Remove the three hose clamps from the rubber tee
connection.
Remove the rubber tee connection.
Remove the capscrews, seal retainers, gaskets and seals

from each aftercooler.
Discard the seals and gaskets.
Remove the aftercooler housing pressure sensor.

Remove the aftercooler housing temperature sensor.
WARNING
or get personal assistance to lift this assembly.
Remove two of the aftercooler mounting capscrews.
Install two guide studs. Use a hoist, two tee-handles, and
a lifting sling.
Attach the tee-handles, sling, and hoist. Raise the hoist
until there is tension on the sling.
Remove the remaining 10 capscrews.
Remove the aftercooler assembly.
QSK60 Engines
NOTE: The QSK60 engine contains an individual air
crossover for each aftercooler. The configuration of the
left-bank front and right-bank rear air crossovers are
different from those used on the right-bank front and left-
bank rear, but removal procedures are the same.
Loosen the two hose clamps between the turbocharger
and the air crossover.
Remove the 12 capscrews from the air crossover.
Remove the air crossover, gasket, and hose from the
turbocharger and aftercooler.
Discard the gasket.

Remove the three hose clamps from the rubber tee.
Remove the rubber tee connection.
Remove the capscrews, seal retainers, gaskets, and seals

Remove the intake manifold pressure sensor.

Remove the intake manifold temperature sensor.
WARNING
or get personal assistance to lift this assembly.
Due to the weight of a cast iron assembly, the assembly
must be disassembled as it is removed if a hoist can not
be used. Go to the Disassembly section of this procedure.
With an aluminum assembly, remove two of the
aftercooler mounting capscrews.
Install two guide studs. Use a hoist, two tee-handles, and
a lifting sling.
Attach the tee-handles, sling, and hoist. Raise the hoist
until there is tension on the sling.
Remove the remaining ten capscrews
Remove the aftercooler assembly.
Disassemble
Remove the aftercooler cover capscrews, cover and
gasket.
Discard the gasket.
WARNING
Remove the aftercooler element and gaskets.
Inspect for Reuse

Inspect the cylinder head intake ports and the aftercooler
for indications of coolant leakage.
Pressure Test
Plug one water tube with a hose that has a pipe plug
installed.
Attach an air line and pressure regulator to the remaining
tube.
Heating the tank of water to 50°C [122°F] improves the
test results.
Place the aftercooler in a tank of water.
Apply air pressure and test for leaks.
Air Pressure 415 kPa [ 60 psi ]
Do not attempt to repair a leaking element. The element
must be replaced.
Machine
QSK60 Engines
Machine the aftercooler housing and the aftercooler
cover only if a new core is being installed.
NOTE: This procedure only shows one side of the
aftercooler housing and aftercooler cover, the opposite
side is a mirror image of the of the one shown. The
dimensions and datum line are identical.
Draw a line through the middle three capscrew holes (A)
on the end of the aftercooler housing.
On each side of the aftercooler housing, draw a line

through the middle of the aftercooler element mounting
holes (B).
Line (A) is used as the datum on both sides of the

aftercooler housing.
Measure from line (B) along line (A) and mark a line at 112
mm [4.41 in] on both sides of the aftercooler housing.
Measure from line (B) along line (A) and mark a line at 788
mm [31.02 in] on both sides of the aftercooler housing.
Center punch the four holes.
Place the aftercooler housing in a drill press.

Drill four holes using a 8.5 mm drill to depth of 33 mm [1.3
in].
Clean the holes.
Tap the four holes using a M10 x 1.5-H tap.

Assemble the aftercooler cover to the aftercooler housing

without the aftercooler core.
Draw a line through the center of capscrew holes (A) on

the side of the aftercooler cover.
Draw a line through the center of the capscrew holes (B)

on the end of the aftercooler cover.
Center punch the aftercooler cover at the intersection of

lines A and B.
Place the assembly in a drill press.
Use a 6 mm drill to drill the center punched marks to a

depth of 42 mm [1.65 in].
Enlarge the holes by using a 6.426 mm drill to a depth of
36 mm [1.47 in]
Disassemble the aftercooler cover and aftercooler

housing.
Remove the dowel pins from their present location and
install them into the newly drilled holes.
Place the new gasket onto the aftercooler housing and

add two extra holes for the dowel pins.
Aftercooler cover, Part Numbers 4001329 and 4001330,

require four extra slots to be added to provide clearance
for new aftercooler element mounting capscrews.
Datum line (A) is the edge of the aftercooler cover where

the aftercooler element water outlet protrudes.
Measure from datum line (A) 800 mm [31.50 in] and make
a mark.
Measure from datum line (A) 124 mm [4.88 in] and make
a mark.
Place the aftercooler cover into a milling machine.

Use a 35 mm [1.38 in] slot drill to machine the slots in the
aftercooler cover.
Align the slot faced milling drill to the center line of the
aftercooler cover.
Move the slot faced milling drill to the first 124 mm [4.88
in] mark.
Move the slot faced milling drill 66 mm [2.59 in] toward the
first 124 mm [4.88 in] mark.
Drill a new slot to the depth of 20 mm [0.79 in].
Repeat the drilling process for the three remaining marked
areas.
The new slots will be the same size as the existing 12 slots.
Remove all debris and thoroughly clean the cover.
Assemble
QSK45 Engines
WARNING
Make sure the aftercooler supports are positioned
correctly.
Install the lower aftercooler element gasket.
Install the aftercooler element and top gasket.
Install the 12 capscrews and tighten in the sequence

shown.
Torque Value:
Aftercooler 45 N•m [ 33 ft-lb ]
Element
Capscrews
Apply a light coat of Anti-Seize lubricant, Part Number

3824759, to the aftercooler cover capscrew threads.
Install the aftercooler cover.
Install the 29 aftercooler cover capscrews.
Tighten the 29 capscrews in the sequence shown.

Torque Value:
QSK45 45 N•m [ 33 ft-lb ]
Aftercooler
Cover
Capscrews
QSK60 Engines
NOTE: For cast iron systems, if a crane can not be used,
the system must be assembled on the engine by mounting
the intake manifolds first then assembling the
aftercoolers.
If the existing aftercooler does not have flange cracks and
can be reused, it is recommended U-shaped clamping
plates be installed.
The plate will help lower the assembly stress and increase
the strength of the aftercooler element flange.
WARNING
Make sure the aftercooler element supports are positioned
correctly.
Install lower aftercooler element gasket.
Install the aftercooler element and top gasket.
Install the 12 capscrews and tighten in the sequence

shown.
Torque Value:
Aluminum 45 N•m [ 33 ft-lb ]
Aftercooler
Assembly
Element
Capscrews
Torque Value:
Cast Iron 65 N•m [ 48 ft-lb ]
Aftercooler
Assembly
Element
Capscrews
Apply a light coat of Anti-Seize lubricant, Part Number

3824579, to the capscrew threads.
Install the aftercooler cover and capscrews.
Tighten the 39 aftercooler cover capscrews in the

sequence shown.
Torque Value:
Aftercooler
Assembly
Torque Value:
Aftercooler
Assembly
Install
QSK45 Engines
WARNING
Use guide studs long enough to protrude beyond the
installed part.
Install two guide studs in the lower row of capscrew holes
in the cylinder heads.
Install the intake gaskets, with the raised bead of the
gasket toward the cylinder head, to the manifold with
screws.
Use Lubriplate™ 105 to lubricate the aftercooler element
spouts.
Lightly tap the aftercooler assembly into location so the
core spouts are positioned in the water connector.
Install the aftercooler and the top row of capscrews.
Tighten the capscrews only enough to hold the assembly
on the engine.
Remove the guide studs, and install the bottom row of
capscrews.
Tighten the aftercooler assembly mounting capscrews in

the sequence shown.
Torque Value:
QSK45 45 N•m [ 33 ft-lb ]
Aftercooler
Mounting
Capscrews
Install the aftercooler housing pressure and temperature

senors.
Torque Value:
Aftercooler 15 N•m [ 133 in-lb ]
Housing
Pressure and
Temperature
Sensors
Position the air crossover and the hose (16) on the

turbocharger. Install the v-band clamp (18) on the air
crossover and the tee-connection.
Install the hose clamps (15) between the tee-connection
(13) and the aftercooler.
Install the tee-connection and gasket (14) with four
capscrews. Install the hose on the connection.
Torque Value:
Aftercooler 45 N•m [ 33 ft-lb ]
Connection
Tee Mounting
Capscrews
Install the hose clamps (19 and 15) between the air
crossover (17) and the turbocharger.
Torque Value:
Intake Air 9 N•m [ 80 in-lb ]
Systems Hose
Clamps
Lubricate the seal with clean engine oil.

Install the seal on the retainer.
Lubricate the outer diameter of the water bosses on the
aftercooler element with Lubriplate™ 105.
Slide the gasket on the water bosses.
Slide the seal and the retainer on the tube.

Install the two rubber tee connections on the aftercooler
tubes.
Install the three hose clamps on the rubber tee
connections.
QSK60 Engines
WARNING
Use guide studs long enough to protrude beyond the
installed part.
Install two guide studs in the lower row of capscrew holes
in the cylinder heads.
Install the intake gaskets, with the raised bead of the
gasket toward the cylinder head, to the aftercooler
housing with screws.
Use Lubriplate™ 105 to lubricate the aftercooler element
core spouts.
Lightly tap the aftercooler assembly into location so the
core spouts are positioned in the water connector.
Install the aftercooler and the top row of capscrews.
Tighten the capscrews only enough to hold the assembly
on the engine.
Remove the guide studs, and install the bottom row of
capscrews.
Tighten the aftercooler assembly mounting capscrews in

the sequence shown.
Torque Value:
Aftercooler
Assembly
Torque Value:
Aftercooler
Assembly
After 20 to 30 minutes, tighten the aftercooler assembly
capscrews in the sequence shown.
Torque Value:
Aftercooler
Assembly
Torque Value:
Aftercooler
Assembly
Install the intake manifold pressure and temperature

sensors.
Torque Value:
Intake Manifold 15 N•m [ 133 in-lb ]
Temperature
and Pressure
Sensors

left-bank front and right-bank rear air crossovers are
different from those used on the right-bank front and left-
bank rear, but installation procedures are the same.
Position the air crossover, gasket, and hose on the
turbocharger and aftercooler.
Install the two hose clamps (1) between the turbocharger
and the air crossover (3).
Torque Value:
Intake Air 9 N•m [ 80 in-lb ]
System Hose
Clamps
Install and tighten the 12 capscrews on the air crossover

in the pattern shown.
Torque Value:
Air Crossover 45 N•m [ 33 ft-lb ]
Mounting
Capscrews

Lubricate the outer diameter of the water bosses on the
Install the two rubber tee connections on the four

aftercooler tubes.
Install three hose clamps on the rubber tee connections.
Finishing Steps

Procedure 010-129.
QSK45 and QSK60 Aftercooler Element
Aftercooler Coolant Tube (010-006)

WARNING
WARNING
personal injury.
Clean the aftercooler water inlet and outlet tubes with
solvent and dry with compressed air.
Make sure the tubes are clean and free from debris.
Check the tubes for cracks, dents or damage.

Replace the tube if damaged.
Aftercooler Element (010-008)

Preparatory Steps
QSK45 Engines
WARNING
WARNING
Aftercooler Element QSK45 and QSK60
Remove the air crossover from the turbocharger and

aftercooler. Refer to Procedure 010-002
QSK60 Industrial and Power Generation
WARNING
WARNING

left bank front and right bank rear air crossovers are
different from those used on the right bank front and left
bank rear, but the removal procedures are the same.
Remove the air crossover from the turbocharger and
aftercooler. Refer to Procedure 010-002.
WARNING
WARNING
008-018.
Procedure 010-129.
• Remove the air crossover from the turbocharger and
Remove
QSK45 Engines
Remove the six capscrews, three covers, gaskets, and
seals from each water transfer tee-connecton of the two
aftercooler tubes.
Remove the two tee connections from the aftercooler
tubes.

WARNING
Remove the aftercooler assembly. Refer to Procedure
010-002.
Remove the aftercooler cover capscrews, cover, and

gasket.
WARNING
QSK60 Engines
Remove the six capscrews, three covers, gaskets, and
seals from each water transfer tee connection of the two
aftercooler tubes.
Remove the two water transfer tee connections from the
aftercooler tubes.

WARNING
Remove the aftercooler assembly. Refer to Procedure
010-002.
Remove the aftercooler cover capscrews and cover.
WARNING
Pressure Test
Use a hose plugged with a pipe plug and attach it to one
water tube as shown.
Attach an air line and gauge to the remaining tube.
Apply air pressure and check for leaks.
Heating the tank water to 50°C [122°F] improves the test
results.
Check for aftercooler element leaks.
Do not attempt to repair a leaking element. The element
must be replaced.
Machine
QSK60 Engines
NOTE: This procedure only shows one side of the air
intake manifold and aftercooler cover, the opposite side is
a mirror image of the first side. The dimensions and
reference lines are all identical.
The early design air intake manifold and cover require the
dowel pins to be moved in order to fit the new aftercooler
elements.
Draw a line through the middle of the end three capscrew
holes of the air intake manifold as indicated by line A.
Draw two lines through the middle of the aftercooler core

mounting capscrew holes as indicated by line B.
Using line A as the reference line, measure from A along

both line B's and mark two marks on each line. One at 112
mm [4.41 in] from line A, and one at 788 mm [31.02 in]
from line A.
Center punch the four holes.
Attach the air intake manifold to a vertical drill.

Drill the four holes using an 8.5 mm drill to a depth of 33
mm [1.3 in].
Clean the holes and remove the debris.
Tap the four holes using a M10 X 1.5-H tap.
Assemble the air intake manifold and aftercooler cover

without the aftercooler core.
Draw a line through the center of the capscrew holes

shown in line A.
Draw a line through the center of the capscrew holes

shown in lines A and B.
Center punch the cover where the lines intersect.

Attach the assembly to a vertical drill.
Drill two holes where marked.

Use a 6 mm drill and drill to a depth of 42 mm [1.65 in] to
enlarge the holes using a 6.426 mm drill to a depth of 36
mm [1.417 in].
Disassemble the aftercooler cover and air intake manifold.

Remove the dowel pins from their old location and fit them
in the two new holes.
Place the new gasket over the air intake manifold and add
two extra holes in the gasket for the dowel pins.
The old aftercooler covers, Part Number 4001329 and

4001330, need four extra slots added to provide clearance
for the four new aftercooler mounting capscrews.
Mark the cover using the dimensions shown.

Reference line A is the edge of the cover where the
aftercooler core water outlet protrudes.
Attach the marked aftercooler cover to a milling machine.

Align the center of the slot drill with the marks in the
aftercooler cover and the center line A.
Move the slot/flat faced drill away from the center line 66
mm [2.59 in].
Use a 35 mm [1.38 in] slot drill to machine four new slots
to a depth of 20 mm [0.79 in].
The new slots should be the same as the existing 12 slots.

Thoroughly clean the cover and remove any debris.
Assemble the modified parts.

The old aftercooler core must not be used if a crack in the mounting flange is found. See Figures 1 and 2.
Figure 1 Figure 2
If cracks are not found on the aftercooler core, recondition it using the U-shaped clamping plate, Part Number
4066244, is recommended. The new plate will help lower the assembly stress and increase the strength of the
aftercooler core flange.
Install
QSK45 Engines
WARNING
Install the aftercooler housing. Refer to Procedure
010-002.
WARNING
Make sure the aftercooler element supports are positioned
correctly.
Install the aftercooler elements and gaskets.
Coat the threads of all of the aftercooler cover capscrews

with anti-seize lubricant, Part Number 3824759.
Position the aftercooler cover on the aftercooler and install
the 29 capscrews.


Lubricate the outside diameter of the water bosses on the

Position the water transfer tee connection covers,
gaskets, and seals on the four aftercooler tubes.
Position the two tee connections on the four aftercooler
tubes.
Install three covers, gaskets, and seals on the two tee
connections of the four aftercooler tubes with six
capscrews.
QSK60 Engines
WARNING
Install the aftercooler housing. Refer to Procedure
010-002.
WARNING
Make sure the aftercooler supports are positioned
correctly.
Install the aftercooler elements and new gaskets.
Coat the threads of all aftercooler cover capscrews with

anti-seize lubricant, Part Number 3824759.
Position the aftercooler cover on the aftercooler and install
the capscrews.
Tighten the aftercooler cover capscrews in the sequence

shown.
Lubricate the seal with Lubriplate™ 105.

Lubricate the outside diameter of the water bosses on the
aftercooler element with clean engine oil.
Install the water transfer tee connection covers on the

aftercooler outlet and inlet tubes.
Install the water transfer tee connection between the
aftercoolers, and place the water supply tube in the water
transfer connection.
Tighten the capscrews on the end covers of the water
transfer tee connection.
Finishing Steps
QSK45 Engines
Install the air crossover from the turbocharger and
aftercooler. Refer to Procedure 010-002
QSK60 Industrial and Power Generation

Install the air crossover from the turbocharger and

• Install the air crossover from the turbocharger and
Procedure 010-129.
Air Cleaner Assembly (Engine-Mounted) QSK45 and QSK60
Air Cleaner Assembly (Engine-

Mounted) (010-013)
Preparatory Steps
Procedure 010-129.
Remove
Loosen the two hose clamps securing the turbocharger
inlet connection to the filter box.
Remove the four capscrews, nuts, and isolators in the
bottom of the air filter box.
WARNING
Lift and remove the air filter box.
The opposite bank is similar, repeat the previous steps to
remove the other bank air filter box.
If the air filter box support structure is being removed,

remove the following components:
006-017.
• Remove the gear oil cooler. Refer to Procedure
008-041.
Remove the 16 capscrews securing the air filter box
support runners to the air cleaner support frame and
remove the support runners.
QSK45 and QSK60 Air Cleaner Assembly (Engine-Mounted)
Remove the capscrews securing the fuel line bracket to

the cross beam.
WARNING
NOTE: It can be necessary to loosen the four capscrews
securing the air cleaner support frame to the flywheel
housing.
Remove the eight capscrews securing the cross beam to
the support frame and remove the cross beam.
WARNING
Remove the four capscrews securing the support frame to
the flywheel housing and remove the support frame.
The opposite side is similar, repeat this step to remove the
other support frame.
Install
WARNING
Install and finger tighten the four capscrews securing the
support frame to the flywheel housing. Capscrews will be
tightened later in this procedure.
The opposite side is similar, repeat this step to install other
support frame.
Air Cleaner Assembly (Engine-Mounted) QSK45 and QSK60
WARNING
Install and finger tighten the eight capscrews securing the
cross beam to the support frame. The capscrews will be
tightened later in this procedure.
Install the capscrews securing the fuel line bracket to the

cross frame.
Tighten the eight capscrews securing the cross beam to

the support frames.
Tighten the four capscrews securing the support frame to

the flywheel housing.
The opposite side is similar, repeat this step to install the
other support frame.
QSK45 and QSK60 Air Cleaner Assembly (Engine-Mounted)
If the air filter box support structure is being installed,

install the following components:
• Install the gear oil cooler. Refer to Procedure
008-041.
006-017.
Install the 16 capscrews securing the air filter box support
runners to the air cleaner support frames.
WARNING
Install the four isolators on the air filter box bracket.
Install the air filter box onto the isolators and align the
capscrews holes.
Make sure that the turbocharger inlet connection boots

are over the filter box flanges.
Install the four capscrews and nuts.
Opposite bank is similar, repeat previous steps to install
the other filter box.
Finishing Steps
Procedure 010-129.
Air Leaks, Air Intake and Exhaust Systems QSK45 and QSK60
Air Leaks, Air Intake and Exhaust

Systems (010-024)
Inspect for Reuse
CAUTION
The engine air intake must be filtered to prevent dirt
and debris from entering the engine. If intake air
piping is damaged or loose, unfiltered air can enter
the engine and cause premature wear.
Inspect the system for damaged or loose intake piping.
Replace damaged pipes.
Tighten loose clamps.
Stall speed is not full power.

Operate the engine at rated rpm and load.
Listen for a high-pitched noise from the turbocharger.
This type of noise can be caused by an air leak from the

following:
• Turbocharger-to-aftercooler air supply hose leak
• Air crossover-to-aftercooler connection leak
• Air crossover-to-intercooler connection leak
• Turbocharger-to-exhaust manifold gasket leak
• Turbine housing-to-bearing housing sealing surface
leak
• Compressor housing-to-bearing housing sealing
surface leak.
If a turbocharger-to-aftercooler air supply hose leak is
found, inspect the hose for damage.
Replace damaged hose. Refer to Procedure 010-008.
QSK45 and QSK60 Air Leaks, Air Intake and Exhaust Systems
If a air crossover-to-aftercooler connection leak is found,

replace the air crossover gasket.
If a air crossover-to-intercooler connection leak is found,

inspect for damaged hoses or loose hose clamps.
Replace damaged hoses.
Tighten loose clamps.
If a turbocharger-to-exhaust manifold gasket leak is found,

replace the turbocharger base gasket.
If a turbine housing-to-bearing housing sealing surface

leak is found, tighten any loose capscrews.
If an air leak is still present, replace the turbocharger.
If a compressor housing-to-bearing housing sealing

surface leak is found, tighten the V-band clamps.
If an air leak is still present, replace the turbocharger.
Pressure Test
On-Engine Repair
• Remove the turbocharger heat shield if required,
refer to Procedure 010-076
• Remove the exhaust manifold heat shield if required,
• Remove the air inlet piping from the turbocharger,
• Remove the exhaust outlet piping from the
turbocharger, refer to Procedure 010-033.
CAUTION
personal injury.
Check the condition of the seals prior to installing the
exhaust manifold leak tester, Part Number 4918234.
Replace seals if necessary.
With the turbocharger on the engine, install the clamp with
the two seals centered over both sides of the
turbocharger's air inlet and exhaust outlet connections.
Tighten the wing nut until the clamp seals are slightly
compressed on the turbocharger inlet and outlet.
Connect the shop air hose (1) to the inlet air pressure
regulator (2). Verify the air pressure regulator, Part
Number 3164231, is at 0 kPa [0 psi] before continuing.
Connect the hose to the fitting on the turbocharger's
exhaust outlet side of the exhaust manifold tester.
NOTE: The pressure will decrease slowly due to open

valves in the combustion chamber.
Slowly adjust the air pressure regulator until the gauge
indicates 69 kPa [10 psi] maximum pressure.
Spray a soap and water mixture onto the turbocharger's

exhaust manifold mounting area. Check for bubbles, if
bubbles are present, replace the turbrocharger-mounting
gasket. Refer to Procedure 010-034.
NOTE: Small amounts of bubbles are acceptable. These

will seal during the engine operation as the bellows
expand at operating temperature.
Spray a soap and water mixture onto the exhaust bellows.
Check for bubbles, if large bubbles exist, tighten the
exhaust bellow clamp(s) and repeat the pressure test
procedures.
If large amounts of bubbles still exist, replace the exhaust
bellow gasket(s). Refer to Procedure 011-007 and repeat
the pressure test procedures.
For engines with exhaust bellows, spray a soap and water

mixture onto the cylinder head next to the exhaust
manifold gasket mounting area and surrounding exhaust
system components.
Check for bubbles, if bubbles exist, replace the gasket(s).
Refer to Procedure 011-007 and repeat the test
procedures.

mixture on the exhaust manifold adapter gasket and
mounting area.
If large amounts bubbles exist, replace the exhaust
manifold adapter gasket. Refer to Procedure 011-007 and
repeat the test procedures.
Make certain that the air pressure regulator is set at 0 kPa

[0 psi] before removing the clamp, air pressure regulator,
and hose.
Remove the shop hose (1) from the inlet air pressure
regulator.
Remove the hose from the fitting on the exhaust manifold
tester (2).
Remove the clamp from the turbocharger.
• Install the exhaust outlet piping to the turbocharger,

• Install the air inlet piping to the turbocharger, refer
to Procedure 010-130
• Install the exhaust manifold heat shield if required,
• Install the turbocharger heat shield if required, refer
Pressure Test
Off-Engine Repair
• Remove the turbocharger, refer to Procedure
010-033.
With the turbocharger removed, locate the correct

mounting pattern on the pressure test plate (1) and the
rubber seal (2) from the exhaust manifold leak test kit, Part
Number 4918187.
Install the rubber seal and the pressure test tool plate onto
the exhaust manifold mounting flange. Install the
approbate hardware to hold down the pressure test plate
and rubber seal to exhaust manifold. Tighten the
capscrews.
CAUTION
personal injury.
Connect the shop air hose (1) to the inlet air pressure
regulator (2). Verify the air pressure regulator, Part
Number 3164231, is at 0 kPa [0 psi] before continuing.
Connect the hose to the fitting on the turbocharger's
exhaust outlet side of the exhaust manifold tester.
NOTE: The pressure will decrease slowly due to open
valves in the combustion chamber.
Slowly adjust the air pressure regulator until the gauge
indicates 69 kPa [10 psi] maximum pressure.
NOTE: Small amounts of bubbles are acceptable. These

will seal during the engine operation as the bellows
expand at operating temperature.
Spray a soap and water mixture onto the exhaust bellows.
Check for bubbles. If large bubbles exist, tighten the
exhaust bellow clamp(s) and repeat the pressure test
procedures.
If large amounts of bubbles still exist, replace the exhaust
bellow gasket(s). Refer to Procedure 011-007 and repeat
the pressure test procedures.

mixture onto the cylinder head next to the exhaust
manifold gasket mounting area and surrounding exhaust
system components.
Check for bubbles. If bubbles exist, replace the gasket(s),
refer to Procedure 011-007 and repeat the test
procedures.
Air Intake Restriction QSK45 and QSK60
On engines with exhaust bellows and exhaust manifold

adapter gaskets, spray a soap and water mixture
surrounding the mounting area.
If large amounts bubbles exist, replace the exhaust
manifold adapter gasket. Refer to Procedure 011-007 and
repeat the test procedures.
Make certain that the air pressure regulator is set at 0 kPa

[0 psi] before removing the clamp, air pressure regulator,
and hoes.
Remove the shop hose (1) from the inlet air pressure
regulator (2).
Remove the hose from the fitting on the pressure test tool
plate (3).
Remove the rubber seal, pressure test plate, capscrews,
and nuts from exhaust manifold mounting flange.
• Install the turbocharger, refer to Procedure 010-033
Air Intake Restriction (010-031)

Measure
The gauge adapter (or fitting) must be installed at a 90-
degree angle to the airflow in a straight section of pipe.
The adapter location must be at least one pipe diameter
before the turbocharger.
The adapter must not extend through the wall of the air
intake tubing.
If the adapter must be located in a curved section of
tubing, locate it on the flat side of the curve, not in the
radius.
Install the gauge adapter.
QSK45 and QSK60 Air Intake Restriction
Install a manometer in the intake piping between the

turbocharger and the air filter. The gauge must have a
capacity of 93 mm H 2O [25 in H 2O].
Stall speed is not full power. Operate the engine at rated

rpm and load.
Operate the engine at full throttle and rated rpm with
maximum load. Record the reading of the gauge or
manometer.
Maximum Operating Air Restriction - Dirty Air Filter

mm H2O in H2O
635 MAX 25
If the restriction exceeds specifications, replace or clean

the air filter element. Refer to the OEM's instructions.
Inspect the intake air piping for damage; refer to the

OEM's instructions.
If damage is not visible, check the size and routing of the
intake air piping; refer to the Installation
Recommendations.
Turbocharger QSK45 and QSK60
Turbocharger (010-033)
This procedure can be easily done on the QSK45 engine,
but it can involve much more time and/or cost with QSK60
engines.
Add 1 unit of fluorescent tracer, Part Number 3376891, to
each 38 liters [10 gal] of engine lubricating oil.

Allow the turbocharger to cool, and remove the exhaust

pipe from the turbine housing.
QSK45 and QSK60 Turbocharger
Use a high-intensity black light, Part Number 3824524 or

3824754, to inspect the turbine housing outlet for oil.
A dark blue glow indicates fuel slobber, and a yellow glow
indicates oil carryover.
The coolant temperature needs to be maintained at a

minimum of 71°C [160°F].
If fuel is found in the turbine housing, the problem is
excess, unburned fuel. To correct the problem, decrease
the idle period, or increase the idle rpm.
If oil is found in the turbine housing, disconnect the oil

drain tube from the cylinder block.
Disconnect the oil drain tube from the turbocharger.

Remove any support clamps and the hose.
Remove and discard the o-ring gasket.
Clear any restrictions found in the hose.
Discard the hose if it is cracked, frayed, or will not bend
without cracking.
Check the angle of the drain tube. The angle of the tube
must be within 35 degrees of vertical. Adjust the
turbocharger, if necessary.
If the drain tube is free of restrictions and at the correct

angle, check the crankcase breather and tube to verify
they are not plugged or restricted.
Check the turbocharger axial clearance and radial

clearance. Refer to the Inspect for Reuse step in this
procedure.
Install exhaust pipe into turbine housing.

If these checks do not reveal the problem, measure the
crankcase (blowby). Refer to Procedure 014-005.

This procedure can be easily done on the QSK45 engine,
but it can involve much more time and/or cost with QSK60
engines.
Add 1 unit of fluorescent tracer, Part Number 3376891, to
each 38 liters [10 gal] of engine lubricating oil.

Allow the turbocharger to cool, and remove the exhaust

pipe from the turbine housing.
Remove the aftercooler heat shields. Refer to Procedure
010-129.
Remove the turbocharger heat shields. Refer to
Procedure 010-076.
Use a high-intensity black light, Part Number 3824524 or

3824754, to inspect the turbine housing outlet for oil.
A dark blue glow indicates fuel slobber, and a yellow glow
indicates oil carryover.
The coolant temperature needs to be maintained at a

minimum of 71°C [160°F].
If fuel is found in the turbine housing, the problem is
excess, unburned fuel. To correct the problem, decrease
the idle period, or increase the idle rpm.
If oil is found in the turbine housing, disconnect the oil

drain tube from the cylinder block.
Disconnect the oil drain tube from the turbocharger.

Remove and discard the o-ring gasket.
without cracking.
Check the angle of the drain tube. The angle of the tube
must be within 35 degrees of vertical. Adjust the
turbocharger, if necessary.

angle, check the crankcase breather and tube to verify
they are not plugged or restricted.
Check the turbocharger axial clearance and radial

clearance. Refer to the Inspect for Reuse step in this
procedure.
Install exhaust pipe into turbine housing.

Install the turbocharger heat shields. Refer to Procedure
010-076.
Install the aftercooler heat shields. Refer to Procedure
010-129.
crankcase (blowby). Refer to Procedure 014-005.
Inspect for Reuse

NOTE: The configuration illustrated is similar to the
QSK45 engine. The same procedure is to be used for the
QSK60 and the QSK60 two-stage engines.
Remove the air intake piping from the turbocharger.
Remove the hose and two clamps between the air

crossover and the turbocharger.
Remove the clamp between the air crossover and the
aftercoolers or intercoolers.
Remove the air crossover.
Inspect the compressor discharge and air crossover

piping for oil.
If oil is in the compressor discharge or crossover piping,

check the axial clearance of the turbocharger.
Check the radial clearance of the turbocharger.
Check for intake restriction. Refer to Procedure 010-031.

Disconnect the oil drain hose from the cylinder block.

Remove and discard the o-ring seal (9).
Disconnect the oil drain hose from the turbocharger.

Remove and discard the o-ring gasket (5).
without cracking.
Check the angle of the drain tube.

The angle of the tube must be within 35 degrees of
vertical. Adjust the turbocharger, if necessary. Refer to
Procedure 010-034 for the high-pressure turbochargers
and Procedure 010-035 for the low-pressure
turbochargers.

angle, check the crankcase breathers and tubes to make
sure they are not plugged or restricted.

crankcase pressure (blowby). Refer to Procedure
014-005.
CAUTION
Cover all openings of the turbocharger to prevent
steam or solvent from entering the oil cavities. Steam
or solvent in the oil cavities can cause premature wear
and damage.
Clean gasket areas of the turbocharger.
Cover all openings of the turbocharger.
WARNING
WARNING
WARNING
personal injury.
Clean the exterior of the turbocharger with solvent or
steam.
Dry the turbocharger with compressed air.
Check the turbine and compressor impellers for fretting.

Check the vanes for cracks or other damage.
Repair or replace the turbocharger if the vanes are
damaged.
Measure the turbocharger shaft end clearance with a dial

indicator.
Turbocharger Shaft End Clearance

mm in
HX60 Turbocharger 0.051 MIN 0.002
0.152 MAX 0.006
HX82 and HX83 0.051 MIN 0.002
Turbochargers
0.125 MAX 0.005
If the turbocharger is not within specifications, repair or
replace the turbocharger.
The center housing rotating assembly is replaced as a
complete unit for HX83 turbochargers.
Push the compressor impeller end of the shaft toward the

housing.
Using a feeler gauge that is not more than 13 mm [0.5 in]
wide, measure the clearance between the impeller and the
housing at the minimum clearance point.
Perform the same measurement for the turbine wheel.
HX60 and HX82 Turbocharger Radial Bearing

Clearance
mm in
Compressor Impeller 0.15 MIN 0.006
0.45 MAX 0.018
Turbine Wheel 0.20 MIN 0.008
0.55 MAX 0.022
HX83 Turbocharger Radial Bearing Clearance

mm in
0.70 MAX 0.028
0.77 MAX 0.031
Using a dial indicator, check the turbocharger compressor

impeller radial movement.
Turbocharger Compressor Impeller Radial Movement

mm in
0.584 MAX 0.023
HX82 and HX83 0.485 MIN 0.019
Turbochargers
0.786 MAX 0.031
Disassemble
HX60 Turbocharger
Before disassembly, check the turbine impeller and
compressor impeller for damage.
Measure the bearing radial movement and axial clearance
to make sure the center housing rotating assembly is
within specifications.
Remove the compressor and turbine housings.
Always make sure the turbine wheel shaft and

compressor impeller is marked before disassembly of the
center housing rotating assembly.
If marks do not exist, scribe the shaft and compressor
impeller before removing the compressor impeller
locknut.
The cleaning process can remove indelible ink. A mark
filed on the shaft and a line scribed on the compressor
impeller nose is recommended.
Place the center housing rotating assembly on a suitable
fixture with a 19 mm 12 point socket on the turbine
impeller.
Using a 13 mm wrench turn the compressor impeller

locknut in a clockwise direction to remove it.
Remove the compressor impeller locknut.
Remove the compressor impeller.
It is permissible to tap the protruding turbine shaft gently

with a soft hammer if the split ring seals are stuck in the
bore.
Slide the center housing off of the turbine shaft.
WARNING
To reduce the possibility of personal injury, always
wear safety glasses when removing or installing a
sealing ring.
Do not score the turbine wheel or shaft when removing
the sealing rings.
Carefully remove the twin split sealing rings from the
turbine shaft.
Discard the sealing rings.
WARNING
snap ring.
Using snap ring pliers, remove the heat shield snap ring.
Remove the heat shield.
WARNING
snap ring.
With the bearing housing on a clean flat surface, use snap
ring pliers to remove the insert snap ring.
WARNING
Do not use excessive force when removing the oil seal
plate assembly. Fragments can break off at high
velocity. To reduce the possibility of personal injury,
always wear safety glasses when removing the oil seal
plate assembly.
Using a pair of pliers, remove the oil seal plate assembly.
If the oil seal plate is stuck in place, it is permitted to use
two screwdrivers positioned under the exposed lip to pry
out the seal plate assembly.
Remove the oil slinger from the oil seal plate.
Using a small screwdriver, release the oil baffle from the

oil seal plate.
Discard the oil baffle.
Remove the o-ring seal from the oil seal plate.

Discard the o-ring.
Remove the split ring seal(s) from the oil slinger.

Discard the split seal(s).
Remove the thrust bearing from the pin locations in the

housing.
Discard the thrust bearing.
Remove the thrust collar.

WARNING
snap ring.
Using snap ring pliers remove the snap ring from the
compressor side bearing bore.
Remove the journal bearing.
Remove the lower snap ring.
Discard snap rings and bearing.
WARNING
snap ring.
Turn the housing over.
Using snap ring pliers remove the snap ring from the
turbine side bearing bore.
Discard snap rings and bearing.
WARNING
snap ring.
Certain turbochargers can have a pressed steel baffle
fitted into the inlet section.
The baffle is not serviceable and must be replaced if
damaged.
Remove the baffle steel retaining ring and baffle.
HX82 Turbocharger
Scribe a line between the turbocharger compressor
housing and the center housing rotating assembly.
Scribe a line between the turbocharger turbine housing
and the center housing rotating assembly.
Place the turbocharger into a suitable vise.
Loosen the compressor V-band clamp nut.
Remove the compressor housing.
Remove the compressor V-band clamp.

CAUTION
Use care when handling the turbocharger when the
compressor housing is removed. The compressor
impeller blades can be easily damaged.
Use a hammer and chisel to bend the lock tabs away from
the capscrews.
Remove the capscrews and locking plates.
CAUTION
Never hit the compressor impeller. This can damage
the axial thrust system and severely damage the
blades of the compressor impeller.
Rotate the center housing rotating assembly in the turbine
housing.
If the center housing rotating assembly will not rotate in
the turbine tap the housing several times with a hammer
to loosen the center housing rotating assembly.
Separate the center housing rotating assembly from the
turbine housing.
Make sure the compressor impeller and shaft have

balance marks.
If balance marks do not exist, scribe the shaft and
compressor impeller nose before removing the locknut.
Remove the compressor impeller locknut.

Remove the compressor impeller.
Use care when removing the turbine shaft so the turbine

shaft is not scratched.
Remove the turbine shaft (1) and heat shield (2).
Remove the sealing ring on the turbine side of the shaft.
Remove the four diffuser mounting capscrews.

Remove the diffuser.
Remove the nozzle vane ring from the diffuser.

Remove the oil seal ring from the nozzle vane ring.
Remove the oil partition and the o-ring.
Remove the axial clearance adjustment shim.
Remove the axial thrust plate (1).

Remove the thrust ring (2).
Using a pair of snap ring pliers, remove the upper snap

ring.
Turn the housing over and repeat the process.
HX83 Turbocharger
complete assembly for the HX83 turbocharger.
Place the turbocharger in an appropriate vise.
Loosen the compressor V-band locknut.
CAUTION
Use care when removing the compressor housing.
The compressor impeller blades can be easily
damaged when the compressor housing is removed.
Carefully remove the compressor housing and V-band
clamp.
Use a hammer and a chisel to bend the lockplate tabs

away from the turbine housing capscrews.
Remove and discard the turbine housing capscrews and
lockplates.
CAUTION
Use care when separating the center housing rotating
assembly from the turbine housing. The turbine
blades can be easily damaged when the center
housing rotating assembly is separated from the
turbine housing.
Separate the center housing rotating assembly from the
turbine housing.
WARNING
WARNING
personal injury.
CAUTION
Do not bead blast an area of a component for a long
period of time. Bead blasting areas for a long periods
of time can affect the component balance.
Soak all of the components in a non-caustic metal cleaner
to loosen deposits.
Never use a wire brush or a metal scraper on any
turbocharger component.
On aluminum components a bristle brush can be used.
Dry the components with compressed air.
Bead blast the turbine housing if chemicals do not clean
it.
It can be necessary to bead blast the seal ring groove area
of turbine wheel using a low grade medium shot.
If bead blasting is required for any component the
cleaning process must be repeated.
The surface adjacent to the turbine and compressor
wheels on the stationary housings must be clean, smooth,
and free of deposits.
CAUTION
Do not attempt to straighten a bent shaft, premature
turbocharger failure can occur.
Place the turbine shaft on a vee block.
Set a dial indicator on the shaft.
Rotate the turbine wheel and check for movement on the
dial indicator.
Turbocharger Shaft Bend

mm in
0.025 MAX 0.001
If the turbine shaft is not within specifications, the turbine
Inspect the compressor and turbine impellers for nicks,

cracks, and blade tips for wear.
If an impeller is damaged it must be replaced.
Inspect the turbine shaft for wear or damage.
If turbine shaft is damaged it must be replaced.
Inspect the bearing journals for excessive scratches and

wear. Minor scratches are acceptable.
Measure the turbine bearing journal area.
Turbocharger Turbine Shaft Journals

mm in
If the turbocharger turbine shaft journals are not within
specifications, the turbocharger turbine shaft must be
replaced.
Inspect sealing ring groove for wear. The side of the walls
of the groove must be perpendicular with the shaft center
line.
Measure the sealing ring groove.
Turbocharger Turbine Shaft Sealing Ring Groove

Width
mm in
If the turbocharger turbine shaft sealing ring groove width
is not within specifications, the turbocharger turbine
CAUTION
Make sure the compressor and turbine impellers are
individually balanced. Failure to balance the impellers
can cause excessive vibration and premature
turbocharger failure.
Check the balance of the turbine shaft assembly to make
sure it is within specifications.
Turbine Shaft Balance Limits
Turbine Impeller End Compressor Impeller End
7.2 gmm [0.010 oz ins] 12.3 gmm [0.017 oz ins]
Mark the compressor impeller and shaft with to aid in

alignment during assembly.
Inspect the turbine housing for signs of turbine impeller

rub (1).
If any signs of turbine impeller rubbing are found the
turbine housing must be replaced.
Inspect the tapped holes for damaged threads (2).
Repair damaged threads or replace the turbine housing.
Check for signs of cracking or flaking caused by possible
overheating (3).
Replace turbine housing if cracked.
Check the flange for flatness.
Turbocharger Turbine Housing Flange Flatness

mm in
0.010 MIN 0.004
If the turbocharger turbine housing flange is not within
specifications, the turbocharger turbine housing must be
repaired or replaced.
Check the compressor housing for signs of the

compressor impeller rubbing.
If any signs of the compressor impeller rubbing are found,
replace the compressor housing.
Inspect the compressor impeller for bent or cracked

blades, or blades worn at the end.
Replace the compressor impeller if any damage is found.
Inspect the center housing for signs of wear or cracking in

the bearing bore and retaining groove area.
Replace the center housing if damaged.
HX60 Turbocharger
Inspect the journal bearing bores for wear and score
marks.
Replace the center housing if scratching is severe.
Measure the center housing bearing bore.
HX60 Turbocharger Center Housing Journal Bearing

Bore
mm in
22.27 MAX 0.877
If the turbocharger center housing journal bearing bore
is not within specifications, the turbocharger center
housing must be replaced.
Make sure the groove locations for the journal bearing
snap rings are free from deposits.
Measure the center housing journal bearing snap ring
groove width.
HX60 Turbocharger Center Housing Journal Bearing

Snap Ring Groove Width
mm in
1.25 MAX 0.049
If the turbocharger center housing journal bearing snap
ring groove width is not within specifications, the
turbocharger center housing must be replaced.
Make sure the oil cavity is free from carbon and debris that
can result in failure.
Make sure all oil port threads are clean and check with the
appropriate thread gauge.
Oil Port Threads

Oil Flanges Oil Adapter
M10 x 1.25 M16 x 1.5
Make sure all coolant port threads are clean.

Check the threads with a M18 x 1.5 thread gauge.
Measure the oil seal plate snap ring groove width.
Turbocharger Oil Seal Plate Retaining Ring Groove

Width
mm in
2.0 MAX 0.079
If the turbocharger oil seal plate retaining ring groove
width is not within specifications, the center housing
must be replaced.
Inspect the oil slinger sealing ring grooves for scoring or

other damage.
Replace the oil slinger if the sealing ring grooves are
damaged.
Measure the oil slinger sealing ring groove width.
Turbocharger Oil Slinger Sealing Ring Groove Width

mm in
1.70 MAX 0.067
If the turbocharger oil slinger sealing ring groove width
is not within specifications, the oil slinger must be
replaced.
Check for signs for of rubbing and scoring on the thrust
surface of the oil slinger.
Replace the oil slinger if damaged.
Checking the heat shield for signs of distortion, rubbing or

cracking.
Replace the heat shield if damaged.
Check the thrust collar for cracks and scoring on the thrust
face.
Replace the thrust collar if cracked or scored.
Check the baffle for damage.

The baffle is not serviceable and must be replaced if
damaged.
HX82 Turbocharger
Check the nozzle vane ring groove and wear and signs of
cracking.
Check the nozzle vane flat area for signs of friction.
Replace the nozzle vane ring if damage is found.
Check the diffuser bore for excessive wear or damage.

Replace the diffuser plate if damaged or excessively worn
Make sure the heat shield is not warped.

Check the heat shield for signs of rubbing.
Replace the heat shield if warped or damaged.
Assemble
HX60 Turbocharger
The turbocharger manufacturer can use a separate part
balance process. The turbine shaft balance must always
be checked when rebuilding the turbocharger.
The turbocharger turbine shaft will have marks on the end
of the turbine shaft and the compressor impeller nose.
The thrust collar and oil slinger will not have marks.
Only use a genuine Holset® compressor impeller and

turbine shaft which has been individually check balanced
for long life and quiet operation.
Components that are included in the turbine shaft balance
are:
• Turbine wheel and shaft
• Thrust collar
• Oil slinger
• Locknut.
Balance is achieved by rotating the components in a
purpose built balance rig and in compliance with the
balance rig procedure
Always make sure the balance marks on the turbine shaft

and compressor impeller are in alignment when rebuilding
the turbocharger.
WARNING
snap ring.
CAUTION
Make sure the snap ring is fitted into the center
housing with the beveled edge facing the journal
bearing. Premature turbocharger will result from
incorrect installation.
Place the center housing on a clean flat surface with the
compressor mating face down.
Use snap ring pliers to install the turbine side inner journal
bearing snap ring with beveled edge facing bearing.
Lubricate the journal bearing with clean engine oil and

install it into the center housing.
Lubricate the oil control sleeve with clean engine oil and
install it into the center housing.
WARNING
snap ring.
Use snap ring pliers to install the snap ring with the
bevelled edge facing the journal bearing.
Turn the center housing over and repeat the journal
bearing installation process for the compressor side.
WARNING
snap ring.
Install the heat shield.
Use snap ring pliers to install the heat shield snap ring.
WARNING
sealing ring.
Use ring expander pliers to install the new split ring seals
into the grooves on the turbine shaft.
Align the split ring seal so that the gap in the split rings
are 180 degrees apart.
Insert the shaft into the center housing journal bearings.
A slight rotation of the wheel will assist in locating the split
ring seals.
Make sure the turbine shaft rotates freely.
Support the turbine impeller in a suitable fixture.

Make sure all thrust contact faces are clean.
Install the thrust collar.
Apply clean engine oil to the installed thrust collar.

Install the thrust bearing onto its locating pins in the center
housing.
Apply a light coat of clean engine oil onto the oil seal plate.
Install a new o-ring onto the oil seal plate.
Install new split ring seals onto the oil slinger.
Lubricate the oil slinger with clean engine oil.

Insert the oil slinger into the oil seal plate.
Press fit the oil baffle into the oil seal plate.
Place the center housing rotating assembly on fixture

supporting the housing.
Install the oil seal plate into the center housing rotating
assembly.
Tap the oil seal plate with a soft hammer to seat it into
position.
Make sure the o-ring was not cut during the seal plate
insertion.
WARNING
snap ring.
Place a 19 mm 12 point socket onto the turbine impeller
and set the center housing rotating assembly on a fixture
supporting the socket.
Use snap ring pliers to install the snap ring, with the
chamfered side facing up, into the center housing rotating
assembly.
It can be necessary to lift the center housing rotating
assembly to fully expose the snap ring groove.
Use a soft hammer and drift to make sure the snap ring is
properly installed.
Align the balance marks on the compressor impeller and

turbine shaft.
Install the compressor impeller onto the turbine shaft.
Apply a coat of anti-seize to the compressor impeller

locknut face and turbine shaft threads to avoid loss of
alignment during installation of the locknut.
Thread the nut onto the shaft in a counterclockwise
direction.
Tighten the compressor impeller locknut.

CAUTION
Use care when installing the center housing rotating
assembly into the turbine housing. The turbine wheel
blades can be easily damaged.
Set the turbine housing on a clean flat surface.
Place the V-band clamp into position loosely on the turbine
housing.
Carefully slide the center housing rotating assembly into
the turbine housing.
Align the marks on the turbine housing to the center

housing rotating assembly.
Position the turbine V-band clamp on the center housing
rotating assembly and turbine housing.
Install a new locknut and tighten.
Check the turbocharger shaft end clearance.
HX60 Turbocharger Shaft End Clearance

mm in
0.152 MAX 0.006
Check the turbocharger radial bearing clearance.
HX60 Turbocharger Radial Bearing Clearance

mm in
0.15 MIN 0.006
0.45 MAX 0.018
CAUTION
Use care when installing the compressor housing
onto the turbocharger. The compressor impeller can
be easily damaged.
Place the turbocharger turbine housing on a flat clean
surface.
Place the compressor housing V-band clamp loosely onto
the center housing rotating assembly.
Carefully place the compressor housing over the
compressor impeller onto the center housing rotating
assembly.
Align the marks on the compressor housing to the marks

on the center housing rotating assembly.
Position the V-band clamp on the compressor housing and
center housing rotating assembly.
Install a new nut and tighten.

NOTE: Some turbochargers have a coating applied to the
internal surface of the turbine housing. This special
coating is abraded by the turbine impeller and can affect
turbocharger rotation until its unique form is fully formed.
HX82 Turbocharger
CAUTION
The snap ring must be installed with the chamfer side
of the snap ring facing the bearing. Premature failure
can occur if the snap rings are installed incorrectly.
Insert the inner snap ring, with the chamfer side facing the
bearing, into the turbine side of the center housing.
Lubricate the center rotating housing turbine side bearing

shell.
Lubricate the inside diameter of the bearing.
Place the bearing into the center housing.
CAUTION
The snap ring must be installed with the chamfer side
of the snap ring facing the bearing. Premature failure
can occur if the snap rings are installed incorrectly.
Insert the outer snap ring, with the chamfer side facing the
bearing, into the turbine side of the center housing.
Turn the center housing over and repeat the snap ring and
bearing installation for the compressor side.
Turn the center rotating housing over and install the

thermal shield.
Install a new sealing ring in the groove in the turbine shaft.
Lubricate the turbine shaft bore in the center housing with

clean engine oil.
Position the seal ring so the split is opposite the oil flow.
Lightly press on the turbine impeller while turning to aid in
installation of the turbine shaft.
CAUTION
Use care when positioning the axial thrust plate pins.
If crushing occurs replace the pins.
Set the turbine wheel in an appropriate support.
Use a pair of pliers to pull the axial thrust plate pins out to
an approximate height of 4.83 mm [0.19 in].
Use clean oil to lubricate the turbine shaft (1), thrust ring
(2), and the axial thrust plate (3).
Install the thrust ring (2) and the axial thrust plate (3) onto
the turbine shaft (1).
Install the adjustment shim with the letter T facing up.
Install the oil partition.

Install the sealing ring onto the diffuser plate nozzle vane.
Use clean engine oil to lubricate the nozzle vane sealing

ring.
Install the nozzle vane into the diffuser plate.
Use clean engine oil to lubricate the new o-ring.

Install the o-ring into the center housing rotating assembly
compressor side.
Place the diffuser plate on the center housing rotating

assembly and install the capscrews.
Tighten the capscrews in the sequence illustrated in the

graphic.
CAUTION
When using the original compressor impeller and
shaft, the alignment marks must line up to maintain
the balance. If the compressor impeller and turbine
shaft are not aligned vibration and premature
turbocharger failure will occur.
Install and align the compressor impeller onto the turbine
shaft.
Thread the locknut, flat side down, onto the turbine shaft
in a counterclockwise direction.
Tighten the locknut.
Place the center rotating housing assembly into the

turbine housing.
Align the scribe marks on the turbine housing
Apply a coating of anti-seize to the new turbine housing
capscrews.
Install the capscrews with new locking plates onto the
turbine housing.
Use a dial indicator to check the turbocharger end

clearance.
Turbocharger End Clearance

mm in
0.051 MIN 0.002
0.125 MAX 0.005
Use a dial indicator to check the compressor impeller

radial movement at the nose of the impeller.
Turbocharger Radial Movement

mm in
0.15 MIN 0.006
0.45 MAX 0.018
CAUTION
Use care when installing the compressor housing
onto the turbocharger. The compressor impeller can
be easily damaged.
Carefully install the compressor housing on the center
housing rotating assembly.
Align the scribe mark on the compressor housing with the

mark on the center housing rotating assembly.
Install and tighten the V-band clamp.
Use a hammer and chisel to bend the locking tabs over

the capscrews on the turbine housing.
HX83 Turbocharger
Install the center housing rotating assembly into the
turbine housing.
Apply anti-seize compound to the threads of the new
turbine housing capscrews.
Install the new lockplates and turbine housing capscrews.
Use a hammer and chisel to bend the lockplate tabs over

the turbine housing capscrews.
Loosely fit the V-band clamp over the center housing

rotating assembly.
Install the and align the compressor housing.
Tighten the V-band clamp.
CAUTION
Insufficient compressor impeller to compressor
housing clearance will cause serious engine damage.
Insert a tapered wire feeler gauge between the
compressor housing and compressor impeller.
Push the compressor impeller away from the compressor
housing and use the tapered wire feeler gauge to check
the clearance.
HX83 Turbocharger Compressor Impeller Radial

Bearing Clearance
mm in
0.15 MIN 0.006
0.70 MAX 0.028
CAUTION
Insufficient compressor impeller to compressor
housing clearance will cause serious engine damage.
Insert a tapered wire feeler gauge between the
compressor housing and compressor impeller.
Push the compressor impeller toward the compressor
housing and use the tapered wire feeler gauge to check
the clearance.
HX83 Turbocharger Compressor Impeller Radial

Bearing Clearance
mm in
0.15 MIN 0.006
0.70 MAX 0.028
CAUTION
Insufficient turbine impeller to turbine housing
clearance will cause serious engine damage.
Insert a tapered wire feeler gauge between the turbine
impeller and turbine housing.
Push the turbine impeller away from the turbine housing
and use the tapered wire feeler gauge to check the
clearance.
HX83 Turbocharger Turbine Impeller Radial Bearing

Clearance
mm in
0.20 MIN 0.008
0.77 MAX 0.031
CAUTION
Insufficient turbine impeller to turbine housing
clearance will cause serious engine damage.
Insert a tapered wire feeler gauge between the turbine
impeller and turbine housing.
Push the turbine impeller toward the turbine housing and
use the tapered wire feeler gauge to check the clearance.
HX83 Turbocharger Turbine Impeller Radial Bearing

Clearance
mm in
0.20 MIN 0.008
0.77 MAX 0.031
Turbocharger, High Pressure QSK45 and QSK60
Turbocharger, High Pressure

(010-034)
Preparatory Steps
WARNING
WARNING
WARNING
WARNING
008-018.
Procedure 010-129.
• Remove the turbocharger inlet connections. Refer to
Procedure 010-130.
Procedure 010-076.
Remove
Loosen the hose clamps on the hose between the air
crossover and the turbocharger.
Slide the hose down the turbocharger outlet.
NOTE: Do not disconnect the air crossover from the
aftercooler.
QSK45 and QSK60 Turbocharger, High Pressure
QSK60 Two Stage

High-pressure turbochargers are used on all QSK45 and
QSK60 engines and are mounted directly to the exhaust
manifold. The QSK45 engine uses two turbochargers and
the QSK60 engine uses four turbochargers. The QSK60
two-stage engine also has four low-pressure
turbochargers.
Removal of a high-pressure turbocharger on a QSK60
two-stage engine often requires the removal of low-
pressure turbochargers and/or other components.
Determine which of the four high-pressure turbochargers

to remove.
• Left-bank rear
• Right-bank front
• Left-bank front
• Right-bank rear.
Left-Bank Rear or Right-Bank Front

The left-bank rear and right-bank front turbochargers are
located under the low-pressure turbochargers.
Remove the low-pressure turbocharger directly above the
high-pressure turbocharger requiring removal. Refer to
Procedure 010-035.
Disconnect the oil supply line.

Make sure the o-ring is in the correct location and has
not been damaged.
Remove the two capscrews (1).

Disconnect the oil drain line (2) from the turbocharger (3).
Discard the gasket (4).
without cracking.
Disconnect the coolant supply hose (2) and coolant return

hose (1) from the turbocharger.
The coolant supply hose (2) is at the bottom of the
turbocharger bearing housing, and the return hose (1) is
on the topside of the turbocharger bearing housing.
Loosen the two hose clamps on the hose between the

turbocharger inlet and the intercooler.
Slide the hose toward the turbocharger.
Remove the V-band clamp at the bellows to the turbine

side of the turbocharger.
QSK45 Single Stage

Loosen the clamps between the turbocharger outlet and
the air-crossover-to-aftercooler connection.
Slide the hose and clamps up the air crossover.
QSK60 Two Stage

Loosen the clamps between the turbocharger outlet and
the air-crossover-to-aftercooler connection.
Slide the hose and clamps up the air crossover.
WARNING
Note the position of the spacers and direction of the
capscrews for reassembly.
Remove the four capscrews (3), spacers (5), and flange
nuts (4).
Remove the turbocharger (2) and gasket (1).
Discard the gasket (1), capscrews (3), and flange nuts (4).
Left-Bank Front or Right-Bank Rear

The left-bank front and right-bank rear turbochargers are
located under the exhaust outlet connection and require
removal of the exhaust outlet and mounting base.
Remove the exhaust outlet and mounting base.
Remove the four capscrews from each end of the top

cross support brace (1) between the two exhaust outlet
connections (2).
Remove the top cross support brace (1).
Remove the three capscrews (3) from each end of the two
inboard support struts (4).
Remove the seven capscrews from each of the support

braces between the exhaust outlet mounting base and the
two-stage frame.
Remove the support braces.
Loosen the clamps on the hose between the low-pressure

turbocharger and the intercooler intake crossover.
Slide the hose and clamps onto the air crossover.
Remove the 12 capscrews connecting the intercooler

intake crossover to the intercooler.
Disconnect, at the turbocharger, the V-band clamps

connecting the bellows on the legs of the exhaust outlet
flange to the low-pressure turbochargers.
Disconnect the exhaust piping from the exhaust outlet

flange.
Remove the 30 capscrews connecting the exhaust outlet

flange mounting base to the two-stage frame.
WARNING
Remove the exhaust outlet flange and mounting base
from the two-stage frame.
WARNING
Note the position of the spacers and direction of the
capscrews reassembly.
nuts (4).
Discard the gasket (1), capscrews (3), and flange nuts (4).
Install
Check for Correct Component
Compare the assembly number (1) on the turbocharger
dataplate with the turbocharger specified in the Control
Parts List, Bulletin 3379133 (2).
The CPL number for each engine is listed on the engine's
dataplate (3).
Holset® turbochargers are used on the QSK45 and QSK60

engines. Refer to the data tag on the turbocharger to
determine the model.
NOTE: All turbocharger oil and water fittings are the flat-
face o-ring types of fittings. Make sure the o-ring is in place
before attaching the hose(s) to the fittings.
The Holset® turbocharger uses a 9/16-18 UNF, straight-
thread, o-ring type of oil supply fitting.
WARNING
CAUTION
Do not reuse old capscrews (3) or flange nuts (4).
Discard these components. Reusing these
components can contribute to exhaust leaks.
Apply an anti-seize compound to the mounting capscrews.
The word OUT or the raised gasket bead must be
positioned toward the turbocharger.
Install the gasket.
Do not install the turbocharger without spacers.
Install the turbocharger (2) and gasket (1) with four
capscrews (3), spacers (5), and flange nuts (4).
Tighten the flange nuts (4).
The turbocharger uses capscrews to attach the bearing

housing to the turbine housing.
Position the turbocharger drain tube. The drain tube
must be within 35 degrees of vertical. Turn the bearing
housing to align the tube, if necessary.
Bearing Housing Adjustment

Bend the lockplate off the capscrew heads.
Remove the capscrews to allow the bearing housing to
rotate.
Lift the compressor and bearing housing, rotate the
bearing housing, and align the drain tube and the
capscrew holes.
Apply anti-seize compound, Part Number 3824879, to the

capscrews.
Install the lockplates and capscrews.
Bend the lockplate tabs over the capscrews.
Install the oil drain tube and gasket.

Pour 50 to 60 cc [2.0 to 3.0 oz] of clean engine oil into the

turbocharger oil supply fitting.
Connect the oil supply hose.

Tighten the hose fitting.
Connect the coolant supply hose (1) and the coolant return
hose to the turbocharger (2).
Tighten the hose fittings.
The coolant supply hose (2) and the coolant return hose
(1) must be installed diagonally opposed to each other to
provide adequate coolant flow around the turbocharger
bearing.
Check the air-crossover-to-turbocharger alignment.

• Install the air crossover on the aftercooler.
• Look at the alignment between the crossover and the
turbocharger compressor outlet.
• Remove the crossover, and proceed with the
assembly if the alignment is correct.
• Proceed to the next step to adjust the compressor
housing if the alignment is not correct.
To adjust the turbocharger compressor housing

alignment:
• Loosen the V-band clamp.
• Turn the compressor housing to the correct
alignment.
• Tighten the clamp.
• Tap the clamp with a mallet, and tighten the clamp
again.
Install the hose and two hose clamps between the

turbocharger and the aftercooler inlet connection.
Tighten the clamps.
Connect the inlet piping to the turbocharger.

Tighten the clamps.
Connect the exhaust piping to the turbocharger.

QSK60 Two Stage

Determine which of the four high-pressure turbochargers
requires installation:
• Left-bank rear
• Right-bank front
• Left-bank front
• Right-bank rear.
WARNING
Apply an anti-seize compound to the mounting capscrews.
The word OUT or the raised gasket bead must be
positioned toward the turbocharger.
Install the gasket.
Do not install the turbocharger without spacers.
Install the turbocharger (2) and gasket (1) with four
capscrews (3), spacers (5), and flange nuts (4).
CAUTION
Do not reuse old capscrews (1) or flange nuts (2).
Discard these components. Reusing these
components can contribute to exhaust leaks.
Tighten the flange nuts (4).
Position the turbocharger drain tube. The drain tube

must be within 35 degrees of vertical. Turn the bearing
housing to align the tube, if necessary.
The turbocharger uses capscrews to attach the bearing
housing to the turbine housing.
Bearing Housing Adjustment

Bend the lockplate off the capscrew heads.
Remove the capscrews.
Rotate the bearing housing. Align the drain tube and the
capscrew holes.
Install the lockplates and capscrews.

Bend the lockplate tabs over the capscrews.
Install the oil drain tube and gasket.


Connect the oil supply line.

Connect the coolant supply hose (2) and the coolant return
hose (1) to the turbocharger.
Tighten the hose fittings.
NOTE: The remaining steps will vary according to which
turbocharger is being installed.
The coolant supply hose (2) and the coolant return hose
(1) must be installed diagonally opposed to each other to
provide adequate coolant flow around the turbocharger
bearing.
Left-Bank Rear or Right-Bank Front

Install the V-band clamp between the bellows and turbine
side of the turbocharger.
Install the hose and two clamps between the low-pressure

turbocharger outlet and the intercooler intake crossover.
Tighten the clamps.
Connect the intercooler intake air crossover located

between the low-pressure turbocharger and the
intercooler to the intercooler.
Tighten the 12 capscrews.
The left-bank rear and right-bank front turbochargers are

located under the low-pressure turbochargers.
Install the low-pressure turbocharger directly above the
high-pressure turbocharger being installed. Refer to
Procedure 010-035.
Left-Bank Front or Right-Bank Rear
WARNING
CAUTION
Care must be taken not to damage the bellows
mounted to the exhaust outlet flange while setting the
mounting plate in place.
Position the exhaust outlet flange and mounting base on
the two-stage frame.
Install the 30 capscrews connecting the exhaust outlet

mounting base to the two-stage frame.
Tighten the 30 mounting capscrews.
Connect the bellows on each leg of the exhaust outlet

flange to the low-pressure turbocharger outlet.
Tighten the V-band clamps.
Install the two support braces between the two-stage

frame and the exhaust outlet connection mounting base.
Tighten the seven capscrews on each support brace.
Install the top cross support brace (1) between the two
exhaust outlet connections (2).
Tighten the eight capscrews (3).
Install the two inboard support struts (4).
Tighten the three capscrews (3) at each end.
Connect the intercooler intake air crossover located

between the low-pressure turbocharger and the
intercooler to the intercooler.
Tighten the 12 capscrews.
Install the hose clamp connecting the intercooler intake air

crossover and the low-pressure turbocharger.
Install the exhaust piping on the exhaust outlet flange with

12 capscrews and nuts.
Turbocharger, Low Pressure QSK45 and QSK60
Finishing Steps
Operate the engine to the required coolant temperature

Operating Coolant Temperature: 71 °C [ 160 °F ]

Procedure 010-076.
• Install the turbocharger inlet connections. Refer to
Procedure 010-130.
Procedure 010-129.
• Operate the engine to the required coolant
Operating Coolant Temperature: 71 °C [ 160 °F ]
Turbocharger, Low Pressure (010-035)

Preparatory Steps
WARNING
WARNING
QSK45 and QSK60 Turbocharger, Low Pressure
Remove
The low-pressure turbochargers are used only on the
QSK60 two-stage engine configuration, and are mounted
to the two-stage frame assembly above the high-pressure
turbochargers.
Determine which of the four low-pressure turbochargers

requires removal. If it is a left bank-rear or right-bank front
turbocharger, loosen the clamps on the hose between the
turbocharger and the intercooler connection.
Disconnect the oil supply hose.

Verify the o-ring is in the correct position and has not been
damaged.
Remove the two oil drain line capscrews (1).

Remove the oil drain line (2) from the turbocharger (3).
Discard the hose if it is cracked, frayed or will not without
cracking.
Remove the inlet piping to the turbocharger.
Remove the V-band clamp between the exhaust bellows

and the turbocharger.
WARNING
Note the position of the spacers and direction of
capscrews for assembly.
nuts (4).
Check for Correct Component

Compare the assembly number (1) on the turbocharger
data plate with the turbocharger specified in the Control
Parts List, Bulletin 3379133 (2).
The CPL number for each engine is listed on the engine's
dataplate (3).
QSK45 and QSK60 Turbocharger, Low Pressure
Install
Holset® turbocharger(s) are used on the QSK45 and the
QSK60 engines. Refer to the data tag on the turbocharger
to determine the model.
All turbocharger fittings are the flat-face o-ring type. Make

sure the o-ring is in place before attaching the hose(s) to
the fittings.
The Holset® turbocharger uses a 9/16-18 UNF straight
thread, o-ring type of oil supply fitting.
WARNING
Install a new turbocharger gasket (1).
Install the turbocharger (2) with capscrews (3), spacers (5)
and flange nuts (4).
Install and tighten the V-band clamp between the exhaust

bellows and turbocharger.
Install the inlet piping and clamp to the turbocharger.

Tighten the clamp.
Install a new gasket (4) on the turbocharger oil drain line.

Lubricate the oil drain line mounting capscrews with anti-
seize compound, Part Number 3824879.
Install the drain line (2) and two drain line mounting
capscrews (1) to the turbocharger (1).
Tighten the turbocharger drain line mounting capscrews.

Make sure the o-ring is in the correct position and is not

damaged.
Install the oil supply hose.
QSK45 and QSK60 Turbocharger Coolant Hoses
Install the hose and two clamps between the low-pressure

turbocharger outlet and the intercooler intake crossover.
Tighten the clamps.
Finishing Steps
Fill the coolings system. Refer to Procedure 008-018.
Operate the engine to the required coolant temperature
Operating Coolant Temperature 71 °C [ 160 °F ]
Turbocharger Coolant Hoses (010-041)

Preparatory Steps
WARNING
WARNING
Remove
Single Stage
NOTE: The following steps for the coolant supply and
return hoses apply to all four high pressure turbocharger
locations.
Disconnect the coolant supply hose from the turbocharger
and the water manifold.
Remove the male union from the turbocharger and the
elbow from the water manifold.
Turbocharger Coolant Hoses QSK45 and QSK60
Disconnect the coolant return hose from the turbocharger

and the water transfer connection.
Remove the male union from the turbocharger and water
transfer connection.
NOTE: The following procedure to remove the air bleed

petcock is the same for the right front and the left rear high
pressure turbocharger locations.
1. Remove the petcock from the nut.
2. Remove the nut from the union.
3. Remove the union from the turbocharger.
Discard the o-ring.
Remove the coolant return hose (1) from both the water
transfer connections.
Remove both unions (2).
Remove the coolant return hose from the water transfer

connection and the thermostat housing.
Remove the union from the water transfer connection and
the elbow from the thermostat housing.
Remove the plug from the water transfer connection.

Discard the o-ring.
Two Stage
NOTE: The following steps for the coolant supply and
return hoses apply to all four high pressure turbocharger
locations.
Disconnect the coolant supply hose from the turbocharger
and the water manifold.
Remove the union fittings from the turbocharger and the
elbow fitting from the water manifold.
For the rear turbochargers, remove the p-clips securing

the rear turbocharger coolant lines to the two stage frame.
Remove the turbocharger coolant return lines from the
turbocharger and the manifold.
For the rear turbochargers, remove the union from the
turbocharger and the reducer and union from the
manifold. For the front turbochargers, remove the union
from the turbocharger and the elbow from the manifold.
Remove the clip securing the coolant return line at the left
bank front of the engine.
Remove the coolant return line from the side manifold to
the front center manifold on each side.
Remove the coolant return line from the center manifold
to the thermostat housing.
Remove the male unions and T-fitting from the manifolds.

Remove the elbow from the thermostat housing.
Remove the drain cock from the front center manifold.
Remove the capscrews securing each of the three

manifolds and the two stage frames.
Remove the manifolds.
Inspect for Reuse

Check the coolant supply and return hose for cracks.
Inspect the unions, elbows, T-fittings, reducer nuts, and
drain cocks for damage, stripped threads, and cracks.
Replace if damage is found.
Install
Single Stage
NOTE: The following steps are for the coolant supply and
return hoses and apply to all four high pressure
turbocharger locations.
Install the new o-ring on the supply and return union
fittings and install the fittings on the turbochargers.
Torque Value:
Turbocharger 72 N•m [ 52 ft-lb ]
Fittings
Install the new o-ring on the elbow fitting and install the
fitting into the water manifold.
Torque Value:
Water Manifold 72 N•m [ 52 ft-lb ]
Elbow
Install new face seal o-rings and connect the turbocharger
coolant supply hose between the turbocharger union and
the water manifold elbow.
Torque Value:
Hose
Install new o-rings on the male unions to the turbocharger

and water transfer connection and install.
Torque Value:
Male Unions 72 N•m [ 52 ft-lb ]
coolant return line between the turbocharger union and
the water transfer connection.
Torque Value:
Hose
Install a new face seal o-ring on the drain cock nut (3) and
install the nut.
Torque Value:
Drain Cock Nut 45 N•m [ 33 ft-lb ]
Apply thread sealant, Cummins Part Number 3375066, or
equivalent, to the drain cock (2). Install the drain cock into
the nut and tighten two turns from finger tight.
Install new o-rings on the remaining unions and install

them into the water transfer connection.
Torque Value:
Water Transfer 100 N•m [ 74 ft-lb ]
Connection
Unions
Install a new o-ring on the elbow fitting and install the

elbow fitting into the thermostat housing.
Install the new o-ring and install the male union into the
water transfer connection.
Torque Value:
Thermostat 100 N•m [ 74 ft-lb ]
Housing Elbow
and Union
Install a new face seal o-ring and connect the turbocharger
coolant return line between the water transfer connection
and the thermostat housing elbow.
Torque Value:
Line
Install a new o-ring on the unions (2) and install them into
the water transfer connections.
Torque Value:
Water Transfer 72 N•m [ 52 ft-lb ]
Union
coolant return line between the turbocharger and the
water transfer connections.
Torque Value:
Hose
Two Stage
Install the capscrews securing each of the three manifolds
to the stage frame.
Torque Value:
Manifold 45 N•m [ 33 ft-lb ]
Capscrews.
Install a new o-ring on the elbow and install it in the

thermostat housing.
Torque Value:
Thermostat 100 N•m [ 74 ft-lb ]
Housing Elbow
Install a new o-ring onto the T-fitting and install it into the
front center manifold.
Torque Value:
T-fitting 100 N•m [ 74 ft-lb ]
Install a new o-ring on each of the remaining large unions
and install them into the manifolds.
Torque Value:
Large Unions 100 N•m [ 74 ft-lb ]
Install a new o-ring onto the drain cock union and install it
into the front center manifold.
Torque Value:
Drain Cock 72 N•m [ 52 ft-lb ]
Union
Install a new face seal o-ring on the drain cock nut and
install the nut.
Torque Value:
Apply thread sealant, Cummins Part Number 3375066, or
equivalent, to the drain cock. Install the drain cock into the
nut and tighten two turns from finger tight.
Install new face seal o-rings on the coolant return line and
install it between the front center manifold T-fitting and the
thermostat elbow fitting.
Torque Value:
Line
install it between the front center manifold and the right
bank manifold.
Torque Value:
Line Right
Bank
install it between the front center manifold and the left
bank manifold.
Torque Value:
Line Left Bank
Install the clips securing the coolant return line to the two
stage frame.
Torque Value:
Line Clips 45 N•m [ 33 ft-lb ]
Install a new face seal o-ring on each of the reducers.

Install the reducers and nuts to the right and left bank
manifold unions.
Torque Value:
Reducers 80 N•m [ 60 ft-lb ]
Install new o-rings onto the male unions and install the
unions into the rear turbocharger drain ports.
Torque Value:
Turbocharger 72 N•m [ 52 ft-lb ]
Drain Port
Unions
Install new face seal o-rings and install the coolant return
lines between the rear turbochargers and the right and left
bank manifold reducers.
Torque Value:
Line
Install the four p-clips onto the two hoses installed.
Torque Value:
P-clip 45 N•m [ 33 ft-lb ]
Capscrews
Install new o-rings onto the turbocharger supply line
unions. Install the unions onto the turbochargers.
Torque Value:
Supply Line 72 N•m [ 52 ft-lb ]
Unions
Install new o-rings onto the turbocharger supply line

elbows. Install the elbows into the water manifold.
Torque Value:
Water Manifold 72 N•m [ 52 ft-lb ]
Elbows
Install new face seal o-rings and install the coolant supply
lines on the four high pressure turbochargers.
Torque Value:
Lines
Finishing Steps
QSK45 and QSK60 Turbocharger Oil Drain Line
Turbocharger Oil Drain Line (010-045)

Remove
Remove the capscrew securing the drain tube to the

engine block. Discard the o-ring.
QSK60 Two Stage

Remove the capscrew, nut, and p-clips securing the
turbocharger oil drain tube.

Turbocharger Oil Drain Line QSK45 and QSK60
Remove the capscrew securing the drain tube to the

engine block. Discard the o-ring.
WARNING
WARNING
WARNING
personal injury.
Use solvent to clean the turbocharger oil drain tube and
male union adapter elbow.
Inspect the turbocharger oil drain line to be sure it is not

bent, kinked, or damaged in any way.
Inspect the turbocharger drain line for obstructions.
Replace the drain line if any damage or restrictions are
found.
QSK45 and QSK60 Turbocharger Oil Drain Line
Install
Lubricate a new o-ring and install it on the end of the

Attach the turbocharger drain tube to the engine block
with the capscrew.
QSK60 Two Stage

Lubricate a new o-ring and install it on the end of the

Attach the turbocharger drain tube to the engine block
with the capscrew.
Turbocharger Oil Supply Line QSK45 and QSK60
Install the turbocharger oil drain line p-clip, bolt and nut.
Turbocharger Oil Supply Line

(010-046)
Remove
NOTE: The steps listed below applies to both banks of the
engine.
Remove the two capscrews and clamps from the oil supply
lines.
QSK45 and QSK60 Turbocharger Oil Supply Line
WARNING
WARNING
used engine oil can be a carcinogenic and cause
Disconnect the oil supply tube from the reducer (1) on the
flywheel housing. Discard the o-ring.
Disconnect the oil supply tube from the T-fitting (2).
Discard the o-ring.
Remove the oil supply tube (3).
Disconnect the turbocharger oil supply tube from the T-

fitting (1). Discard the o-ring.
Disconnect the oil supply tube from the male union (2).
Discard the o-ring.
Remove the oil supply line (3).
Disconnect the oil supply hose from the T-fitting and

discard the o-ring.
Remove the union from the top of the turbocharger and

discard the o-ring.
Disconnect the oil supply hose from the reducer and

union. Discard the o-ring.
Remove the capscrew securing the clamp to the engine

block.
Remove the two capscrews securing the braces to the

engine block. Remove the brace.
QSK60 Two Stage

NOTE: The steps listed below applies to both banks of the
engine.
Remove the two capscrews and clamps from the oil supply
lines.
Disconnect the oil supply tube from the reducer on the

flywheel housing. Discard the o-ring.
Disconnect the oil supply tube from the hose. Remove the
oil supply line and discard the o-ring.
Disconnect the oil supply hose from the union on the oil
supply manifold. Discard the o-ring.
Disconnect the p-clip securing the oil supply lines from the
manifolds to the turbochargers.
Disconnect the oil supply lines from the manifold and

Remove the oil supply lines from the turbocharger unions

and discard the o-rings.
Remove the male unions from the turbochargers and

Remove the elbow and unions from the oil supply

manifold. Discard the o-rings.
Remove the oil supply manifold by removing the two

capscrews.
WARNING
WARNING
Some solvent are flammable and toxic. Read the
WARNING
compressed air. Flying debris or dirt can cause
personal injury.
Clean the turbocharger oil supply lines and components
with solvent and dry with compressed air.
Inspect the turbocharger oil supply hoses for cracks,

damage, or restrictions. Replace the hose if damaged.
Inspect the p-clips. If damaged replace.
Inspect the turbocharger oil supply tubes for damage,

kinks, or restrictions. Replace if any damage is found.
Inspect the male unions for damage, cracks, and stripped

threads. Replace if damaged.
Inspect the oil supply line braces for cracks, damage, and
corrosion. Replace if damaged.
Inspect the oil supply manifold for cracks, damage,

corrosion and stripped threads. Replace if damaged.
Install
Attach the braces to the engine block with the capscrews.
Attach the clips to the engine using the capscrews.

Install new o-rings on the male unions and install them into
the turbochargers.
Install the T-fitting.

Install the oil supply line clamps.

Attach the oil supply tube to the reducer (1).

Install a new o-ring on the T-fitting (2) and attach the other
end of the oil supply tube (3) to the T-fitting.
Attach the oil line (3) to the union (2) on the turbocharger.
Install a new o-ring and attach the oil supply hose to the
T-fitting (1) union.
QSK60 Two Stage

Install the oil supply manifold.
Assemble the oil supply manifold by installing new o-rings

on the male unions and installing them into the supply
manifold.
Install the male union elbow into the oil supply manifold
by first positioning the locknut.
1. Locknut
2. Washer
3. O-ring.
Install new o-rings on the union elbow and apply a light

coat of clean engine oil to each o-ring.
Install the elbow union in the oil supply manifold until the
backup washer (1) contacts the port face.
Position the elbow union to align the connection to the

turbocharger oil supply line. Do not back off more than
one full turn.
Inspect to verify the o-ring is not pinched and backup

washer seats flat on the face of the port.
Use two wrenches to hold the male elbow in the desired
Install the assembled oil supply manifold to the engine

block with two capscrews.
the turbochargers.
Install the male union elbow into the oil supply manifold
by first positioning the locknut.
1. Locknut
2. Washer
3. O-ring.
Install new o-rings on the union elbow and apply a light

coat of clean engine oil to each o-ring.
Install the elbow union in the turbocharger until the backup

washer (1) contacts the port face.
Position the elbow union to align the connection to the
turbocharger oil supply line. Do not back off more than
one full turn.
Inspect to verify the o-ring is not pinched and backup

washer seats flat on the face of the port.
Use two wrenches to hold the male elbow in the desired
Install a new o-ring on the reducer and install it on the male
union.
Attach the oil supply line to the reducer.

Install the oil supply line clips.

Install a new o-ring and attach the union elbow to the oil
supply line.
Install a new o-ring onto each end of the oil supply hose
and install onto the elbow and oil supply manifold.
First Stage Turbochargers

Install a new o-ring and attach the oil supply line to the
union on the turbocharger.
Install a new o-ring on the union fitting on the oil supply

manifold and attach the oil supply hose.
Second Stage Turbochargers

On the right bank rear turbocharger, install a new o-ring
on the turbocharger union and attach the oil supply hose.
Install a new o-ring on the oil supply manifold and attach

the oil supply hose.
Attach the oil supply line p-clip.

On the right bank front turbocharger, install a new o-ring

on the turbocharger union and attach the oil supply hose.

On the left bank rear turbocharger, install a new o-ring on

the turbocharger union and attach the oil supply hose.


On the left bank front turbocharger, install a new o-ring on

the turbocharger union and attach the oil supply hose.


QSK45 and QSK60 Turbocharger Heat Shield
Turbocharger Heat Shield (010-076)

Preparatory Steps
Procedure 010-129.
• Remove the turbocharger inlet connection. Refer to
Procedure 010-130.
Remove
NOTE: Left-front and right-rear turbocharger heat shields
are similar, as well as, right-front and left-rear.
The following steps are for removing the left-front and
right-rear heat shields.
Remove the nine capscrews securing the turbocharger
heat shield to the exhaust cavity heat shield.
NOTE: If removing the heat shield bracket is not

necessary for repair, only remove the capscrews securing
the bracket to the heat shield. If the bracket is being
removed, note the location of the p-clip mounting for
assembly.
Remove six capscrews securing the rear heat shield
bracket.
Turbocharger Heat Shield QSK45 and QSK60
Remove the six capscrews securing the front heat shield

bracket.
The following steps are for removing the right-front and

left-rear heat shields.
Remove the eight capscrews securing the turbocharger
heat shield to the exhaust cavity heat shield.
NOTE: If removing the heat shield bracket is not

necessary for repair, only remove the capscrews securing
the bracket to the heat shield. If the bracket is being
removed, note the location of the p-clip mounting for
assembly.
Remove the six capscrews securing the rear heat shield
bracket.
Remove the six capscrews securing the front heat shield

bracket.
QSK45 and QSK60 Turbocharger Heat Shield
Install
The following steps are for installing the left-front and
right-rear heat shields.
Install the turbocharger heat shield.
Install and hand tighten all 12 heat shield bracket
capscrews.
Install the nine capscrews securing the turbocharger heat
shield to the exhaust cavity heat shield.
Tighten the six capscrews securing the rear heat shield

bracket.
Tighten the six capscrews securing the front heat shield

bracket.
The following steps are for installing the right-front and

left-rear heat shields.
Install the turbocharger heat shield.
Install and hand tighten all 12 heat shield bracket
capscrews.
Install the eight capscrews securing the turbocharger heat
shield to the exhaust cavity heat shield.
Turbocharger Heat Shield QSK45 and QSK60
Tighten the six capscrews securing the rear heat shield

bracket.
Tighten the six capscrews securing the front heat shield

bracket.
Finishing Steps
• Install the turbocharger inlet connection. Refer to
Procedure 010-130.
Procedure 010-129.
QSK45 and QSK60 Frame, Two-Stage Turbocharger
Frame, Two-Stage Turbocharger

(010-082)
Preparatory Steps
WARNING
WARNING
This procedure is designed to remove the two-stage
assembly from a QSK60 two-stage engine with a minimal
amount of disassembly and requires a minimum of 305-
mm [12-in] overhead clearance.
The approximate weight, after removal of suggested
components, is 885 kg [1951 lb].
008-018.
WARNING
WARNING
008-018.
• Remove the turbocharger oil supply lines. Refer to
Procedure 010-046.
• Remove the turbocharger oil return lines. Refer to
Procedure 010-045.
• Remove the turbocharger cooling hoses. Refer to
Procedure 010-041.
• Remove the intercooler assembly. Refer to
Procedure 010-083.
Frame, Two-Stage Turbocharger QSK45 and QSK60
Remove
With Mechanically Actuated Injectors
This procedure is designed to remove the two-stage
assembly from a QSK60 two-stage engine with a minimal
amount of disassembly and requires a minimum of 305-
mm [12-in] overhead clearance.
The approximate weight, after removal of suggested
components, is 885 kg [1951 lb].
It is a good practice to mark the location of all lines during
removal.
Disconnect the coolant lines from the thermostat housing.
Position the coolant lines aside.
Disconnect the air intake piping between the air filter(s)

and low pressure turbochargers.
Disconnect the air intake piping at the inlet side of each
turbocharger.
Remove the 12 exhaust outlet flange capscrews and nuts.

flange.
Remove the supports.

Remove the 12 capscrews connecting the air crossover to
the aftercooler cover.
Remove the clamps from the hose connecting the air
crossover to the high pressure turbocharger.
Remove the air crossover.
Disconnect the oil supply lines from the flywheel housing.
Disconnect the oil drain lines at the cylinder block for all
eight turbochargers.
Remove and discard the o-ring seal (9).

removal.
Disconnect the oil supply lines from each of the four high-
pressure turbochargers.
Disconnect the V-band clamp at the bellows on the turbine

side of the four high-pressure turbochargers.
Remove the 12 capscrews from each of the four

intercooler intake crossovers to the low-pressure
turbochargers.
Loosen the hose clamps on each end of the four air

connection hoses for the four intercooler intake
crossovers and the four low pressure turbochargers.
NOTE: The left rear low-pressure turbocharger
connection is shown. The other low-pressure turbocharger
connections are similar.
Loosen the two intake hose clamps each on the four high
pressure turbochargers and the two intercoolers.
Disconnect the hose clamp at the intercooler.
NOTE: The front intercooler water supply and return

connections are shown. The rear intercooler connections
are similar.
Disconnect the water supply and return piping from the
intercoolers.
Remove the capscrews from each of the four feet of the

intercooler.
Remove the lifting eye from the bracket between the

intercooler and the two-stage frame.
WARNING
the possibility injury, use a hoist or get assistance to
remove this assembly.
Install a 12 mm [0.47 in] lifting device in the top of the
intercoolers.
Remove the intercoolers.
Install the two lifting eyes on the two-stage frame.

Remove the four capscrews from the bracket connecting

the low temperature aftercooling housing to the two-stage
frame.
Remove the three capscrews from each of the two

brackets connecting the low temperature aftercooling
thermostat housing to the two-stage frame.
Remove the ten capscrews connecting the frame to each

of the three center support brackets.
Remove the two capscrews connecting each of the

outboard brackets to the two-stage frame.
WARNING
Connect the lifting straps to the two-stage frame lifting
eyes.
Remove the two-stage frame from the engine.

Disconnect the air intake piping between the air filter(s)
and low pressure turbochargers.
Disconnect the air intake piping at the inlet side of each
turbocharger.
Remove the 12 exhaust outlet flange capscrews and nuts.

flange.
Repeat the above for the exhaust on the opposite side of
the engine.
Remove the 12 capscrews connecting the air crossover to

the aftercooler cover.
Remove the clamps from the hose connecting the air
crossover to the high pressure turbocharger.
Remove the air crossover pipe.
Disconnect the V-band clamp at the bellows on the turbine

side of the four high-pressure turbochargers.
Remove the four capscrews from the bracket connecting

the low temperature aftercooling housing to the two-stage
frame.
Remove the three capscrews from each of the two

brackets connecting the low temperature aftercooling
thermostat housing to the two-stage frame.
Remove the nine capscrews connecting the frame to each

of the three center support brackets.
Remove the four capscrews connecting each of the

outboard brackets to the two-stage frame.
WARNING
eyes.
Remove the two-stage frame from the engine.

Two Stage
WARNING
WARNING
personal injury.
Steam clean the two-stage turbocharger frame and dry
Inspect the turbocharger frame for cracks and other
damage.
Repair or replace the turbocharger frame if cracked or
damaged.
Install
WARNING
eyes.
Position and align the two stage frame on the three center
support brackets on the engine.
Do not tighten the two-stage frame assembly capscrews

until all capscrews have been in the supports and
brackets.
Align the two-stage frame assembly capscrew holes with
the center support bracket capscrew holes.
Install the 10 capscrews connecting the two-stage frame
to each of the center support brackets.

the outboard support brackets.
Install the capscrews connecting the two-stage frame to
each of the outboard support brackets.

the two low temperature thermostat housing bracket
capscrew holes.
each of the two low temperature aftercooling thermostat
housing brackets.
Tighten all of the two-stage frame assembly mounting

capscrews.
Remove the lifting eyes from the two-stage frame.
WARNING
the possibility injury, use a hoist or get assistance to
remove this assembly.
intercoolers.
Install the Intercoolers.
Remove the lifting eye from the intercoolers.

Install the lifting eye onto the two-stage frame assembly.
Tighten the lifting eye capscrew.
Install the intercooler mounting capscrews.

Install the coolant supply and return piping onto the

intercoolers.
Install the low temperature aftercooling thermostat

housing coolant supply lines.
Install the four intercooler intake crossovers.

Install the hoses and clamps on the right-bank rear and

left-bank front high-pressure turbochargers.
Install the intake hoses and clamps on each of the four

high-pressure turbochargers.
Make sure the oil supply line o-ring is not damaged.

Install the oil supply lines on the four high-pressure
turbochargers and tighten the fittings.
Install new o-ring seals on all of the turbocharger oil drain

lines.
Install the oil drain lines into the cylinder block.
Tighten the oil drain line capscrews.
Make sure the oil supply line o-ring is not damaged.

Install the low-pressure turbocharger oil line to each low-
pressure turbocharger.
Connect the two oil supply lines at the flywheel housing.

Install the air crossover that connect the left bank front and
right bank rear high-pressure turbocharger to the
aftercoolers.
Install the clamps on the hose connections at the air
crossover to the high-pressure turbochargers.
Install the air crossover supports.

Install the V-band clamp and the exhaust bellows to the

turbocharger exhaust outlet flanges.
Tighten the V-band clamp nut.
Connect the intake pipping between the air filter(s) and the
low-pressure turbochargers at the inlet side of the
turbochargers.
WARNING
eyes.
Position and align the two stage frame on the three center
support brackets on the engine.
Do not tighten the two-stage frame assembly capscrews

until all capscrews have been in the supports and
brackets.
the center support bracket capscrew holes.
Install the nine capscrews connecting the two-stage frame
to each of the center support brackets.

the outboard support brackets.
each of the outboard support brackets.

the two low temperature thermostat housing bracket
capscrew holes.
each of the two low temperature aftercooling thermostat
housing brackets.
Tighten all of the two-stage frame assembly mounting

capscrews.
Connect the intake pipping between the air filter(s) and the
low-pressure turbochargers at the inlet side of the
turbochargers.
QSK45 and QSK60 Intercooler Assembly
Finishing Steps

• Install the intercooler assembly. Refer to Procedure
010-083.
• Install the turbocharger cooling hoses. Refer to
Procedure 010-041.
• Install the turbocharger oil return lines. Refer to
Procedure 010-045.
• Install the turbocharger oil supply lines. Refer to
Procedure 010-046.
Intercooler Assembly (010-083)

Preparatory Steps
WARNING
WARNING
Remove
removal.
Disconnect the coolant lines from the thermostat housing.
Position coolant lines aside.
Intercooler Assembly QSK45 and QSK60
Remove the 12 capscrews from each of the four

intercooler intake crossovers and the two intercoolers.

crossovers and the four low-pressure turbochargers.
NOTE: The left rear high-pressure turbocharger

connection is shown. The other high-pressure
turbocharger connections are similar.
Loosen the two intake hose clamps each on the four high-
pressure turbochargers and the two intercoolers.
Disconnect the hose clamp at the intercooler.

are similar.
intercoolers.
Remove the capscrews from each of the four feet of the

intercooler.
Remove the lifting eye from the bracket between the

intercooler and the two-stage frame.
WARNING
assistance to remove this assembly.
Install a M12 x 1.75 threaded eye bolt in the top of the
intercoolers.
Remove the intercoolers.
Inspect for Reuse

Inspect the intercooler assembly for cracks and
indications of coolant leakage.
Disassemble
Remove the petcock vent from the intercooler.
WARNING
or get assistance to remove this component.
Remove the 26 capscrews, intercooler cover, and
intercooler gasket from the intercooler housing.
Remove the air grommet from the air vent tube.
Remove the intercooler mounting bracket.

Remove capscrew (1), flange (2), pipe (4) and seal (3) from
each of the intercooler fittings (5).
Remove the capscrews (6), intercooler fittings (5), and
seals (7) from the intercooler housing (8) and intercooler
element (9).
WARNING
Remove the 22 capscrews (10) and the intercooler
element (9) from the intercooler housing.
Pressure Test
WARNING
conditions.
Plug one intercooler water tube with a hose that has a pipe
plug secured into one end it.
Attach an air line and a regulator to the remaining water
tube.
Apply air pressure and submerge the intercooler element
into a tank of water.
Inspect the intercooler element for leaks.
Do not attempt to repair a leaking intercooler element. If
an intercooler element has a leak, it must be replaced.
Assemble
WARNING
The intercooler element must be positioned on the
intercooler housing alignment dowels during installation.
Position the intercooler element (9) in the intercooler
housing (8) and install the 22 capscrews (10).

illustration.
Install the air grommet on the air vent tube.
Install the intercooler bracket and six capscrews.

WARNING
intercooler cover.
Position the intercooler gasket and cover on the
intercooler.
Install the 26 intercooler cover capscrews.
Slightly tighten the four capscrews near the air grommet
to hold the air grommet in position.

illustration.
Install the flange (2), seal (3), and pipe (4) in each of the
two intercooler fittings (5) with the capscrew (1).
Install the two intercooler fittings (5) with and seals (7) in
the intercooler (8) and element (9) with the capscrews (6).
Apply pipe sealant to the threads of the petcock.

Install the petcock vent on the intercooler.
Install
WARNING
assistance to remove this assembly.
Install the lifting eye to the top of the intercoolers.
Make sure the hoses from the intercooler to the high-
pressure turbochargers are aligned during installation.
Position the intercooler on the frame.
CAUTION
The intercooler air hoses contain glass fibers.
Installing a hose without first moving the intercooler,
and/or forcing the hose into position will damage the
glass fibers and cause premature failure.
Install the intake hoses and two clamps each on the four
high-pressure turbochargers.
CAUTION
Do not overtighten the clamps. Overtightening the
clamps will damage the hose and cause premature
failure.
The clamps must be positioned so that the edge of the
clamp is between 3 mm [0.125 in] and 6 mm [0.250 in]
from the inner edge of the bead. Clamps must not
overhang the edge of the hose.
Remove the intercooler lifting eye from the intercooler

housing.
Install the lifting eye mounting capscrews onto the two-
stage frame.
Install the intercooler mounting capscrews.

Position new o-rings on the coolant supply and return

piping.
Install the coolant supply and return piping into the
intercoolers.
Install and tighten the flange bolts if removed.
Install the LTA thermostat housing coolant supply line.

Tighten the fitting.
Install the four intercooler intake crossovers with 12

capscrews each.
Intercooler Element QSK45 and QSK60
Install the hoses and clamps on the four intercooler intake

crossovers and the low-pressure turbochargers.
Finishing Steps
Intercooler Element (010-084)

Preparatory Steps
WARNING
WARNING
Remove
CELECT™ or Centry™
NOTE: The front intercooler element removal procedure
is shown. The rear intercooler element removal procedure
is similar.
Remove the 12 capscrews each from four intercooler
intake crossovers and the two intercoolers.
QSK45 and QSK60 Intercooler Element

crossovers and the four low-pressure turbochargers.
Remove the four intercooler intake crossovers.
Remove the petcock vent from the intercooler.

are similar.
intercoolers.
Remove six capscrews from the bracket and intercooler.

WARNING
or get assistance to remove this assembly.
Install a 12-mm [0.47-in] lifting device in the top of the
intercooler.
Remove the 26 capscrews and the intercooler cover and
gasket from the intercooler.
Remove the air grommet from the air vent tube.
Remove one capscrew (1), flange (2), seal (3), and pipe (4)
each from two intercooler fittings (5).
Remove four capscrews (6), two intercooler fittings (5),
and seals (7) from the intercooler (8) and element (9).
WARNING
Remove the 22 capscrews (10) and the element (9) from
the intercooler (8).
Pressure Test
results.
Use a hose, plugged with a pipe plug, to plug one water
tube as shown.
Attach an air line and gauge to the remaining water tube.
Apply air pressure, submerge the intercooler element, and
check for leaks.
Do not attempt to repair a leaking element. If an element
has a leak, it must be replaced.
Install
WARNING
The intercooler element must be positioned on the
intercooler alignment dowels during installation.
Position the element (9) in the lower intercooler housing
(8) with 22 capscrews (10).
Tighten the capscrews in the pattern shown.

Install the air grommet on the air vent tube.

WARNING
Install a 12-mm [0.47-in] lifting device in the top of the
intercooler cover.
Slightly tighten the four capscrews near the air grommet
to hold the air grommet in position.
Position the intercooler gasket and cover on the
intercooler with 26 capscrews.
Tighten the capscrews in the pattern shown.

Install the flange (2), seal (3), and pipe (4) in each of two
intercooler fittings (5) with one capscrew (1).
Install the two intercooler fittings (5) and seals (7) in the
intercooler (8) and element (9) with four capscrews (6).
Install the bracket to the intercooler with six capscrews.

Apply pipe sealant to the threads of the petcock.

Install the petcock vent on the intercooler.

are similar.
Connect the water supply and return piping to the
intercoolers.
Install the four air connection hoses on the four intercooler

intake crossovers and the four low-pressure
turbochargers with two clamps each.
NOTE: The front intercooler element installation

procedure is shown. The rear intercooler element
installation procedure is similar.
Install the four intercooler intake crossovers and gaskets
on the two intercoolers with 12 capscrews each.
Aftercooler Heat Shield QSK45 and QSK60
Finishing Steps
Aftercooler Heat Shield (010-129)

Remove
Disconnect the latch on the front and rear turbocharger
heat shields supporting the top of the aftercooler heat
shield.
NOTE: There are two alignment pins. The two shields

must be separated from each other before removal.
Disconnect the latch connecting the front and rear
aftercooler heat shields.
Disconnect the latches on the bottom rail.
Install
Position the rear aftercooler heat shield on the bottom rail
first and latch to the rear turbocharger heat shield.
Then position front aftercooler heat shield on bottom rail
and latch to the front turbocharger heat shield using the
alignment pins.
Latch the bottom of both aftercooler heat shields to the
bottom rail.
QSK45 and QSK60 Turbocharger Inlet Connections
Turbocharger Inlet Connections

(010-130)
Preparatory Steps
Procedure 010-129.
Remove
Loosen the two hose clamps securing the turbocharger
inlet connection to the filter box and the compressor side
of the front turbocharger.
Remove the two capscrews securing the front
turbocharger inlet connection to the bracket on the front
turbocharger heat shield.
Remove the front turbocharger inlet connection.
Loosen the two hose clamps on the boot securing the rear
turbocharger inlet connection to the filter box.
Slide the boot completely onto the turbocharger inlet
connection.
Loosen the hose clamp securing the turbocharger inlet
connection to the rear turbocharger compressor and
remove the turbocharger inlet connection.
remove the other bank turbocharger inlet connection.
Install
Install the rear turbocharger inlet connection onto the rear
turbocharger inlet connection and onto the rear
turbocharger compressor flange and tighten hose clamp.
Slide the other boot onto the filter box flange and tighten
both clamps.
Turbocharger Inlet Connections QSK45 and QSK60
Install the turbocharger inlet connection onto the flanges

of the filter box and the compressor side of the front
turbocharger.
Install the two capscrews securing the right front
turbocharger inlet connection to the bracket on the right
front turbocharger heat shield.
Tighten the two hose clamps securing the turbocharger
inlet connection to the filter box and the compressor side
of the front turbocharger.
install the other bank turbocharger inlet connection.
Finishing Steps
Procedure 010-129.
QSK45 and QSK60
Section 11 — Exhaust System — Group 11 Page 11-a
Section 11 — Exhaust System — Group 11

Section Contents
Page
Exhaust Connection Pipe ................................................................................................................................11-2
Finishing Steps...............................................................................................................................................11-5
Install..............................................................................................................................................................11-4
Single Stage.................................................................................................................................................11-4
Two Stage....................................................................................................................................................11-4
Remove..........................................................................................................................................................11-2
Single Stage.................................................................................................................................................11-2
Two Stage....................................................................................................................................................11-2
Exhaust Connection Pipe (Turbocharger to Turbocharger) ...........................................................................11-5
Finishing Steps...............................................................................................................................................11-7
Install..............................................................................................................................................................11-6
Remove..........................................................................................................................................................11-5
Exhaust Manifold Heat Shield .......................................................................................................................11-24
Finishing Steps............................................................................................................................................. 11-32
Install............................................................................................................................................................11-27
Remove.........................................................................................................................................................11-24
Exhaust Manifold, Dry .....................................................................................................................................11-7
Finishing Steps............................................................................................................................................. 11-20
QSK45 Engines..........................................................................................................................................11-20
QSK60 Single Stage Industrial and Power Generation................................................................................11-21
QSK60 Two Stage......................................................................................................................................11-22
QSK45 Engines............................................................................................................................................11-7
QSK60 Single Stage Industrial and Power Generation..................................................................................11-7
Install............................................................................................................................................................11-12
QSK45 Engines............................................................................................................................................11-8
QSK60 Single Stage Industrial and Power Generation..................................................................................11-9
QSK60 Two Stage......................................................................................................................................11-10
Remove.........................................................................................................................................................11-10
Exhaust Restriction .......................................................................................................................................11-22
Measure........................................................................................................................................................11-22
Service Tools ...................................................................................................................................................11-1
Exhaust System..............................................................................................................................................11-1
QSK45 and QSK60
Page 11-b Section 11 — Exhaust System — Group 11

Section 11 — Exhaust System — Group 11 Page 11-1
Service Tools
Exhaust System
Repair Location.

Manometer
Used to measure exhaust restriction.
ST-1111-3
Anti-Seize Compound
Used to speed assembly and disassembly of studs, bolts, capscrews,
3824879 flanges, and fittings.

3375958
Nylon Lift Strap (1 in x 6 ft)

3375957
Exhaust Connection Pipe QSK45 and QSK60
Page 11-2 Section 11 — Exhaust System — Group 11
Exhaust Connection Pipe (011-001)

Preparatory Steps
• Remove the bolts securing the OEM exhaust
connection to the exhaust connection pipe. Refer to
the manufacturer's installation instructions.
• Repeat for the exhaust connection pipe on the other
bank.
Remove
Single Stage
NOTE: The same procedure is used on either side of the
exhaust connection pipe.
Remove the four capscrews and nuts securing the bellows
to the exhaust connection pipe (1). Discard the gasket.
WARNING
Remove the four capscrews securing the exhaust
connection to the rocker lever housings (2).
Remove the capscrews securing the exhaust connection
pipe to the rocker lever housings (3). Remove the exhaust
connection pipe.
Repeat for the other side.
Two Stage
Remove the four capscrews and nuts securing the bellows
to the exhaust connection pipe (1). Discard the gasket.
QSK45 and QSK60 Exhaust Connection Pipe
WARNING
Remove the seven capscrews and spacers securing the
exhaust connection pipe to the two stage frame (2).
Remove the exhaust connection pipe.
WARNING
WARNING
WARNING
Use solvent to clean the exhaust connection pipe.
Clean the exhaust connection pipe with a steam cleaner
to remove any remaining residue.
Inspect the exhaust connection pipe for any signs of
damage or deterioration.
If damage is found that will allow exhaust gas leakage,
replace the exhaust connection pipe.
Exhaust Connection Pipe QSK45 and QSK60
Install
Single Stage
WARNING
Install the four capscrews securing the exhaust
connection to the rocker lever housings (2).
Torque Value:
Exhaust 45 N•m [ 33 ft-lb ]
Connection to
Rocker Lever
Housing
Install the three capscrews securing the exhaust
connection pipe to the rocker lever housing (3).
Torque Value:
Connection to
Rocker Lever
Housing
Install a new gasket and the four capscrews and nuts

securing the bellows to the exhaust connection pipe (1).
Torque Value:
Connection to
Bellows
Two Stage
WARNING
Install the seven capscrews and spacers securing the
exhaust connection pipe to the two stage frame (2)
Torque Value:
Connection to
Frame
QSK45 and QSK60 Exhaust Connection Pipe (Turbocharger to Turbocharger)
Install a new gasket and the four capscrews and nuts

securing the bellows to the exhaust connection pipe (1).
Torque Value:
Connection to
Bellows
Finishing Steps
• Install the bolts securing the OEM exhaust
connection to the exhaust connection pipe. Refer to
the OEM installation instructions.
• Repeat for the exhaust connection pipe on the other
bank.
Exhaust Connection Pipe

(Turbocharger to Turbocharger)
(011-002)
Remove
Remove the four capscrews and spacers securing each of
the bellows to the exhaust connection pipe.
Remove the bellows and discard the gaskets.
WARNING
Remove the four capscrews securing the exhaust
connection pipe to the two stage frame.
Exhaust Connection Pipe (Turbocharger to Turbocharger) QSK45 and QSK60
WARNING
WARNING
cleaning, follow manufacturer's recommendations for
use. Wear goggles and protective clothing to reduce
the possibility of personal injury.
WARNING
Clean the exhaust connection pipe with solvent.
Clean the remaining residue on the exhaust connection
pipe with a steam cleaner.
Inspect the exhaust connection pipe for any signs of
damage or deterioration.
If damage is found that allows exhaust gas leakage,
replace the exhaust connection pipe.
Install
WARNING
NOTE: The exhaust connection pipe must be installed
with the outboard side marking facing the outboard side.
Install the four capscrews securing the exhaust
connection pipe to the two stage frame.
Torque Value:
Connection
Pipe to Frame
Install the four capscrews and spacers for each of the

bellows with a new gasket.
Torque Value:
Connection
Pipe to Bellows
QSK45 and QSK60 Exhaust Manifold, Dry
Finishing Steps
WARNING
• Install the low pressure turbochargers. Refer to
Procedure 010-035.
• Remove the low pressure oil drain lines. Refer to
Procedure 010-045.
• Remove the low pressure oil supply lines. Refer to
Procedure 010-046.
Exhaust Manifold, Dry (011-007)

General Information
QSK45 Engines
The QSK45 engine exhaust manifold is designed so that
all six cylinders on each bank are connected to a single
common outlet located near the center between number
3 and number 4 cylinders.
QSK60 Single Stage Industrial and Power Generation

The QSK60 engine exhaust manifold is designed as a
pulse-style with twin high-pressure turbocharging on each
bank. Each turbocharger serves four cylinders. The
turbocharger exhaust outlet feeds into a main exhaust
outlet for each bank.

The marine exhaust system used on the QSK60 marine
engine is designed with unique flanges.
The marine exhaust manifold side profile is shown in the
graphic.
Exhaust Manifold, Dry QSK45 and QSK60
The marine exhaust manifold bellows has a different

design than the industrial exhaust manifold bellows.
The marine exhaust manifold bellows is shown.
The exhaust manifold bellows gasket is located in the end

of the bellows.
The bellows will not seal without the gasket in place.
The graphic shows the marine exhaust manifold bellows

with the gasket fitted in place.
Preparatory Steps
QSK45 Engines
WARNING
Remove the two turbochargers. Refer to Procedure
010-034.
WARNING
Remove the four clamps and the exhaust connection.
WARNING
Remove the four turbochargers. Refer to Procedure
010-034.
WARNING
Procedure 010-129.
• Remove the turbocharger inlet connections. Refer to
Procedure 010-130.
Procedure 010-076.
• Remove the four clamps and the exhaust
connection.
• Remove the four turbochargers. Refer to Procedure
010-034.
Procedure 011-015.
QSK60 Two Stage
WARNING
Remove the two-stage platform. Refer to Procedure
010-082.
WARNING
Remove the high-pressure turbochargers. Refer to
Procedure 010-034.
Remove
CAUTION
The exhaust manifolds must be disassembled to
remove them from the engine. Failure to disassemble
the exhaust manifolds will result in exhaust manifold
bellows damage.
When removing the exhaust manifolds, remove one
section of the exhaust manifold at a time beginning from
either end of the manifold. Note the location and
orientation of each section during removal.
Remove the exhaust manifold mounting capscrew lock
tabs. Discard the lock tabs.
Remove the exhaust manifold mounting capscrews and
spacers.
Note the direction of the bellows. They must be installed

correctly for proper engine performance. If a directional
arrow is not visible, then mark the bellows. The open end
of the sleeve inside the bellows always points in the
direction of exhaust flow (toward the turbine inlet).
Remove the v-band clamp from either end of the bellows.
Remove the end section of the exhaust manifold.
Discard the manifold gaskets.
CAUTION
Never attempt to compress the exhaust manifold
bellows. Bellows compression can result in damage to
the bellows and an exhaust leak.
NOTE: It is not always necessary to remove all exhaust
manifold sections and bellows. Remove only those
components required.
Remove the v-band clamp and the bellows section from
the next section of the exhaust manifold.
Repeat the steps above until the required sections of the
exhaust manifold and bellows have been removed.
CAUTION
The exhaust manifolds must be disassembled to
remove them from the engine. Failure to disassemble
the exhaust manifolds will result in exhaust manifold
bellows damage.
When removing the exhaust manifolds, remove one
section of the exhaust manifold at a time beginning from
either end of the manifold. Note the location and
orientation of each section during removal.
Remove the exhaust manifold mounting capscrew lock
tabs. Discard the lock tabs.
Remove the exhaust manifold mounting capscrews and
spacers.
Note the direction of the bellows. They must be installed

correctly for proper engine performance. If a directional
arrow is not visible, then mark the bellows. The open end
of the sleeve inside the bellows always points in the
direction of exhaust flow (toward the turbine inlet).
Remove the v-band clamp from either end of the bellows.
Remove the end section of the exhaust manifold.
Remove the exhaust manifold bellows gaskets located on
either side of the bellows.
Discard the manifold gaskets.
CAUTION
Never attempt to compress the exhaust manifold
bellows. Bellows compression can result in damage to
the bellows and an exhaust leak.
NOTE: It is not always necessary to remove all exhaust
manifold sections and bellows. Remove only those
components required.
Remove the v-band clamp and the bellows section from
the next section of the exhaust manifold.
Remove the exhaust manifold bellows gaskets located on
either side of the bellows.
Repeat the steps above until the required sections of the
exhaust manifold and bellows have been removed.
WARNING
Use a steam cleaner to clean the exhaust manifold and
components.
Inspect the exhaust manifold components for cracks,
warps, or leaks at the joints.
Inspect the bellows for cracks or damage.
If any of the sections leak or are damaged, the manifold
section must be replaced.
Install
NOTE: The exhaust manifold for the QSK60 is shown. The
procedures for the QSK45 are similar.
The exhaust manifold must be assembled as it is being
installed.
Do not tighten the bellows clamps until all of the exhaust
manifolds are installed.
Apply anti-sieze compound, Part number 3824879, to the
exhaust mounting capscrews.
The exhaust manifold bellows are directional. Make sure
they are installed in the proper manner when installing the
exhaust manifold.
All exhaust manifold gaskets must be installed with the

bead toward the manifold.
Position the exhaust manifold mounting section gaskets
and the turbocharger mounting sections, right-bank
cylinders number 5 and 6, or left-bank cylinders number
3 and 4.
Install the exhaust manifold mounting spacers and

capscrews.
Center the exhaust manifold section front to rear.
Install the exhaust manifold lock plates on the capscrews.
Make sure the bellows are installed in the proper direction.

All of the bellows clamps must be installed with the clamp
screw toward the opposite bank of the engine, with the
screw pointing up.
Loosely install the bellows clamp and the bellows on the
manifold section just installed.
Position the gasket and the exhaust manifold section for

right-bank cylinders number 3 and 4, or left-bank number
5 and 6.

capscrews.
Install the exhaust manifold mounting capscrew lock
plates.
Install the bellows clamp.

Tighten the bellows clamps.
Ring dowels are used to locate and position the crossover

section.
Position the crossover exhaust manifold section to the
exhaust manifold section for right-bank cylinders number
7 and 8, or left-bank cylinders number 1 and 2.
Do not tighten the mounting capscrews.
Loosely install the bellows clamps and bellows to the ends

of the upper exhaust manifold section.
Position the crossover exhaust manifold section on top of

the exhaust manifold section for right-bank cylinders
number 3 and 4, or left-bank number 5 and 6.
Loosely install the bellows clamps and bellows to the
upper exhaust manifold section mounted to the
turbocharger mounting exhaust manifold section for right-
bank cylinders number 5 and 6, left-bank cylinders
number 3 and 4.
Do not tighten the bellows clamps.
Position the turbocharger mounting section of the exhaust

manifold and the gasket for right-bank cylinders 1 and 2,
left-bank cylinders 7 and 8.
Position the bellows clamp on the bellows and the
turbocharger mounting section.

capscrews.
Install the exhaust manifold capscrew lock plates.
Connect the bellows clamp.
Do not tighten the bellows clamp.
Position the end section of the exhaust manifold for right-

number 1 and 2.

capscrews.
Do not tighten the capscrews.
Tighten all exhaust manifold mounting capscrews that

have not been tightened.
plates on the remaining capscrews.
Make sure all of the bellows clamps are oriented with the
clamp screw toward the opposite bank of the engine with
the screw pointing up. This allows accessibility after
complete assembly.
Tighten all of the exhaust manifold bellows.

The exhaust manifold must be assembled as it is being
installed.
Do not tighten the bellows clamps until all of the exhaust
manifolds are installed.
Apply anti-sieze compound, Part number 3824879, to the
exhaust mounting capscrews.
The exhaust manifold bellows are directional. Make sure
they are installed in the proper manner when installing the
exhaust manifold.
All exhaust manifold gaskets must be installed with the

bead toward the manifold.
Position the exhaust manifold mounting section gaskets
and the turbocharger mounting sections, right-bank
cylinders number 5 and 6, or left-bank cylinders number
3 and 4.

capscrews.
Install the exhaust manifold lock plates on the capscrews.
Install the bellows gasket onto each end of the bellows.

Install the bellows in the proper direction
All of the bellows clamps must be installed with the clamp
screw toward the opposite bank of the engine, with the
screw pointing up.
Loosely install the bellows clamp and bellows on the
manifold section just installed.
Position the gasket and the exhaust manifold section for

right-bank cylinders number 3 and 4, or left-bank number
5 and 6.

capscrews.
plates.
Install the bellows clamp.

Tighten the marine application bellows clamps.
Ring dowels are used to locate and position the crossover

section.
Position the crossover exhaust manifold section to the
exhaust manifold section for right-bank cylinders number
7 and 8, or left-bank cylinders number 1 and 2.
Install the bellows gasket onto each end of the bellows.

Loosely install the bellows clamps and bellows to the ends
of the upper exhaust manifold section.
Position the crossover exhaust manifold section on top of

the exhaust manifold section for right-bank cylinders
number 3 and 4, or left-bank number 5 and 6.
Loosely install the bellows clamps and bellows to the
upper exhaust manifold section mounted to the
turbocharger mounting exhaust manifold section for right-
number 3 and 4.
Do not tighten the bellows clamps.
Position the turbocharger mounting section of the exhaust

manifold and the gasket for right-bank cylinders 1 and 2,
left-bank cylinders 7 and 8.
Position the bellows clamp on the bellows and the
turbocharger mounting section.

capscrews.
Install the exhaust manifold capscrew lock plates.
Connect the bellows clamp.
Do not tighten the bellows clamp.
Position the end section of the exhaust manifold for right-

number 1 and 2.

capscrews.
Do not tighten the capscrews.
Tighten all exhaust manifold mounting capscrews that

have not been tightened.
plates on the remaining capscrews.
Make sure all of the bellows clamps are oriented with the
clamp screw toward the opposite bank of the engine with
the screw pointing up. This allows accessibility after
complete assembly.
Tighten all of the marine application bellows clamps.
Finishing Steps
QSK45 Engines
WARNING
The QSK45 engine exhaust manifold is designed so that
all six cylinders on each bank are connected to a single
common outlet located near the center between number
3 and number 4.
Install the two turbochargers. Refer to Procedure 010-034.
WARNING
The QSK60 engine exhaust manifold is designed as a
pulse-style with twin high-pressure turbocharging on each
bank. Each turbocharger serves four cylinders. The
turbocharger exhaust outlet feeds into a main exhaust
outlet for each bank.
Install the exhaust connection and the four clamps.
WARNING
Install the four turbochargers. Refer to Procedure
010-034.
WARNING
Procedure 011-015.
• Install the four turbochargers. Refer to Procedure
010-034.
• Install the exhaust connection and the four clamps.
Procedure 010-076.
Procedure 010-130.
Procedure 010-129.
Exhaust Restriction QSK45 and QSK60
QSK60 Two Stage
WARNING
Install the high-pressure turbochargers. Refer to
Procedure 010-034.
WARNING
Install the two-stage platform. Refer to Procedure
010-082.
Exhaust Restriction (011-009)

Measure
Connect a pressure gauge in the exhaust piping. The
gauge must have a capacity of 160 mm Hg [6 in Hg].
The pressure gauge adapter, or fitting, must be installed

at a 90-degree angle to the exhaust flow in a straight
section of pipe. The adapter location must be a minimum
of 254 mm [10 in] after the turbocharger.
The adapter must not extend through the wall of the
exhaust tubing.
If the adapter must be located in a curved section of
tubing, locate it on the flat side of the curve, not in the
radius, or the measured valve will not be accurate.
Connect a 305 mm [12 in] piece of metal tubing between
the gauge adapter and the gauge hose. This will prevent
damage to the hose from extreme heat.
QSK45 and QSK60 Exhaust Restriction
Operate the engine at rated rpm and load; record the

manometer reading.
Exhaust Restriction - QSK45 and QSK60 Single Stage

and QSK60 Marine
mm Hg in Hg
75 MAX 3.0
Exhaust Restriction - QSK60 Two Stage

mm Hg in Hg
50 MAX 2.0
Stall speed is not full power.
If the exhaust restriction exceeds the specification,

inspect the exhaust piping for damage. Refer to the
OEM's instructions.
If damage is not visible, check the size and routing of the
exhaust piping. Refer to the installation recommendation
bulletin.

Exhaust Manifold Heat Shield QSK45 and QSK60
Exhaust Manifold Heat Shield

(011-015)
Preparatory Steps
WARNING
WARNING
Procedure 010-129.
• Remove the turbocharger inlet connection. Refer to
Procedure 010-130.
• Remove the air cleaner assembly. Refer to
Procedure 010-013.
Procedure 010-076.
Remove
Remove both turbocharger coolant supply lines (1).
Remove the junction block coolant supply lines (2) and the
associated hardware.
Remove the turbocharger oil supply lines (3).
Remove the four capscrews securing the oil supply tube
bracket (4).
Remove the oil supply tube.
Remove the support brackets securing the coolant
junction block and the junction block.
Loosen the clamp securing the rubber tee connections.

Remove the capscrews securing the aftercooler water
tube which connect the aftercooler to the exhaust
manifold heat shield.
QSK45 and QSK60 Exhaust Manifold Heat Shield
Remove the front exhaust cavity heat shield and front right
corner plate capscrews.
Remove the front exhaust cavity heat shield and the front
right corner plate.
Loosen the water outlet tube nut and remove the tube from
the back of the engine.
NOTE: If the exhaust cavity heat shield does not need to
be completely removed from the engine, the fitting does
not have to be removed. If exhaust cavity heat shield has
to be completely removed from the engine the fitting
must be removed.
Remove the right rear corner exhaust cavity heat shield
capscrews.
Remove the right rear corner exhaust cavity heat shield.
NOTE: It will possibly be necessary to loosen the exhaust

manifold capscrews to allow clearance with the
turbocharger heat shield.
NOTE: It will possibly be necessary to remove left bank
rocker covers numbers two, three, six, and seven to allow
for removal of the side exhaust cavity heat shields. If the
rocker covers are removed, use clean rags to prevent dirt
intrusion.
Remove the front and rear side exhaust cavity heat shield
capscrews, as well as necessary coolant piping.
Remove the front and rear side exhaust cavity heat shield.
NOTE: The opposite bank is similar. Use the same steps
to remove the opposite bank side exhaust cavity heat
shields.
Remove the remaining rear exhaust cavity heat shield

capscrews.
NOTE: Two of the rear exhaust cavity heat shield
capscrews are used in the turbocharger oil supply line.
Remove the rear exhaust cavity heat shield.
Remove the left and right bank exhaust manifold heat

shield capscrews.
There are four capscrews that have nuts located
underneath the left and right bank exhaust manifold heat
shield.
Remove the capscrews and nuts in the rear of the left and
right bank exhaust manifold heat shield capscrews.
WARNING
reduce the possibility of injury, use a hoist or get
The left bank exhaust manifold heat shield must be
removed before the right bank exhaust manifold heat
shield because there is a water retention cover that
overlaps the right bank exhaust manifold heat shield.
There are two M12 tapped holes that are available for
lifting eyes or slings.
Remove the left and right bank exhaust manifold heat
shields.
The front exhaust manifold heat shield support bracket

has tapped holes and is mounted on the right bank
number one and left bank number two rocker lever
housings.
Remove the capscrews and the front exhaust manifold
heat shield support bracket.
The rear exhaust manifold heat shield support bracket has

slotted holes and is mounted on the number eight right
and left bank rocker lever housings.
Remove the capscrews and the rear exhaust manifold
heat shield support bracket.
Install
When the front exhaust manifold heat shield support
bracket is installed onto the engine the slotted holes
must face toward the front of the engine.
Place the front exhaust manifold heat shield support
bracket onto rocker lever housings right bank one and left
bank two.
Install the four M10 x 25 mm capscrews through the
bracket and into the rocker lever housing.
Finger tighten the capscrews only.
When the rear exhaust manifold heat shield support

bracket is installed onto the engine the slotted holes
must face toward the rear of the engine.
Place the rear exhaust manifold heat shield support
bracket onto the number eight right and left rocker lever
housings.
Install the four M10 x 25 mm capscrews through the
exhaust manifold heat shield bracket and into the rocker
lever housings.
Finger tighten the capscrews only.
WARNING
reduce the possibility of injury, use a hoist or get
The right bank exhaust manifold heat shield must be
installed first because of the overlapping water retention
cover.
Make sure the water connections are facing towards the
front of the engine and the holes in the heat shield line up
with those on the right bank side supports, when installing
the right and left bank exhaust manifold heat shields.
Place the right bank exhaust manifold heat shield
(identified as heat shield with the smaller lip) onto the front
and rear heat shield support brackets.
Place the left bank exhaust manifold heat shield onto the
front and rear heat shield support brackets.
Install the four M10 x 70 mm capscrews that secure the

right and left bank exhaust manifold heat shields to the
front support bracket. Finger tighten the capscrews only.
Install the four M10 x 80 mm capscrews and nuts that
secure the right and left bank exhaust manifold heat
shields to the rear support bracket. Finger tighten the
capscrews only.
Install the exhaust cavity rear heat shield.

When installing the exhaust cavity rear heat shield
capscrews, thread in the capscrews, but do not tighten.
Thread the eight M10 x 25 mm upper exhaust cavity rear
heat shield capscrews into the exhaust manifold heat
shields.
Thread the three M10 x 25 mm lower exhaust cavity rear
heat shield capscrews into the engine block.
NOTE: The installation process is similar for the right and

left bank rocker lever housing exhaust cavity heat shields.
Install the right and left bank, number four and five rocker
lever housing exhaust cavity heat shields.
Configure the LTA connections for securing to the exhaust

manifold heat shields as shown in the graphic. Only one
S-tube is illustrated in the graphic.
Install the o-ring into the grooves on both ends of the S-
tubes.
Fit the wear sleeve over the end of each S-tube, just clear
of the o-ring beading.
Apply hellerine to the o-ring on the end with the free
moving flange and insert it into the triangular block
aligning the flange holes with the block holes.
Install the LTA connections to the exhaust manifold heat

shields.
Install the three M8 x 90 mm capscrews through the holes
in the flange and the triangular blocks for each
connection.
Hang the gasket over the three capscrew ends.
Press the thermostat housing, with the ports facing
towards the front of the engine, onto the exhaust manifold
heat shield S-tubes.
Tighten the six capscrews.
Install the front heat shield.

Install the nine capscrews that secure the exhaust
manifold heat shield to the top exhaust cavity heat shields
and the engine block. Finger tighten the capscrews only.
Install the right front corner plate and capscrews. Finger
tighten the capscrews only.
NOTE: The left bank rear side exhaust cavity heat shield
is shown in the graphic. The right bank front side exhaust
cavity heat shield is similar.
Install the left bank rear side exhaust cavity heat shield.
Install the two M10 x 25 mm capscrews. Finger tighten the
capscrews only.
Install the right bank front side exhaust cavity heat shield.
Install the M10 x 25 mm two capscrews. Finger tighten the
capscrews only.
NOTE: The right bank rear side exhaust cavity heat shield
is shown in the graphic. The left bank front side exhaust
cavity heat shield is similar.
Install the right bank rear side exhaust cavity heat shield
to the rocker lever housings.
Install the six M10 x 25 mm capscrews. Finger tighten the
capscrews only.
Install the left bank front side exhaust cavity heat shield to
the rocker lever housings.
Install the six M10 x 25 mm capscrews. Finger tighten the
capscrews only.
Install the right bank rear corner plate.

Install the five M6 x 12 mm capscrews.
Install the two M6 x 12 mm capscrews through the right
bank rear corner plate into the right bank rear side exhaust
cavity heat shield.
Install the left bank rear corner plate.
Install the five M6 x 12 mm capscrews.
Install the three M6 x 12 mm capscrews through the left
bank corner plate into the left bank rear side exhaust
cavity heat shield.
Align all brackets with the capscrews.

Tighten capscrews (1) through (5) on the rear heat exhaust
cavity heat shield in sequence.
Tighten the four exhaust manifold heat shield front

support bracket capscrews, (6) through (9) in sequence.
Tighten the four exhaust manifold heat shield rear support
bracket capscrews, (10) through (13) in sequence.
Tighten the remaining rear exhaust manifold heat shield

capscrews.
Tighten the left and right rear corner plate capscrews.

NOTE: Do not tighten the right front corner plate when

competing this step.
Starting at the rear of the engine, tighten all of the right
bank side exhaust cavity heat shield (1) capscrews, and
the right bank front and rear exhaust manifold heat shield
(2) support bracket capscrews.
Starting at the front of the engine, tighten all left bank side
exhaust cavity heat shield (3) capscrews, and the left bank
front and rear exhaust manifold heat shield support
bracket (4) capscrews.
Tighten the front exhaust cavity heat shield capscrews,

and front right corner plate capscrews.
NOTE: Opposite bank is similar, use the same steps to

install the opposite bank junction block and associated
hardware.
Install the junction block and mounting brackets.
Install the oil supply tube and bracket (4) and associated
mounting hardware.
Install and tighten the turbocharger oil supply lines (3).
Install and tighten the junction block coolant supply line
(2) and the associated mounting hardware.
Install and tighten both turbocharger coolant supply lines
(1).
Insert the aftercooler water tube into the rubber tee

connection and install the capscrews securing the tube to
the exhaust manifold heat shield.
Tighten the clamps securing the rubber tee connections.
Finishing Steps
Procedure 010-076.
• Install the air cleaner assembly. Refer to Procedure
010-013.
Procedure 010-130.
Procedure 010-129.
• Fill the engine with coolant. Refer to Procedure
008-018.
QSK45 and QSK60
Section 12 - Compressed Air System - Group 12 Page 12-a
Section 12 - Compressed Air System - Group 12

Section Contents
Page
Air Compressor ............................................................................................................................................. 12-11
Single Cylinder...........................................................................................................................................12-14
Twin Cylinder.............................................................................................................................................12-14
Finishing Steps............................................................................................................................................. 12-18
Install............................................................................................................................................................12-15
Single Cylinder...........................................................................................................................................12-15
Twin Cylinder.............................................................................................................................................12-16
Remove.........................................................................................................................................................12-12
Single Cylinder...........................................................................................................................................12-12
Twin Cylinder.............................................................................................................................................12-13
Air Compressor (Oil Carryover) .................................................................................................................... 12-22
Air Compressor Carbon Buildup .....................................................................................................................12-2
Initial Check....................................................................................................................................................12-2
Air Compressor Pin Bore Wear .......................................................................................................................12-4
Initial Check....................................................................................................................................................12-4
Air Compressor Unloader and Valve Assembly .............................................................................................12-7
Assemble........................................................................................................................................................12-9
Holset® QE230, QE296, and QE338 A/C Model............................................................................................12-9
Disassemble...................................................................................................................................................12-8
Holset® QE230, QE296, and QE338 A/C Model............................................................................................12-8
Finishing Steps............................................................................................................................................. 12-11
Initial Check....................................................................................................................................................12-7
Air Governor (Air Compressor Pumps Continuously) ..................................................................................12-19
Initial Check..................................................................................................................................................12-19
Air Governor (Air Compressor Will Not Pump) .............................................................................................12-18
Initial Check..................................................................................................................................................12-18
Air Leaks, Compressed Air System ..............................................................................................................12-21
Initial Check..................................................................................................................................................12-21
Air Starting Motor ..........................................................................................................................................12-23
General Information.......................................................................................................................................12-23
Service Tools ...................................................................................................................................................12-1
Compressed Air System..................................................................................................................................12-1
QSK45 and QSK60
Page 12-b Section 12 - Compressed Air System - Group 12

Section 12 - Compressed Air System - Group 12 Page 12-1
Service Tools
Compressed Air System
Repair Location.

Anti-seize Compound
Lubricant that speeds assembly and disassembly of studs, bolts,
3824879 capscrews, flanges, and fittings.
Standard Puller
Use to pull the drive gear. Use with puller capscrews that have M8 x
ST-647 1.25-6H thread.
Air Compressor Carbon Buildup QSK45 and QSK60
Page 12-2 Section 12 - Compressed Air System - Group 12
Air Compressor Carbon Buildup

(012-003)
Initial Check
There are several different air compressor options
available on the QSK45 and QSK60 engines.
NOTE: The illustrations shown are of the SS model single-
cylinder air compressor. Differences in procedures
between the other air compressor models will be shown
where necessary.
WARNING
personal injury.
Open the drain cock on the wet tank to release
compressed air from the system.
Remove the air inlet and outlet connections from the air
compressor.
Measure the total carbon deposit thickness inside the air

discharge line as shown.
The carbon deposit thickness must not exceed 1.6 mm
[0.06 in].
QSK45 and QSK60 Air Compressor Carbon Buildup
WARNING
The air discharge line must be capable of
withstanding extreme heat and pressure to prevent
personal injury and property damage. Refer to the
manufacturer's specifications.
If the total carbon deposit thickness exceeds specification,
remove and clean, or replace the air discharge line. Refer
to the manufacturer's material specifications.
WARNING
The air discharge line must be capable of
withstanding extreme heat and pressure to prevent
personal injury and property damage. Refer to the
Continue to check for carbon buildup in the air discharge
line connections up to the first connection, or wet tank.
Clean or replace all lines and fittings with carbon deposits
greater than 1.6 mm [0.06 in]. Refer to the manufacturer's
specifications for cleaning or replacement instructions.
CAUTION
Do not use a sharp object to remove carbon. The
sealing surfaces can be damaged.
Remove the air compressor head and valve assembly;
refer to the Master Repair Manual, Holset® Air
Compressors, Bulletin 3666121.
Clean the compressor head and valve assembly
components with solvent and a nonmetallic brush to
remove carbon.
Inspect the valve assembly components for reuse; refer to
the Master Repair Manual, Holset® Air Compressors,
Bulletin 3666121.
Assemble the air compressor using new gaskets and o-

rings; refer to the Master Repair Manual, Holset® Air
Install and tighten the air inlet and outlet connections.
Air Compressor Pin Bore Wear QSK45 and QSK60
Close the wet tank drain cock.

Operate the engine and check for air leaks.
Air Compressor Pin Bore Wear

(012-010)
Initial Check
WARNING
The unloader valve body is installed with spring
tension. Use care when removing to reduce the
possibility of personal injury. Always wear protective
eye wear.
NOTE: This procedure applies to SS and ST models
only.
Hold the unloader valve body down, and remove the two
captive washer capscrews and the two plain washers.
Remove the unloader valve body.
Remove the o-ring seal.
Remove the rectangular ring seal.
CAUTION
To avoid damage to the air compressor, do not allow
any debris to fall into the air compressor cylinder.
NOTE: Disassembly of the center unloader valve on
Holset® two-cylinder air compressors is similar to the
single-cylinder unloader valve.
Remove the unloader valve cap and the unloader valve
spring.
Remove the intake valve seat and valve.
Remove the intake valve spring.
QSK45 and QSK60 Air Compressor Pin Bore Wear
CAUTION
Do not use a screwdriver. A screwdriver can gouge
the top of the piston.
Insert the small end of a 3/8-inch drive socket extension
152 to 254 mm (6- to 10-inches long) through the exhaust
valve seat onto the top of the piston.
Bar the crankshaft over until the compressor piston

reaches top dead center and the extension starts to move
downward approximately 3 to 6 mm [1/8 to 1/4 in].
CAUTION
To prevent damage to the top of the piston, do not use
a hammer.
Give a quick, hard push downward on the extension, and
listen for a metallic click as wear clearance is taken up.
If significant piston motion is felt or a metallic click is

heard, the pin bores can be worn, and the compressor
must be examined further.
Air Compressor Pin Bore Wear QSK45 and QSK60
All air compressors will not exhibit pin bore wear.

If no motion or sound is heard, the compressor is in
satisfactory condition and does not need to be replaced.
Remove the extension.
Install the intake valve spring with the tang down.

Install the intake valve.
Install the intake valve seat with the flange side up.
Install the unloader valve cap spring.
Install the unloader valve cap.
Use high-temperature grease (Accrolube lubrication
Teflon grease, or equivalent) to lubricate the outside
diameter of the cap.
Install the rectangular ring seal with the grooved side up.
Install the o-ring seal.
Use clean engine oil to lubricate the o-ring seal.
Install the unloader valve body.
Press the unloader valve body down to be sure the tangs
of the unloader valve cap are in the three slots of the intake
valve seat.
QSK45 and QSK60 Air Compressor Unloader and Valve Assembly
CAUTION
Do not overtighten the unloader body capscrews.
Compressor damage will result.
Hold the unloader body down and install the two plain
washers and captive washer capscrews.
Air Compressor Unloader and Valve

Assembly (012-013)
Initial Check
WARNING
Air pressure must be released from system before
removing the air governor to reduce the possibility of
personal injury.
NOTE: The illustrations shown will be of the SS model
single-cylinder air compressor. Differences in procedures
for SS, QE, and ST model Holset® air compressors will be
shown where necessary.
Remove the air governor or air governor hose from the air
compressor unloader body.
Operate the engine to activate the air compressor.

If the air compressor is not pumping, the unloader valve
is malfunctioning and must be repaired or replaced.
Air Compressor Unloader and Valve Assembly QSK45 and QSK60
Disassemble
WARNING
tension. To reduce the possibility of personal injury,
always wear protective eye wear and use care when
removing the unloader valve body.
The following steps are for the Holset® SS, E-Type, and
ST models.
Hold the unloader valve body down, and remove the two
captive washer capscrews and the two plain washers.
Remove the unloader valve body.
Remove the o-ring seal.
Remove the rectangular ring seal.
NOTE: Disassembly of the center unloader valve on

Holset® two-cylinder air compressors is similar to the
single-cylinder unloader valve.
Remove the unloader valve cap and the unloader valve
spring.
Remove the intake valve seat and valve.
Remove the intake valve spring.
Holset® QE230, QE296, and QE338 A/C Model
WARNING
tension. To reduce the possibility of personal injury,
always wear protective eye wear and use care when
removing the unloader valve body.
Hold the unloader valve body down and remove the
capscrews.
Remove the unloader body, unloader cap and spring.

CAUTION
Do not use caustic cleaners. Caustic cleaners can
cause damage to component parts.
Remove all carbon and varnish from the unloader valve
cap body.
QSK45 and QSK60 Air Compressor Unloader and Valve Assembly
For Holset® two-cylinder air compressors, check both

cylinder and center unloader springs. Holset® Engineering
Co., Inc. recommends that new springs be installed during
rebuild.
Use a valve spring tester to check the unloader spring.
Refer to the Compressor Spring Force Specifications
chart in the Holset® Air Compressor Master Repair
Manual, Bulletin 3666121.
Replace the unloader spring if it does not meet the
specifications shown, or the wrong spring has been used.
If the compressor has a flat hat type of unloader cap (1),

it must use an unloader spring and valve seat different
from that used with the three-prong unloader.
Assemble
The following steps are for the Holset® SS, E-Type, and
ST models.
Apply high-temperature grease (Accrolube lubrication
teflon grease or equivalent) to the rectangular ring seal,
unloader cap, and unloader body bore.
Install the unloader spring, cap and valve body.
Holset® QE230, QE296, and QE338 A/C Model

Install the new rectangular V-seal into the unloader body
with the grooved side up.
Liberally lubricate the unloader valve bore above and
below the rectangular ring seal with high-temperature
grease (Accrolube lubrication Teflon grease, or
equivalent).
Air Compressor Unloader and Valve Assembly QSK45 and QSK60
Install a new o-ring seal on the unloader valve body.
Use clean 15W-40 oil or Accrolube lubrication Teflon

grease (or equivalent) to lubricate the seal.
Liberally lubricate the unloader valve body bore and

unloader cap with high-temperature grease (Accrolube
lubrication Teflon grease, or the equivalent).
Install the unloader cap.
Install the unloader spring.
Lubricate the unloader capscrew threads and underhead

with clean engine oil (SAE 15W-40) before installation.
NOTE: The two unloader body screws must not be used
to attach any brackets.
QSK45 and QSK60 Air Compressor
The longer capscrews are used to mount the manifold to

the air compressor.
Assemble the unloader components, and attach the
unloader assembly to the valve plate with the four
capscrews and washers.
Finishing Steps
Air Compressor (012-014)

Preparatory Steps
WARNING
WARNING
Drain the coolant. Refer to Procedure 008-018.
Remove the fuel pump. Refer to Procedure 005-016.

Air Compressor QSK45 and QSK60
Remove
WARNING
WARNING
personal injury.
Use steam to clean the air compressor.
Remove the coolant lines from the air compressor.
Remove the air inlet and outlet connections from the air
compressor.
Single Cylinder
WARNING
Remove the air compressor support bracket and
capscrews.
Remove the air compressor mounting flange capscrews.
Remove the air compressor.
Remove the splined coupling.
Twin Cylinder
WARNING
Remove the air compressor support mounting capscrews
(5).
Remove the air compressor mounting flange capscrews
(6).
Remove the splined coupling (1).
Remove the cover plate/support bracket from the air

compressor.
WARNING
WARNING
personal injury.
Clean the air compressor with solvent and dry with
compressed air.
Inspect the housing for cracks or damage.
If the housing is cracked or damaged it must be replaced.
Inspect the splined coupling for cracks or damage.

If the splined coupling is cracked or damaged it must be
replaced.
Single Cylinder
Measure the crankshaft end clearance.
Single Cylinder Crankshaft End Clearance

mm in
0.05 MIN 0.002
0.69 MAX 0.027
If the crankshaft end clearance is not within specifications
the air compressor must be repaired or replaced. Refer to
Bulletin 3666121.
Twin Cylinder
Measure the crankshaft end clearance
Twin Cylinder Crankshaft End Clearance

mm in
0.038 MIN 0.001
0.200 MAX 0.008
If the crankshaft end clearance is not within specifications
the air compressor must be repaired or replaced. Refer to
Bulletin 3666121.
Install
Single Cylinder
WARNING
Install the splined coupling (1) on the accessory drive
shaft.
Make sure the accessory drive gasket surface is clean
and not damaged.
Install a new gasket and the air compressor.
To aid in assembly, do not tighten the capscrews until the
support bracket is aligned.
Install the four capscrews and nuts (2). The capscrews
must be loose.
CAUTION
The support must be flat against the engine block. If
the support is not flat, the compressor and/or
accessory drive will fail.
Install the two bracket capscrews (5).
Turn the air compressor until the bracket is flat against the
engine block.
Tighten the compressor to accessory drive capscrews (2).

Tighten the support bracket to engine block capscrews (5).
Tighten the bracket to air compressor capscrew (4).
If rubber grommets are used on the coolant lines, make

sure they are installed correctly to prevent cuts or tears to
the grommets that cause coolant leaks.
When flexible tubing is used, make sure the flexible tube
does not rub any other surface.
Install the coolant lines to the air compressor and tighten.
Install the air compressor inlet and outline lines.
Tighten the clamps.
Install the fuel pump drive coupling on the air compressor.
Twin Cylinder
Install the gasket and cover plate/support bracket onto the
air compressor.
Do not tighten the six capscrews. The support must be
adjusted.
WARNING
NOTE: Do not install the splined coupling or the mounting
gasket.
Install the compressor on the accessory drive.
Install the four capscrews (6). Only tighten the capscrews
enough to pull the compressor to the accessory drive. The
compressor must be turned to align the support bracket.
CAUTION
Tighten the four capscrews (6).
Tighten the support bracket capscrews (7) that are
accessible.
WARNING
Remove the four capscrews (6).
Tighten the remaining support to air compressor
capscrews.
WARNING
CAUTION
Install the splined coupling (1), and the gasket.
Install the air compressor.
Install the four capscrews (6) and two capscrews (5).
Torque Value:
Capscrew (6) 60 N•m [ 44 ft-lb ]
Install the fuel pump drive coupling onto the air

compressor.
Install the air inlet and outlet connections to the air
compressor.
Tighten the clamps.
Air Governor (Air Compressor Will Not Pump) QSK45 and QSK60
Install the coolant lines into the air compressor.
Finishing Steps
Install the fuel pump. Refer to Procedure 005-016.

inspect for leaks.
Air Governor (Air Compressor Will Not

Pump) (012-017)
Initial Check
Remove the air governor or air governor line from the air
compressor unloader body.
QSK45 and QSK60 Air Governor (Air Compressor Pumps Continuously)

If the air compressor is pumping, the air governor is
malfunctioning and must be repaired or replaced. Refer
to the manufacturer's instructions.
If the air compressor does not pump, remove, clean, and

inspect the air compressor unloader valve assembly.
Refer to the Master Repair Manual, Holset® Air
If the unloader valve assembly operates correctly, clean
and inspect the exhaust valve assembly. Refer to the
Master Repair Manual, Holset® Air Compressors, Bulletin
3666121.
Air Governor (Air Compressor Pumps

Continuously) (012-018)
Initial Check
Remove the air accessory air lines from the air
compressor governor.
Install pipe plugs in the air governor unloader ports where

accessory air lines were removed.
If the air compressor stops pumping (air pressure stops
rising) at the governed air pressure, there is a leak in an
accessory or an accessory air line. Refer to the equipment
manufacturer's instructions for troubleshooting and
repair.
Air Governor (Air Compressor Pumps Continuously) QSK45 and QSK60
If the air compressor does not stop pumping (air pressure

continues to rise) at the governed air pressure, connect a
regulated shop air pressure line to one of the following:
The air compressor unloader valve port
One of the air governor unloader valve ports.
Make sure the air pressure gauge is accurate, and the

supply lines and fittings are in good condition, before
performing any air pressure checks.
Use a master gauge of known accuracy to check the air
pressure gauge.
Apply 690-kPa [100-psi] air pressure to the unloader port.

If the air compressor stops pumping (air pressure stops
rising), the air governor is malfunctioning and must be
repaired or replaced, or the air governor mounting gasket
is leaking. Refer to the OEM's instructions.
If the air compressor continues to pump (air pressure

continues to rise), the unloader valve is malfunctioning
and must be repaired or replaced. Refer to the Master
Repair Manual, Holset® Air Compressors, Bulletin
3666121.
QSK45 and QSK60 Air Leaks, Compressed Air System
Remove the pipe plugs from the unloader ports used for
accessory air lines.
Install and tighten the accessory air lines.
Connect the line to the unloader valve.
Air Leaks, Compressed Air System

(012-019)
Initial Check
WARNING
personal injury.
NOTE: The illustrations shown will be of the single-
cylinder air compressor. Differences in procedures for SS,
QE, and ST model Holset® air compressors will be shown
where necessary.
Open the drain cock on the wet tank to release air from
the system. Close the drain cock after the pressure is
released.
Air Compressor (Oil Carryover) QSK45 and QSK60

With the air compressor pumping between 550 to 690 kPa
[80 to 100 psi], use a solution of soapy water to check for
air leaks in the following areas:
• Air compressor cover gasket
• Unloader body o-ring
• Air compressor head gasket
• Air compressor valve plate gasket (QE models
only)
• Hose and fitting leaks.
If air leaks are found, replace the leaking gasket or o-ring.
Refer to the Master Repair Manual, Holset® Air
Air Compressor (Oil Carryover)

(012-020)
Inspect for Reuse
NOTE: The illustrations shown will be of the single-
cylinder air compressor. Differences in procedure for one-
or two-cylinder Cummins air compressors will be shown
where necessary.
Cycle the air compressor five times while viewing the
discharge from the air dryer. If the discharge appears
excessively oily, perform the following check.
Remove the air compressor line from the air compressor.

Apply regulated air pressure to the air governor unloader
port.
Operate the engine at low idle for 10 minutes with the air
compressor unloaded (shop air applied to the unloader
port).
Remove the shop air pressure from the unloader port.
Operate the engine at low idle for 10 minutes with a white
cloth over the air compressor discharge port.
QSK45 and QSK60 Air Starting Motor
Remove the white cloth, and check the cloth for

contamination.
If the cloth indicates more than a trace of gray, the air
compressor is using an excessive amount of oil and
must be replaced. Refer to Procedure 012-014.
Install and tighten the air discharge line.

Air Starting Motor (012-022)

General Information
A QSk45 and QSK60 air starting motor is shown in the
illustration.
The air starting motor system (tanks, line sizes, and
valves) is designed and installed by the OEM and the
starting motor suppliers. Refer any questions about the air
starting systems to the manufacturer.
Do not operate the air starting motor with air pressure
lower than 480 kPa [70 psi].
Maintain the air compressor according to the
recommendations outlined in the component
manufacturer's manual.
For maximum efficiency, the hoses, tubes, and lines must
not leak.
Refer to the OEM and starting motor manufacturer's
manuals for specific information regarding the starting
motors, valves, and systems.
Air Starting Motor QSK45 and QSK60
Notes
QSK45 and QSK60
Section 13 — Electrical Equipment — Group 13 Page 13-a
Section 13 — Electrical Equipment — Group 13

Section Contents
Page
Alternator .........................................................................................................................................................13-2
Install..............................................................................................................................................................13-5
Remove..........................................................................................................................................................13-3
Test................................................................................................................................................................13-2
Alternator Pulley .............................................................................................................................................13-9
Alternator Bracket ...........................................................................................................................................13-7
Batteries ........................................................................................................................................................ 13-10
Inspect..........................................................................................................................................................13-10
Battery Cables and Connections .................................................................................................................. 13-11
Belt Tensioner, Automatic (Alternator) .........................................................................................................13-20
Initial Check..................................................................................................................................................13-20
Install............................................................................................................................................................13-23
Remove.........................................................................................................................................................13-22
Drive Belt, Alternator ......................................................................................................................................13-7
Adjust.............................................................................................................................................................13-8
Install..............................................................................................................................................................13-8
Remove..........................................................................................................................................................13-7
Service Tools ...................................................................................................................................................13-1
Electrical Equipment.......................................................................................................................................13-1
Starter Magnetic Switch ................................................................................................................................13-11
Starting Motor ................................................................................................................................................13-17
Finishing Steps............................................................................................................................................. 13-20
Integral Prelub™ Starter..............................................................................................................................13-20
Install............................................................................................................................................................13-19
Remove.........................................................................................................................................................13-18
Starter Solenoid .............................................................................................................................................13-15
Voltage Check...............................................................................................................................................13-15
Starter Switch ................................................................................................................................................13-13
QSK45 and QSK60
Page 13-b Section 13 — Electrical Equipment — Group 13

Section 13 — Electrical Equipment — Group 13 Page 13-1
Service Tools
Electrical Equipment
Repair Location.

Charging - Cranking Systems Analyzer
Use to test generators, alternators, relays, starting motors,
3885847 regulators, and batteries. Contains built-in voltmeter and ammeter.
Belt Tensioner Gauge

Use to measure alternator belt tension.
ST-1138
Digital Multimeter
Use to measure voltage and resistance in a circuit.
3377161
Digital Multimeter
Used to measure voltage and resistance in a circuit.
3164488
Alternator QSK45 and QSK60
Page 13-2 Section 13 — Electrical Equipment — Group 13
Alternator (013-001)
Test
Before performing the following test, be sure the alternator
belt is tightened to the correct specifications. Refer to
Procedure 013-005.
The following instructions are for use with the charging
and cranking system analyzer, Part Number 3885847, or
equivalent.
Set the voltage selector knob to the appropriate scale. For

a 24-VDC system, choose the 40-VDC scale.
Set the amp selector knob to 100 amps.
WARNING
cable last.
Remove the cables to any other battery in the circuit.
Connect the correct analyzer leads to the positive (+) and
negative (• ) terminals on the battery.
Connect the clamp-on amp pickup to the alternator output

cable as far away from the alternator as possible.
QSK45 and QSK60 Alternator
Operate the engine at high idle, and turn the analyzer load
control knob clockwise until a maximum amp reading is
obtained.
Do not let the load volts drop below 26-VDC for a 24-VDC
system.
The maximum amp reading is the alternator output, and
must meet the alternator manufacturer's specifications.
The alternator maximum-rated output is normally stamped

or labeled on the alternator.
Also, check the equipment ammeter gauge. If it does
not read approximately the same as the test equipment,
it must replaced.
If the alternator output is not within 10 percent of rated
output, repair or replace the alternator. Refer to the
WARNING
cable last.
Turn the analyzer load control knob counterclockwise to
the OFF position, and shut off the engine.
Remove the test equipment. Connect all battery cables
that were removed.
Remove
WARNING
cable last.
Disconnect the batteries.
Disconnect the wiring from the alternator.
Loosen the adjusting link and the alternator mounting

capscrews.
The lower jam nut has left-hand threads.
Loosen both of the jam nuts. Turn the adjusting screw to
relieve the belt tension.
Remove the alternator belt.
The three capscrews are SAE Grade 8 and the three

spacers are hardened. Keep the parts together to aid the
assembly procedure.
Remove the parts as shown.

Remove the nut and pulley from the alternator.
QSK45 and QSK60 Alternator
WARNING
WARNING
for use. Wear goggles and protective clothing tor
WARNING
personal injury.
Use solvent or a steam cleaner to clean the pulley and dry
Check the grooves of the pulley for wear and damage.
If worn or damaged, replace the pulley.
Install
Lubricate the shaft with clean engine oil. Install the pulley
and nut on the alternator shaft. Tighten the nut.
The belt must be installed and adjusted before the

capscrews are tightened.
The end of the adjusting link with the largest area at the
capscrew hole must be nearest to the alternator.
Install the alternator and the adjusting link, as shown.
Do not attempt to pry the belt on the pulley.

Install the belt. Turn the adjusting screw
counterclockwise to shorten the link if necessary.
Use a belt tension gauge (Borroughs), Part Number

ST-1293, to measure the poly V-belt tension.
Refer to the Drive Belt Tension Table in Section V.
A belt is considered used if it has been in operation for 10
minutes or longer.
If used belt tension is below the minimum value, tighten
to the maximum value.
Replace the belt if it will not maintain the correct tension.
The lower jam nut has left-hand threads.

Tighten the jam nuts on the adjusting screw.
Tighten the adjusting link and alternator mounting
capscrews.
WARNING
cable last.
Connect the wiring to the alternator.
Connect the batteries.
QSK45 and QSK60 Drive Belt, Alternator
Alternator Bracket (013-003)

WARNING
WARNING
personal injury.
Use solvent to clean the parts and dry with compressed
air.
Check the threads for damage.
Check for cracks.
If any of the above conditions are found, the bracket
must be replaced.
Drive Belt, Alternator (013-005)

Remove
Loosen the adjusting link and the alternator mounting
capscrews.
NOTE: The lower jam nut has left-hand threads.
Loosen both of the jam nuts. Turn the adjusting screw to
relieve the belt tension.
Remove the belt.
Inspect for Reuse

Inspect the belt for cracks, glazing, tears, or cuts. The
belt must be replaced if damaged.
Drive Belt, Alternator QSK45 and QSK60
Install
Do not attempt to pry the belt on the pulley. Turn the
adjusting screw counterclockwise to shorten the link if
necessary.
Install the alternator belt.

Tighten the jam nut on the adjusting screw.
capscrews.
Torque Value:
Jam Nuts 80 N•m [ 59 ft-lb ]
Alternator 115 N•m [ 85 ft-lb ]
Mounting
Capscrews
Adjust
Loosen the alternator and adjusting link mounting
capscrews.
Loosen the jam nuts on the adjusting screw.
Turn the adjusting screw clockwise to increase the belt

tension.
QSK45 and QSK60 Alternator Pulley

Tighten the jam nuts on the adjusting screw.
capscrews.
Torque Value:
Jam Nuts 80 N•m [ 59 ft-lb ]
Alternator 115 N•m [ 85 ft-lb ]
Mounting
Capscrews
Check the belt tension again to be sure it is correct.

Refer to Section V for the proper belt tension.
Alternator Pulley (013-006)

Inspect for Reuse
WARNING
WARNING
Clean the alternator drive and accessory drive pulley with
steam or solvent.
Check the grooves of the pulley for wear. Check the wear
sleeve on the accessory drive pulley. If the pulley must be
replaced, refer to Procedure 009-004.
Batteries QSK45 and QSK60
Batteries (013-007)
Inspect
Use an inductive charging and cranking system analyzer
to load-test the state of charge of maintenance-free
batteries. If the state of charge is low, use a battery
charger to charge the battery. Refer to the manufacturer's
instructions.
Replace the battery if it will not charge to the
manufacturer's specifications or the battery will not
maintain a charge.
WARNING
cable last.
WARNING
personal injury,
NOTE: Maintenance-free batteries are sealed and do
not require the addition of water.
If conventional batteries are used, remove the cell caps or
covers and check the electrolyte (water and sulfuric acid
solution) level.
Fill each battery cell with water. Refer to the
Do not attempt to check the specific gravity of a battery

immediately after adding water. If it is necessary to add
water to allow use of the hydrometer, charge the battery
several minutes at a high rate to mix the electrolyte.
Use a hydrometer to measure the specific gravity of each
cell.
Refer to the accompanying table to determine the battery
state of charge based on the specific-gravity readings.
Battery State of Charge Specific Gravity @ 27°C

[80°F]
100 percent 1.260 to 1.280
75 percent 1.230 to 1.250
50 percent 1.200 to 1.220
25 percent 1.170 to 1.190
Discharged 1.110 to 1.130
If the specific gravity of any cell is below 1.200, the

battery must be charged.
QSK45 and QSK60 Starter Magnetic Switch
Battery Cables and Connections

(013-009)
Inspect for Reuse
Inspect the battery terminals for loose, broken, or
corroded connections. Repair or replace broken cables or
terminals.
If the connections are corroded, remove the cables and

use a battery brush to clean the cable and battery
terminals.
WARNING
Always connect the negative (-) cable last to avoid
sparks that can ignite explosive battery gases.
WARNING
Batteries emit hydrogen gas. To avoid explosion and
personal injury, do not smoke or allow ignition
sources in area when servicing batteries.
Connect and tighten the battery cables. Use grease to
coat the battery terminals to prevent corrosion.
Starter Magnetic Switch (013-017)

Inspect for Reuse
Before inspecting specific starting system components
with the multimeter:
• Inspect terminals for loose, broken, or corroded
connections.
• Replace or repair wiring and components as
necessary.
WARNING
Be sure the starter switch is in the OFF position to
reduce the possibility of electrical shock and personal
injury.
Remove the cable connecting the magnetic switch to the
starter solenoid from the magnetic switch terminal.
Connect the leads of digital multimeter, Part Number
3377161, to the two large switch terminals.
Starter Magnetic Switch QSK45 and QSK60
Set the multimeter to measure resistance.

With the starter switch in the OFF position, the
multimeter must indicate resistance at infinity.
• If the multimeter indicates zero or very little
resistance, replace the magnetic switch.
• If the multimeter indicates resistance at infinity,
proceed with the following instructions.
Turn the starter switch to the START position.

The multimeter must indicate zero or very little resistance.
A click will be heard when the starting switch is turned to
the START position.
If the multimeter indicates resistance at infinity with the

starter switch in the START position and a click is not
heard:
• Turn the starter switch to the OFF position.
• Set the multimeter scale to indicate DC voltage.
Connect the positive (+) lead of the multimeter to the

magnetic switch ground wire terminal and the other lead
to the small magnetic switch terminal.
The multimeter will indicate some voltage across the
magnetic switch terminals. If the multimeter indicates
FULL SYSTEM VOLTAGE, the magnetic switch is
malfunctioning and must be replaced.
QSK45 and QSK60 Starter Switch
If the multimeter indicates no voltage, the magnetic switch

is not the cause of the complaint. Refer to Procedure
013-018.
Turn the starter switch to the OFF position.

Remove the multimeter leads and connect the magnetic
switch to the starter solenoid wire.
Starter Switch (013-018)

Inspect for Reuse
WARNING
Be sure the starter switch is in the OFF position to
reduce the possibility of electrical shock and personal
injury.
Remove the wire connecting the starter switch to the
magnetic switch from the starter switch terminal.
Connect the positive (+) lead of the digital multimeter,
Part Number 3377161, to the starter switch terminal and
the negative (-) lead to a chassis or engine ground
location.
With the starter switch in the OFF position, there must

not be voltage at the starter switch terminal. If the
multimeter indicates voltage, the starter switch is
malfunctioning and must be replaced.
Starter Switch QSK45 and QSK60

The multimeter must indicate system voltage.
If there is no voltage:
• Turn the starter switch to the OFF position.
• Connect the multimeter positive (+) lead to the
starter switch terminal having a wire that connects
the starter switch to the starter solenoid.
If the multimeter indicates system voltage, the starter

switch is defective and must be replaced.
If the multimeter indicates no voltage, the switch is not the

cause of the complaint.
QSK45 and QSK60 Starter Solenoid
Inspect the wiring from the starter switch to the starter

solenoid and from the starter solenoid to the battery.
Replace any broken or damaged wires.
Starter Solenoid (013-019)

Voltage Check
Use the multimeter, Part Number 3377161, and set it to
measure VDC.
Connect the multimeter positive (+) lead to the starter
solenoid positive (+) cable terminal and the negative (• )
lead to the battery cable connection at the starting motor.
The multimeter must show system voltage.
If the multimeter does not indicate system voltage, check

the battery to starting motor cable for broken, loose, or
corroded connections.
If the multimeter indicates system voltage, but the starting

motor will not operate, check the wire connecting the
starter solenoid to the starter switch for broken, loose, or
Starter Solenoid QSK45 and QSK60
If the wire connecting the starter solenoid and starter

switch is not loose or damaged and the starter will not
operate:
• Remove the cable connecting the starting motor and
starter solenoid from the solenoid terminal.
• Connect the multimeter positive (+) lead to the
solenoid positive (+) terminal and the negative (• )
lead to a chassis or engine ground.

If the multimeter indicates system voltage, the starter
solenoid is malfunctioning and must be replaced.
If the multimeter does not indicate system voltage, check

the wire connecting the starter solenoid to the magnetic
switch for broken, loose, or corroded connections.
If the wire connecting the starter solenoid to the magnetic

switch is not loose or damaged and the starting motor
will not operate, check the cable connecting the starter
solenoid to the starting motor for broken, loose, or
QSK45 and QSK60 Starting Motor
Check the cable connecting the starter to the battery for

broken, loose, or corroded connections.
If the cables are not loose or damaged, the starting motor

is defective and must be replaced.
Starting Motor (013-020)

Preparatory Steps
WARNING
cable last.
Integral Prelub™ Starter
WARNING
reproductive toxicity. Avoid inhalation vapors,
WARNING
Starting Motor QSK45 and QSK60
Remove
Disconnect the electrical connections from the starting
motor

Remove the suction hose (1) from the hose fitting (3) on
the back of the integral prelube starter. Disconnect the
other end of the suction hose from the oil pump.
Remove the supply hose (2) from the hose fitting (3) on the
back of the integral prelube starter. Disconnect the other
end of the supply hose from the oil filter head.
WARNING
personal assistance to lift this assembly.
Remove the starting motor capscrews, the starter, the
spacers, and the gaskets.
NOTE: Not all engines contain spacers and gaskets.
Inspect for Reuse
WARNING
Clean the exterior of the motor with steam.
Inspect the gear, shaft, and bushing for wear or damage.
Inspect flywheel ring gear for wear or damage.
Lubricate the bushing with clean engine oil.
NOTE: A pipe plug must be removed to lubricate the
bushing on some starter motors.
QSK45 and QSK60 Starting Motor
Install
WARNING
personal assistance to lift this assembly.
NOTE: Not all engines use spacers.
NOTE: The wet type of flywheel housing requires gaskets
for the starting motor.
Install any spacer or gaskets.
Install the starting motor and capscrews.
Torque Value:
With Cast-Iron 215 N•m [ 159 ft-lb ]
Flywheel
Housing

Install the suction hose (1) to the fittings (3) on the back of
the integral prelube starter. Install the other end of the
suction hose to the suction hose of the oil pump.
Install the supply hose (2) to the fittings (3) on the back of
the prelube starter. Install the other end of the supply hose
to the oil filter head.
Install the electrical connections to the starting motor.

Belt Tensioner, Automatic (Alternator) QSK45 and QSK60
Finishing Steps
WARNING
cable last.

Fill the engine with lubricating oil. Refer to Procedure
007-037.
Belt Tensioner, Automatic (Alternator)

(013-021)
Initial Check
Use belt tensioner gauge, Part Number ST-1138 to
measure the tension on the drive belt.
Refer to the belt tension chart in Section V for the correct
belt tension.
Remove the drive belt and check the tensioner capscrew

torque.
The capscrew grade is located on the head of the
capscrew.
Torque Value:
9.8 Capscrew 45 N•m [ 33 ft-lb ]
10.9 Capscrew 65 N•m [ 48 ft-lb ]
QSK45 and QSK60 Belt Tensioner, Automatic (Alternator)
With the belt removed, make sure the tensioner arm stop
is in contact with the spring case stop.
If the tensioner arm stop is not touching the spring case
stop, the tensioner must be replaced.
After checking the capscrew torque, use a breaker bar

with a 1/2-inch ratchet to rotate the tensioner slowly away
from the area of belt contact.
If the arm rotates with any roughness or hesitancy, replace
the tensioner.
With the belt removed, make sure the tensioner pulley

rotates freely.
Check the tensioner arm pulley and stops for cracks.

If the tensioner arm pulley and stops are cracked, the
tensioner arm must be replaced.
Install the belt.

Make sure the belt tensioner arm stop is not in contact
with the spring casing stop.
If the arm stop and spring casing stop are touching, the
drive belt must be replaced.
After replacing the belt, if the arm stop and spring casing
stop are touching, the tensioner must be replaced.
Check the location of the drive belt on the belt tensioner.

The belt must be centered or centered close to the middle
of the pulley.
Unaligned belts, either too far forward or backward, can
cause belt wear, belt roll-off, or increased, uneven
tensioner bushing wear.
Remove
Remove the drive belt.
Remove the belt tensioner capscrew and the belt

tensioner.
QSK45 and QSK60 Belt Tensioner, Automatic (Alternator)
Inspect for Reuse

Make sure the tensioner arm is not touching the tensioner
cap.
If the tensioner arm is touching the tensioner cap the pivot
tube bushing has failed and the tensioner must be
replaced.
The components of the belt tensioner are:

1. Tensioner cap
2. Tensioner arm
3. Spring case
4. Tensioner pulley
Measure the clearance (5) between the tensioner spring
case (3) and tensioner arm (2) to verify tensioner wear-out
and uneven bearing wear.
Tensioners generally show a larger clearance gap near
the lower portion of the spring case, resulting in the upper
portion rubbing against the tensioner arm.
Spring Tensioner Clearance

mm in
3 MAX 0.12
If the clearance is not within specification, the tensioner
must be replaced.
Always replace the belt when a tensioner is replaced.
Install
CAUTION
To reduce the possibility of capscrew failure, replace
any 9.8 grade belt tensioner mounting capscrew with
a 10.9 grade mounting capscrew.
Install the belt tensioner and capscrew.
Install the drive belt.

QSK45 and QSK60
Section 14 — Engine Testing — Group 14 Page 14-a
Section 14 — Engine Testing — Group 14

Section Contents
Page
Dynamometer Worksheet ................................................................................................................................14-3
Worksheet.......................................................................................................................................................14-3
Engine Compression .....................................................................................................................................14-32
Finishing Steps............................................................................................................................................. 14-36
Pressure Differential Test..............................................................................................................................14-34
Setup............................................................................................................................................................14-33
Engine Run-in (Engine Dynamometer) ..........................................................................................................14-22
Install............................................................................................................................................................14-22
Test............................................................................................................................................................14-22
Engine Throttle Control...............................................................................................................................14-23
Run-In Instructions........................................................................................................................................14-24
Engine Run-in (Without Dynamometer) ........................................................................................................14-10
Finishing Steps............................................................................................................................................. 14-13
Run-In Instructions........................................................................................................................................14-12
Generator Set Applications.........................................................................................................................14-12
Industrial Applications................................................................................................................................ 14-13
Engine Testing (Chassis Dynamometer) ........................................................................................................14-4
Test................................................................................................................................................................14-4
Engine Speed (rpm)......................................................................................................................................14-4
Fuel Pressure...............................................................................................................................................14-5
Fuel Rate.....................................................................................................................................................14-5
Fuel Inlet Restriction.....................................................................................................................................14-5
Fuel Drain Line Restriction...........................................................................................................................14-5
Intake Manifold Pressure..............................................................................................................................14-6
Intake Manifold Air Temperature Control - Chassis Dynamometer test..........................................................14-6
Intake Air Restriction....................................................................................................................................14-7
Intake Manifold Air Temperature Control - Chassis Dynamometer test..........................................................14-7
Engine Blowby.............................................................................................................................................14-7
Lubricating Oil Pressure...............................................................................................................................14-9
Air Compressor.......................................................................................................................................... 14-10
Starting Motor............................................................................................................................................ 14-10
Engine Testing (Engine Dynamometer) ........................................................................................................14-14
Install............................................................................................................................................................14-14
Coolant Plumbing.......................................................................................................................................14-14
Intake Air Temperature Control...................................................................................................................14-14
LTA............................................................................................................................................................14-14
Test............................................................................................................................................................14-15
Engine Throttle Control...............................................................................................................................14-16
Test...............................................................................................................................................................14-17
Engine Speed (rpm)....................................................................................................................................14-17
Fuel Drain Line Restriction......................................................................................................................... 14-17
Intake Air Restriction..................................................................................................................................14-18
Exhaust Air Restriction...............................................................................................................................14-18
Engine Blowby........................................................................................................................................... 14-18
Lubricating Oil Pressure.............................................................................................................................14-20
Engine Coolant Pressure............................................................................................................................14-21
Air Compressor.......................................................................................................................................... 14-21
Starting Motor............................................................................................................................................ 14-21
Engine Testing (In Chassis) ..........................................................................................................................14-26
Stall Speed Check.........................................................................................................................................14-26
Stall Speed Checklist.................................................................................................................................... 14-30
Time Speed Check........................................................................................................................................14-30
Service Tools ...................................................................................................................................................14-1
Engine Testing................................................................................................................................................14-1
QSK45 and QSK60
Page 14-b Section 14 — Engine Testing — Group 14

Section 14 — Engine Testing — Group 14 Page 14-1
Service Tools
Engine Testing
Repair Location.

Vacuum Gauge
Used to check fuel pump inlet restriction.
ST-434
Manometer
Used with blowby check tool, Part Number 3822568, for measuring
ST-1111-3 blowby. Also, used to measure air inlet restriction and exhaust
restriction.
Digital Optical Tachometer

Used to measure engine speed (rpm).
337462
Blowby Check Tool (10-mm [0.406-in] orifice)

Used with manometer, Part Number ST-1111-3, to measure the
3822568 engine crankcase pressure.
Engine Dynamometer Control

Used on an engine dynamometer to control the QSK45 and QSK60
3162245 engines.
INSITE™ Software Kit

Used to troubleshoot, program, and adjust the QSK fuel system.
3886123 Refer to the Troubleshooting and Repair Manual, QSK Fuel System,
QSK19, QSK45, and QSK60 Series Engines, Bulletin Number
3666113.
Page 14-2 Section 14 — Engine Testing — Group 14

Lifting Fixture
Used to lift the engine during installation and removal. This kit
3163264 contains the lift fixture, Part Number 3163265, and four lifting straps,
QSK45 and QSK60 Dynamometer Worksheet
Dynamometer Worksheet (014-001)

Worksheet
Date: Repair Order No: Operator:
ESN: CPL: Fuel Pump Code:
Complaint: SC Code:
PARAMETER CODE SPECIFICATIONS ACTUAL READING

Fuel Pressure (psi @ rpm) 150 to 180 psi at Idle
Fuel Pressure (psi @ rpm) 225 to 250 psi at 1800 rpm
Fuel Pressure (psi @ rpm) 250 to 300 psi at 2,100 rpm
Fuel Rate (lb/hr)
Intake Manifold Pressure (in Hg) See Fuel Pump Code
Intake Manifold Temperature
*Intake Air Restriction 25 in H 2O, Maximum
*Exhaust Air Restriction 3 in Hg, Maximum (2 in Hg - Two-Stage)
*Fuel Inlet Restriction 8 in Hg (Dirty Filter), Maximum
*Fuel Drain Line Restriction 3 psi, Maximum
Engine Blowby See Tables
* Recorded at maximum horsepower speed and full load
Road Speed Limit Engine High Speed Limit

Check Oil Level Low High OK Fuel Quality OK Not OK
Engine Fuel Fuel Turbo Intake Coolant Engine Lube hp

Speed *Rate/Press Temp Inlet Air Manifold Temp/Press Blowby Oil or
Temp Temp/Press Press Torque
* Make sure that the fuel rate is corrected for temperature.
Fuel Temperature Correction for Flow Rate

Less than 7°C [45°F] Flow meter not accurate
7 to 13°C [45 to 55°F] Subtract 2% from flow rate reading
13.0 to 20.0°C [55 to 68°F] Subtract 1% from flow rate reading
20.0 to 29°C [68 to 85°F] No Correction
29 to 42°C [85 to 108°F] Add 1% to flow rate reading
42 to 56°C [108 to 132°F] Add 2% to flow rate reading
Above 56°C [132°F] Flow meter not accurate.
Pressure Conversions
Engine Testing (Chassis Dynamometer) QSK45 and QSK60
25 mm H 2O [1 in H 20] = 1.87 mm Hg [0.074 in Hg] = 0.249 kPa [0.036 psi]

25 mm Hg [1 in Hg] = 0.039 mm H 2O [13.514 in H 20] = 3.386 kPa [0.491 psi]
6.895 kPa [1 psi] = 51.715 mm Hg [2.036 in Hg] = 0.080 mm H 2O [27.7 in H 20]
This Page Can Be Copied for Your Convenience.
Engine Testing (Chassis

Dynamometer) (014-002)
Test
To monitor engine performance properly, record the
following parameters. To limit dynamometer operating
time, instrument the engine to perform as many checks as
possible. The INSITE™ tool will provide most if not all of
the following:
• Engine speed rpm with a verified tachometer
• Fuel pressure
• Fuel rate
• Fuel temperature (if needed to correct fuel rate)
• Fuel inlet restriction
• Fuel drain line restriction
• Intake manifold pressure (per bank).
• Intake air restriction (per bank)

• Exhaust air restriction (per bank)
• Coolant temperature
• Engine blowby
• Lubricating oil pressure
• Coolant pressure
• Inlet manifold air temperature
• Turbocharger inlet air temperature.
Engine Speed (rpm)

Use digital optical tachometer, Part Number 3377462, to
check and verify engine speed.
QSK45 and QSK60 Engine Testing (Chassis Dynamometer)
Fuel Pressure
This measurement can also be taken using INSITE™.
Fuel Rate
This measurement can also be taken using INSITE™.
Use a fuel measuring device to measure the rate of fuel
consumption.

Use the INSITE™ tool or pressure gauge ST-434 to
measure the fuel restriction between the fuel filter and the
gear pump inlet. Refer to Procedure 006-020.
Fuel Drain Line Restriction

Use pressure gauge, Part Number ST-1273, to measure
fuel drain line restriction. Refer to Procedure 006-012.
Intake Manifold Pressure

Measure the intake manifold pressure (turbocharger
boost). This test can be done using INSITE™ or manually.
Refer to the Troubleshooting and Repair Manual, QSK
Fuel System, QSK 19, QSK23, QSK45, QSK60, and
QSK78 Series Engines, Bulletin 3666113, or the
appropriate electronic service tool manual.
Intake Manifold Air Temperature Control - Chassis

Dynamometer test
When operating an engine on a dynamometer, follow
these steps for best results and safe operation.
If the engine is equipped with an automatic fan, lock the
cooling fan in the ON mode. This can be done by installing
a jumper across the temperature switch, or by supplying
shop air to the control valve. Refer to the fan drive
manufacturer for the recommended procedure.
Monitor the intake manifold air temperature using

INSITE™ in the monitor mode, or install Fluke digital
thermometer, Part Number 3822666, and thermocouple
wire kit, Part Number 3822988, into the intake manifold.
The intake manifold air temperature must not exceed 77°
C [171°F].
Maintain intake manifold air temperature to 66°C [110°F]
or below during chassis dynamometer operation.
If the intake manifold temperature exceeds 77°C [171°F],

shut off the engine. Allow the engine to cool.
Check the fan drive. Be sure the fan is locked in the ON
mode.
Remove any obstructions such as a winterfront or debris.
Manually lock the shutters in the OPEN position if
equipped.
Inspect the dynamometer room for adequate supply of
suitably cool or outside air. Make sure that dynamometer
room recirculation is not an issue.
Resume the test.
Intake Air Restriction

Measure the inlet air restriction. Install a manometer, Part
Number ST-1111-3, in the intake air piping.
The gauge adapter must be installed at a 90-degree angle
to the airflow in a straight section of pipe at a minimum of
one pipe diameter before the turbocharger.
Intake Manifold Air Temperature Control - Chassis

Dynamometer test
Measure the exhaust air restriction. Install the pressure
gauge, Part Number ST-1273, or a manometer Part
Number ST-1111-3, in the exhaust air piping.
The gauge adapter must be installed near the
turbocharger in a straight section of pipe at the turbine
outlet.
Engine Blowby
Excessive blowby indicates an air compressor, a
turbocharger, or an engine malfunction, allowing
combustion gases or air to enter the crankcase and build
a pressure higher than normal.
This procedure describes how to measure crankcase
pressure and how to determine the component that is
malfunctioning.
Use the blowby service tool, Part Number 3822568, and a
water manometer, Part Number ST-1111-3. Maximum
gauge capacity is 1270 mm H 2O [50 in H 2O].
Use a length of hose (1) to attach the blowby tool to one

of the crankcase breathers.
Attach a manometer to the location shown (2).
Operate the engine at rated rpm and full load (wide-open

throttle) until a steady reading is obtained.
Compare the blowby readings to previous readings on the
engine. If previous readings for the engine are not
available, compare the blowby reading to new engine
specifications.
Engine Blowby 10-mm [0.406-in] Orifice rpm = All

ratings
mm H2O in H2O
New/Rebuilt Engine 127 MAX 5
Used Engine 330 MAX 13
A sudden increase in blowby indicates a problem. A
gradual increase over a period of time is normal (due to
wear of internal engine components).
If the blowby is higher than normal, check the crankcase

breathers and breather tubes to see whether they are
plugged.
Check the engine oil level. If the level is too high, it can
cause a higher than normal crankcase pressure.
Operate the engine at rated speed. Record the blowby

value.
Isolate the air compressor to determine whether it is

malfunctioning and causing the high blowby pressure.
Relieve the air pressure on the first air tank in the system
after the air compressor (wet tank).
Disconnect the air inlet and outlet connections. Plug the
intake manifold or air piping where the inlet connection
was removed.
Operate the engine at rated speed and full load (wide-

open throttle) until a steady blowby reading is obtained.
Compare the blowby readings to the previous value. If the
blowby is now acceptable, replace the air compressor.
A sudden increase in blowby or a high reading that is

not steady indicates that there is internal damage in the
engine. To determine which cylinder is at fault, refer to the
Troubleshooting Trees, Section TS.
Lubricating Oil Pressure

Use pressure gauge, Part Number. 3375275, or the
INSITE™ tool to measure lubricating oil pressure. Refer to
the Troubleshooting and Repair Manual, QSK Fuel
System, QSK19, QSK23, QSK45, QSK60, and QSK78
Series Engines, Bulletin 3666113.
Install the pressure gauge to the main oil rifle (1) or oil filter
head (2).

kPa psi
Low Idle (Minimum 138 MAX 20
Allowable)
At 1200 rpm (Minimum 207 MAX 30
Allowable)
Engine Run-in (Without Dynamometer) QSK45 and QSK60
Air Compressor
All air compressors manufactured by Cummins Inc. must
be operating during the engine run-in. During the
performance check, all air compressors must be in the
unload or nonoperating mode.
Connect a source of compressed air capable of providing
665 kPa [97 psi] to the air compressor unloader (1). This
air line must contain a valve between the source and the
unloader.
The compressed air load in the accompanying
illustration must be attached to the air compressor outlet
(2).
Use an air tank (2). Install an air regulator (3) capable of

maintaining 345- to 517-kPa [50- to 75-psi] air pressure at
both minimum and maximum engine rpm.
Install a steel tube or high-temperature hose (1).
Hose Temperature (Minimum): 260 °C [ 500 °F ]
Connect the tube or hose (1) to the air compressor outlet.
Starting Motor
Inspect the voltage rating on the starting motor before
installing the electrical wiring.
Install the electrical wiring to the starting motor and
batteries, if used.
If another method of starting the engine is used, follow the
OEM instructions to make the necessary connections.
Engine Run-in (Without Dynamometer)

(014-004)
Preparatory Steps
CAUTION
The lubricating oil system must be primed before
operating the engine after rebuild to avoid internal
component damage. Do not prime the system from
the bypass filter as the filter will be damaged.
All QSK45 and QSK60 industrial application engines are
equipped with an automatic prelube device. If there is
not an automatic prelube device on the engine, follow the
prelube instructions.
QSK45 and QSK60 Engine Run-in (Without Dynamometer)
For engines without an automatic prelube device, use a

pump capable of supplying 205-kPa [30-psi] continuous
pressure.
Remove the pipe plug at the front rear underside of the
one-piece lubricating oil filter head.
Install an extended elbow (1) into the rear port the pipe
plug was removed from. The final position of this elbow is
facing the rear of the engine and slightly inboard to make
sure the check valve clears the front filter on the one-piece
lubricating filter head.
Thighten the elbow.
Apply a small amount of Loctite 641 to the tapered threads
of the male adapter (3) and install it into the flow end of
the check valve (2).
Apply a small amount of Loctite 641 to the tapered threads
of the extended elbow (1) and install the check valve with
the arrow pointing the elbow in the lubricating oil filter
head.
Tighten the check valve.
Connect the pump to the male adapter.
Use a supply of clean oil. Turn the pump to the ON
position. Check the engine oil pressure gauge. When the
gauge indicates oil pressure, begin monitoring the oil level
in the oil pan.
Check the engine lubricating oil level to make sure it is

filled to the proper level.
Engine Run-in (Without Dynamometer) QSK45 and QSK60
WARNING
coolant or spray can cause personal injury.
CAUTION
Do not add cold coolant to a hot engine. This can
cause engine casting damage. Allow the engine to
cool to below 50°C [120°F] before adding coolant.
Check the engine coolant level. Refer to Procedure
008-018.
Use a known source of good quality number 2 diesel fuel.
Number 1 diesel fuels, along with most other alternate
fuels, are lighter (lower specific gravity, higher API gravity)
than number 2 diesel fuel. The lighter the fuel, the lower
the energy content per gallon (liter).
Engine operating specifications can be found in

publications available from the local Cummins Authorized
Repair Location.
Run-In Instructions
Generator Set Applications
Operate the engine in steps, varying the load from 25
percent to 100 percent, until blowby remains constant.
QSK45 and QSK60 Engine Run-in (Without Dynamometer)
Industrial Applications
Operate the equipment in the normal duty cycle at part
load during the first three hours after rebuild.
Do not idle the engine for more than 5 minutes at any one
time.
Do not operate the engine at rated rpm. Operate at 75
percent of rated rpm or lower.
Rated rpm Maximum rpm for First
Three Hours
1900 1425
1800 1350
Do not operate the engine at full load for more than five
minutes at any one time.
Finishing Steps
Remove the pump.
Remove the elbow (1), check valve (2), and adapter (3)
from the lubricating oil filter head.
Install the pipe plug.
Engine Testing (Engine Dynamometer) QSK45 and QSK60
Engine Testing (Engine Dynamometer)

(014-005)
Install
NOTE: Make sure the dynamometer capacity is sufficient
to permit testing at 100 percent of the engine's rated
horsepower. If the capacity is not enough, the testing
procedure must be modified to the restrictions of the
dynamometer.
Use engine lifting fixture, Part Number 3163264, to install
the engine to the test stand. Align and connect the
dynamometer. Refer to the manufacturer's instructions for
aligning and testing the engine.
Coolant Plumbing
Connect the coolant supply to the water inlet connection.
Connect the coolant return to the water outlet connection.
Install the drain plugs, and close all of the water
draincocks.
NOTE: LTA engines require connecting the LTA water
lines to a remote heat exchanger.
Intake Air Temperature Control

The use of a remote heat exchanger is mandatory
whenever a Cummins LTA engine is attached to an engine
dynamometer for the purpose of engine run-in,
performance testing, and/or engine diagnostics. Do not
attempt to run a Cummins LTA engine without any means
of controlling the intake manifold air temperature.
A. Aftercooler water out
B. Aftercooler water in
C. Cooling water out to drain
D. Cooling water in.
LTA
All QSK45 and QSK60 industrial engines require LTA and,
therefore, have unique radiator requirements.
The heat exchanger must be sized to maintain 70°C
[158°F] maximum intake air temperature at full power.
A. Cooling water in
B. Thermostat housing
C. LTA out
D. Cooling water out
E. LTA return.
QSK45 and QSK60 Engine Testing (Engine Dynamometer)
Test
CAUTION
Industrial QSK45 and QSK60 engines are equipped with
an automatic prelube system from the factory. If the
engine is not equipped with an automatic prelube system,
follow the instructions to prelube the engine manually.
For engines without an automatic prelube device, use a

pump capable of supplying 205-kPa [30-psi] continuous
pressure.
Remove the pipe plug at the front rear underside of the
one-piece lubricating oil filter head.
Install an extended elbow (1) into the rear port the pipe
plug was removed from. The final position of this elbow is
facing the rear of the engine and slightly inboard to make
sure the check valve clears the front filter on the one-piece
lubricating filter head.
Tighten the elbow.
Apply a small amount of Loctite® 641 to the tapered
threads of the male adapter (3) and install it into the flow
end of the check valve (2).
Apply a small amount of Loctite® 641 to the tapered
threads of the extended elbow (1) and install the check
valve with the arrow pointing at the elbow in the lubricating
oil filter head.
Tighten the check valve.
Connect the pump to the male adapter.
in the oil pan.
WARNING
CAUTION
008-018.
Check the engine lubricating oil level to make sure it is

filled to the proper level.
Use a known source of good-quality number 2 diesel fuel.
the energy content per gallon (liter).
Remove the pump.

Remove the elbow (1), check valve (2), and adapter (3)
from the lubricating oil filter head.
Engine Throttle Control

Engines that are run on an engine dynamometer require
that the engine harness be installed and connected to the
engine. Additionally, a special engine dynamometer
version of the OEM wiring harness and throttle control
must be installed.
Engine dynamometer kit, Part Number 3163890, is a
special wiring harness and throttle control that has been
developed to enable engine operation out of the chassis.
Engine operating specifications are available from the

local Cummins Authorized Repair Location.
Test
To properly monitor engine performance, record the
following parameters. To limit dynamometer operating
time, instrument the engine to make as many checks as
possible. The INSITE™ electronic service tool will provide
most, if not all, of the following:
• Engine speed rpm with a verified tachometer
• Fuel pressure
• Fuel rate
• Fuel temperature (if needed to correct fuel rate)
• Fuel inlet restriction
• Fuel drain line restriction
• Intake manifold pressure (per bank).
• Intake air restriction (per bank)

• Exhaust air restriction (per bank)
• Coolant temperature
• Engine blowby
• Lubricating oil pressure
• Coolant pressure
• Inlet manifold air temperature
• Turbocharger inlet air temperature.
Engine Speed (rpm)

Use digital optical tachometer, Part Number 3377462,
along with reflective tape, Part Number 3377464, to check
the engine speed.
Fuel Drain Line Restriction

NOTE: Do not measure fuel drain line restriction with the
fuel measuring device installed. This will not measure the
drain line restriction of the vehicle's return plumbing.
Use pressure gauge, Part Number ST-1273, to measure
fuel drain line restriction.
Intake Air Restriction

Install the gauge adapter at a 90-degree angle to the
airflow in a straight section of pipe at a minimum of one
pipe diameter before the turbocharger.
Install the vacuum gauge, Part Number ST-434, or a
manometer, Part Number ST-1111-3, in the intake air
piping.
Measure the inlet air restriction.
Exhaust Air Restriction

Install the gauge adapter near the turbocharger in a
straight section of pipe at the turbine outlet.
Install the pressure gauge, Part Number ST-1273, or a
manometer in the exhaust air piping.
Measure the exhaust air restriction.
Engine Blowby
Excessive blowby indicates an air compressor, a
turbocharger, or an engine malfunction, allowing
combustion gases or air to enter the crankcase and build
a pressure higher than normal.
This procedure describes how to measure crankcase
pressure and how to determine the component that is
malfunctioning.
Use the blowby service tool and a water manometer, Part
Number ST-1111-3. Maximum gauge capacity is 1270 mm
H 20 [50 in H 20].
Blowby Tool Part Number Orifice Size

3822568 10 mm [0.406 in]
Use a length of hose (1) to attach the blowby tool to one

of the crankcase breathers.
Attach a manometer to the location shown (2).
NOTE: The above procedure will not result in accurate
readings on QSK60 engines.
Operate the engine at rated rpm and full load (wide open
throttle) until a steady reading is obtained.
Compare the blowby readings to previous readings on the
engine. If previous readings for the engine are not
available, compare the blowby reading to new engine
specifications.
QSK45 and QSK60 Blowby Limits for All HP and RPM

Rating
mm H2O in H2O
New and Rebuilt 127 MAX 5
Engines
Used Engines 330 MAX 13
A sudden increase in blowby indicates a problem. A
gradual increase over time is normal (due to wear of
internal engine components).
If the blowby is higher than normal, check the crankcase

breathers and breather tubes to see whether they are
plugged.
Check the engine oil level. If the level is too high, it can
cause a higher than normal crankcase pressure.
Isolate the air compressor to determine whether it is

malfunctioning and causing the high blowby pressure.
Relieve the air pressure on the first air tank in the system
after the air compressor (wet tank).
Disconnect the air inlet and outlet connections. Plug the
intake manifold or air piping where the inlet connection
was removed.
Operate the engine at rated speed and full load (wide-

open throttle) until a steady blowby reading is obtained.
Compare the blowby readings to the previous value. If the
blowby is acceptable, replace the air compressor. Refer
to Section12.
A sudden increase in blowby or a high reading that is

not steady indicates that there is internal damage in the
engine.

Use pressure gauge, Part Number 3375275, to measure
lubricating oil pressure.
Install the pressure gauge to the main oil rifle (1) or air filter
head (2).

kPa psi
Low Idle 138 MIN 20
Rated rpm 413 MIN 60
Engine Coolant Pressure

Measure the coolant pressure at the water manifold (1).
Coolant Pressure
kPa psi
241 MAX 35
Air Compressor
All air compressors manufactured by Cummins Inc. must
be operating during the engine run-in. During the
performance check, all air compressors must be in the
unloaded or non-operating mode.
Connect a source of compressed air capable of producing
665 kPa [95 psi] to the air compressor unloader (1). This
air line must contain a valve between the source and the
unloader.
Attach compressed air load to the air compressor outlet
(2).
Use an air tank (2). Install an air regulator (3) capable of

maintaining 345- to 517-kPa [50- to 75-psi] air pressure at
both minimum and maximum engine rpm.
Install a steel tube or high-temperature hose (1).
260°C [500°F].
Connect the tube or hose (1) to the air compressor outlet.
Starting Motor
Inspect the voltage rating on the starting motor before
installing the electrical wiring.
Install the electrical wiring to the starting motor and
batteries, if used.
NOTE: If another method of starting the engine is used,
follow the manufacturer's instructions to make the
necessary connections.
Engine Run-in (Engine Dynamometer) QSK45 and QSK60
Engine Run-in (Engine Dynamometer)

(014-006)
Install
Test
CAUTION
QSK45 and QSK60 industrial engines are equipped with
an automatic prelube system from the factory. If the
engine is not equipped with an automatic prelube system,
follow the instructions to prelube the system manually.
For engines without automatic prelube, use a pump, Part

Number 07600483, capable of supplying 205-kPa [30-psi]
continuous pressure. Connect the pump to the front of the
engine oil cooler as shown.
in the oil pan.
Check the engine lubricating oil level to be sure it is filled

to the proper level.
QSK45 and QSK60 Engine Run-in (Engine Dynamometer)
WARNING
CAUTION
008-018.
Use a known source of good-quality number 2 diesel fuel.
the energy content (BTU) per gallon (liter, etc.).
Engine Throttle Control

Engines that are run on an engine dynamometer require
that the engine harness be installed and connected to the
engine. Additionally, a special engine dynamometer
version of the OEM wiring harness and throttle control
must be installed.
A special wiring harness and throttle control has been
developed to enable engine operation out of the chassis,
Engine Dynamometer Kit, Part Number 3163890.
Engine operating specifications can be found in

publications available from your local Cummins
Authorized Repair Location.
Engine Run-in (Engine Dynamometer) QSK45 and QSK60
Run-In Instructions
Refer to Engine Testing - Engine Dynamometer,
Procedure 014-005, for general operating procedures and
safety precautions.
The run-in test must be performed with the engine
operating at torque peak rpm. Operate a generator set
engine at rated rpm. Refer to the performance charts
available through Cummins Inc.
Use this chart to determine the test load.
Rated RPM Torque Peak
1800 1500
1900 1500
CAUTION
Do not crank the starting motor for more than 30
seconds. Excessive heat will damage the starter.
CAUTION
If the oil pressure is not within specifications, stop the
engine immediately. Both low and high oil pressure
will cause engine damage.
Start the engine. If the engine does not begin operating
after 30 seconds, allow 2 minutes for the starting motor to
cool.
Check the oil pressure.
Main Oil Rifle Pressure (at Low Idle)

kPa kPa psipsi
138483 MAX 2070
If the oil pressure is not within specifications the engine
must be shut down.
CAUTION
Do not operate the engine at idle longer than
specified. Excessive carbon formation will cause
engine damage.
Operate the engine in the idle position and check for leaks.
QSK45 and QSK60 Engine Run-in (Engine Dynamometer)
Adjust the engine rpm to 1200 rpm. Adjust the

dynamometer load to the test load as previously
determined. Operate the engine at this setting until the
coolant temperature indicates 71°C [160°F].
Inspect for leaks.
Repair any leaks found during inspection.
Check all of the gauges, and record the readings.
Do not proceed to the next step until the blowby becomes
stable within specifications.
Adjust the engine rpm to the torque peak rpm. Adjust the
dynamometer load to equal two times the test load.
Operate the engine for two minutes.
Check all the gauges, and record the readings.
Maintain the engine rpm at torque peak rpm. Increase the

dynamometer load to equal three times the test load.
Operate the engine at this load for 2 minutes.
Move the throttle lever to the full-open position. Increase

the load until the engine rpm is at torque peak rpm.
Operate the engine at this setting for 10 minutes or until
the blowby becomes stable within specifications.
Engine Testing (In Chassis) QSK45 and QSK60
Decrease the dynamometer load until the engine rpm

increases to the rated rpm.
Operate the engine at this load for 5 minutes.
CAUTION
Do not turn the engine off immediately. The engine
must be allowed to cool.
CAUTION
Do not operate the engine at idle longer than
specified. Excessive carbon formation can cause
engine damage.
Decrease the dynamometer load completely.
Switch the engine to low idle. Operate the engine at this
setting for 3 to 5 minutes. This will allow the turbocharger
and the other engine components to cool.
Engine Testing (In Chassis) (014-008)

Stall Speed Check
The stall speed is the engine speed (rpm) obtained at full
throttle when the converter output shaft is locked.
The vehicle brakes do not always hold an electronically
controlled transmission.
QSK45 and QSK60 Engine Testing (In Chassis)
CAUTION
Do not exceed 120°C [250°F] converter oil
temperature. If the oil temperature exceeds 120°C
[250°F], put the transmission in neutral, and operate
the engine until the oil temperature is below 120°C
[250°F]. Check the converter oil level.
The following equipment is needed for this check:

• Stopwatch
• INSITE™ tool, or a handheld optical tachometer, Part
Number ST-3377462
• Equipment manufacturer's stall speed and time-to-
stall specifications.
Monitor the engine rpm with the INSITE™ tool.
Put the gear selector in the highest gear or full forward.

In some types of equipment, it is also necessary to engage
the hydraulics.
Make sure the vehicle has good brakes and air pressure
in the brake system.
The brakes must prevent the vehicle from moving when
the engine is at full throttle.
Engage the vehicle brakes or keep the vehicle from
moving.
Operate the engine until the coolant temperature is up to

70°C [158°F] and the converter temperature is 80°C
[180°F] or above.
Alternately, shift from neutral to the highest speed gear
possible, and operate at partial throttle. This will warm the
entire system uniformly.
Bring the engine speed back to low idle.
CAUTION
Do not exceed 120°C [250°F] converter oil
temperature. If the oil temperature exceeds 120°C
[250°F], put the transmission in neutral, and operate
the engine until the oil temperature is below 120°C
[250°F]. Check the converter oil level.
Move the throttle to the full-open position. Do not perform
this test for more than 15 seconds. If the engine speed
continues to slowly increase, the torque converter fluid is
being overheated.
Check the engine speed (rpm) at the point of stall.

Always hold the speed until it is stable.
Take several readings. Be sure the reading is accurate.
Check the stall speed (rpm) against the specifications that

are for the equipment, converter, or automatic
transmission.
The stall speed for the engine and converter/transmission
can vary ±8 percent from the manufacturer's
specifications.
If the stall speed is not within the specifications, refer to

the Stall Speed Checklist at the end of this section.
Check the OEM's troubleshooting procedures for other
reasons for stall speed problems.
After performing the Stall Speed Check through the torque

converter fluid being overheated, calculate the engine
stall speed.
Engine Stall Speed
Stall Speed x 90 percent = Stall Speed Reference Point
Example: 2,089 rpm x 0.90 = 1880 rpm
If the cause for the stall speed being too low is low engine
power output, refer to the Engine Power Output Low
Troubleshooting Chart. Make the correct repair based on
the fuel rate, fuel pressure, and intake manifold pressure
readings.
Time Speed Check

Quickly move the throttle to the full-open position, and
start the stopwatch at the same time.
When the engine speed is 90 percent of the stall speed

rpm, stop the stopwatch.
The type of unit and the stall speed rpm will be different
for different types of equipment. Most types have a stall
speed between 8 and 12 seconds.
Check the equipment manufacturer's specifications for

the time to stall or the acceleration time.
If the time is excessive, refer to Troubleshooting
Symptoms Charts, Engine Acceleration/Response Poor.
Stall Speed Checklist

If The Stall Speed Is Too Low, Check The Following:
Order of Check Yes No Check
1 The tachometer is in error.
2 The engine is up to or above 70°C [160°F].
3 The converter oil is up to temperature 80°C [180°F].
4 The stall has been held long enough for the engine to accelerate to full power.
5 The match curve stall speed was recorded correctly.
The converter oil is to the converter manufacturer's recommendation. Society
6
of Automotive Engineers (example: SAE 30 instead of SAE 10).
If The Stall Speed Is Too Low, Check The Following:

The engine-driven accessory power requirements exceed 10 percent of the
gross engine power. Check for abnormal accessory horsepower losses such as
7 hydraulic pumps, large fans, oversize compressors, etc. Either remove the
accessory or accurately determine the power requirement and adjust
accordingly.
8 The unit is operating at an altitude high enough to affect the engine power.
9 The converter charging pressure is correct.
The tailshaft governor is interfering with and preventing a full-throttle opening.
10
(Disconnect the tailshaft governor).
The converter blading is interfering or in a stage of failure. Check the sump or
11
filter for metal particles.
12 The converter stators are free-wheeling instead of locking.
13 The engine is set for power other than that specified on the power curve.
14 The converter is wrong because of improper build or rebuild of unit.
15 The converter is performing to the published absorption curve.
The engine and converter match is correct. Check the engine and converter
16
models for the proper match.
The engine is matched to an oversize converter. (If this condition is believed to
17
exist, report the engine-converter-accessory information to the factory).
The engine power is down. (The engine torque rise can be less than shown on
18 the standard engine curve). See the fuel setting adjustments and the
turbocharger air manifold pressure check.
It is sometimes easier to change the engine fuel rate than to determine the true cause for low stall speed, but the
customer ends up with an overfueled engine that will also reduce durability. Do not increase the fuel rate as a cure-
all.
If The Stall Speed Is Too High, Check The Following:

1 The engine is high in power.
2 The tachometer is in error.
3 The accessory power requirements are less than 10 percent of the gross engine
power.
4 The converter oil is aerating (foaming) - check for low oil level, air leaks in
suction line, and oil that does not contain a foam inhibitor, or suction screen
or filter. (It will be accompanied by a noticeable loss of machine performance.)
5 The converter is being held at full stall. Check for a slipping front disconnect
clutch or a rotating output shaft. On the converter-transmission package, this
can be impossible to check.
The converter turbine element is beginning to fail and lose blades, or the
6
converter was originally built with the wrong-size element.
The engine and converter match is correct (because of a revision in the engine
7
rating or the converter performance).
On the transmission-converter units with oil sump in the transmission, if the oil
8 level is too high, it can cause severe aeration because of parts dipping in the
oil.
9 The converter is performing to the published absorption curve.
10 The converter charging pressure is correct.
The reasons for abnormal stall speeds listed on the previous page are some which have been encountered by
Cummins representatives and do not include all possible causes. The correction of the problem is either covered in
the vehicle service manual, the converter service manual, or is self-explanatory.
Engine Compression QSK45 and QSK60
Engine Compression (014-012)

Preparatory Steps
• Remove the rocker lever cover. Refer to Procedure
K19, Bulletin 3810307. Refer to Procedure 003-011
in the Troubleshooting and Repair Manual QSK19
Series Engines, Bulletin 3666098. Refer to
Procedure 07-04 in the K38 and K50
Troubleshooting and Repair Manual, Bulletin
3810432. Refer to Procedure 003-011 in the QSK45
and QSK60 Base Engine Troubleshooting and
Repair Manual, Bulletin 3666261. Refer to
Repair Manual QSK78 Series Engines Bulletin
3666727. Refer to Procedure 003-011 in the
Troubleshooting and Repair Manual QSK23 Series
• Remove the rocker lever assembly. Refer to
Procedure 07-09 Troubleshooting and Repair
Manual K19, Bulletin 3810307. Refer to Procedure
003-009 Troubleshooting and Repair Manual QSK19
• Remove the injector. Refer to Procedure 05-09 in the
Troubleshooting and Repair Manual K19, Bulletin
Engines, Bulletin 3666098. Refer to Procedure 05-09
in the K38 and K50 Troubleshooting and Repair
Manual, Bulletin 3810432. Refer to Procedure
006-026 QSK45 and QSK60 Base Engine
Engines Bulletin 3666727. Refer to Procedure
QSK23 Series Engines, Bulletin 4021375.
QSK45 and QSK60 Engine Compression
• Establish top dead center (TDC) on the compression

stroke. Refer to Procedure 07-20 in the
Engines , Bulletin 3666098. Refer to Procedure
07-18 in the K38 and K50 Troubleshooting and
Procedure 006-025 in the QSK45 and QSK60 Base
Engine Troubleshooting and Repair Manual ,
Bulletin 3666261. Refer to Procedure 006-025 in the
Engines , Bulletin 3666727. Refer to Procedure
QSK23 Series Engines , Bulletin 4021375.
Continue to rotate the crankshaft until the piston passes
TDC and is 12.7 mm [0.50 inch] after top dead center
(ATDC).
Rotate the crankshaft in the opposite direction to raise the
piston 6.35 mm [0.250 inch] below TDC.
Setup
Install the appropriate air fitting (supplied with the
differential pressure tester, Part Number 3824223) into the
top of the leak test adapter with thread sealing tape.
Check all o-rings for cracks or damage prior to each
cylinder test and replace if necessary.
Lubricate the o-rings and leak test adapter with 15W-40
lubricating oil.
NOTE: If the injector installation tool, Part Number

3824830, is not available, use a 40 mm [1 9/16-inch]
socket with an extension and a rubber mallet to install the
leak test adapter.
Install the leak test adapter and hold-down clamp into the
cylinder head.
Use injector installation tool, Part Number 3824830, to
seat the leak test adapter in the bore.
The slide hammer will make a dull sound when the leak
test adapter is seated properly.
Install the injector hold-down clamp and capscrew.

NOTE: The crankshaft breather is not to be obstructed

during this test, do not install plugs or orifices as used in
traditional blowby tests.
Close the ball valve on the differential cylinder pressure
tester, Part Number 3824223. Connect the differential
cylinder pressure tester outlet hose to the fitting on the
leak test adapter.
Pressure Differential Test
WARNING
personal injury.
Connect the differential cylinder pressure tester inlet hose
to shop air.
Open the differential pressure tester ball valve slowly,
taking careful note of any crankshaft rotation. If any
rotation is apparent, the piston will not be correctly
positioned in the cylinder. If the piston is correctly
positioned in the cylinder and the engine crankshaft still
rotates, the engine barring mechanism must be locked to
prevent engine rotation.
Make certain that there are no leaks at any connection
joint.
QSK45 and QSK60 Engine Compression
Pressurize the cylinder and adjust the regulator on the

differential pressure tester until gauge (1) indicates 100
psi [689 kPa]. When the reading on gauge (2) has
stabilized, record the pressure reading of both gauges and
record the cylinder number and bank.
If at any time during the test the reading on gauge (2) is
not stable, lightly tap the tops of the engine valves with a
rubber mallet to make certain that they are closed. If the
reading on gauge (2) remains unstable, repeat positioning
procedure described earlier.
Position each remaining cylinder and test.
The leakdown test can be used to determine the relative

condition of a cylinder when compared to other cylinders
in the engine. The leakdown test can also help diagnose
the source of the leak or blowby. This includes, but is
not limited to, air flow from the breather (worn cylinder),
air flow in the intake or exhaust manifold (leaking valves)
or air bubbles in the coolant (leaking cylinder head gasket,
cylinder head crack or cylinder block crack).
Before taking any action based on leakdown test results,
repeat the leakdown test for the suspect cylinder and
compare to the original results. Factory leakdown limits
will not be established, cautious judgment must be used
before replacing parts or taking any action due to results
from the leakdown test.
Additionally, the test results subject to comparison need
to be obtained within a relatively short time frame.
Leakdown test results are expected to vary depending on
engine temperature. Because of this, comparing
leakdown results from different engines is not
recommended.
Remove the differential pressure tester and leak test
adapter.
Finishing Steps
• Install the injector. Refer to Procedure 05-09 in the
006-026 QSK45 and QSK60 Base Engine
• Install the rocker lever assembly. Refer to Procedure
07-09 Troubleshooting and Repair Manual K19,
Bulletin 3810307. Refer to Procedure 003-009
003-009 in the QSK45 and QSK60 Base Engine
• Install the rocker lever cover. Refer to Procedure
K19, Bulletin 3810307. Refer to Procedure 003-011
in the Troubleshooting and Repair Manual QSK19
QSK45 and QSK60
Section 16 — Mounting Adaptations — Group 16 Page 16-a
Section 16 — Mounting Adaptations — Group 16

Section Contents
Page
Engine Lifting Brackets ...................................................................................................................................16-3
Engine Support Bracket, Front .......................................................................................................................16-3
Finishing Steps...............................................................................................................................................16-6
Install..............................................................................................................................................................16-5
Remove..........................................................................................................................................................16-4
Flexplate ..........................................................................................................................................................16-7
Flywheel ..........................................................................................................................................................16-7
Finishing Steps............................................................................................................................................. 16-12
Install............................................................................................................................................................16-10
Remove..........................................................................................................................................................16-9
Flywheel Housing ..........................................................................................................................................16-14
Exploded View.............................................................................................................................................. 16-17
Finishing Steps............................................................................................................................................. 16-29
Install............................................................................................................................................................16-25
Redowel........................................................................................................................................................16-21
Remove.........................................................................................................................................................16-17
Flywheel Ring Gear .......................................................................................................................................16-31
Assemble......................................................................................................................................................16-32
Disassemble..................................................................................................................................................16-31
Service Tools ...................................................................................................................................................16-1
Mounting Adaptations......................................................................................................................................16-1
QSK45 and QSK60
Page 16-b Section 16 — Mounting Adaptations — Group 16

Section 16 — Mounting Adaptations — Group 16 Page 16-1
Service Tools
Mounting Adaptations
Repair Location.

Dowel Pin Extractor
Used to remove dowel pins.
ST-1134
Drill and Ream Fixture

Used to machine dowel pin holes to install oversize dowel pins in the
ST-1232 cylinder block and/or flywheel housing. Used with a drill, reamer, and
the appropriate drill and ream bushing set.
Engine Lifting Fixture

Used to lift the engine during installation and removal. This kit
3163264 contains the lift fixture, Part Number 3163265, and four lifting straps,
Lift Strap (2 in x 6 ft)

Used to aid in the removal and installation of heavy components.
3375957
Lift Strap (1 in x 6 ft)

Used to aid in the removal and installation of heavy components.
3375958
Spring Tester
Used to test spring force.
3375182
Page 16-2 Section 16 — Mounting Adaptations — Group 16

Flywheel Housing Indicator
Used to check flywheel housing run out.
ST-1325
Torque Wrench
Used to tighten flywheel housing capscrews.
3164797
QSK45 and QSK60 Engine Support Bracket, Front
Engine Lifting Brackets (016-001)

WARNING
for use. Wear goggles and protective to reduce the
possibility of personal injury.
Clean the lifting brackets, washers, and capscrews with
solvent.
Check the brackets for cracks. Check the capscrews for
rust and corrosion.
Perform the magnetic crack inspection on the capscrews.
Engine Support Bracket, Front

(016-002)
Preparatory Steps
WARNING
Remove the fan drive belt, if applicable. Refer to
Procedure 008-002.
WARNING
Remove the vibration damper. Refer to Procedure
001-052.
Remove the crankshaft adapter. Refer to Procedure
001-017.
Engine Support Bracket, Front QSK45 and QSK60
Remove
WARNING
Install the engine lifting fixture (1), Part Number 3163264,
and lifting straps (2).
Remove the capscrews that attach the front engine

support to the equipment frame.
Lift the engine off the front support bracket.
Remove the front engine support.

QSK45 and QSK60 Engine Support Bracket, Front
Inspect for Reuse
WARNING
CAUTION
Damaged engine mounts and brackets can cause the
engine to move out of alignment, damage the
driveline components in the equipment, and result in
vibration complaints.
Inspect the front engine mount for cracks or damage.
Inspect all mounting brackets for cracks or damaged bolt
holes.
Replace the bracket if cracked or damaged.
Measure the front support bore.
Front Support Bore

mm in
Previous Engine 279.45 MIN 11.00
Support Bracket
279.95 MAX 11.02
New Engine Support 294.00 MIN 11.57
Bracket
294.07 MAX 11.58
If the front support bore is not within specifications, the
front engine support bracket must be replaced.
Install
WARNING
Install the front engine support.
Engine Support Bracket, Front QSK45 and QSK60
Lower the engine until the front engine support is in

position.
Install and tighten the mounting capscrews.
Remove engine lifting fixture.
Finishing Steps
WARNING
Install the crankshaft adapter. Refer to Procedure
001-017.
Install the vibration dampers. Refer to Procedure 001-052.
WARNING
Install fan drive belt, if applicable. Refer to Procedure
008-002.
QSK45 and QSK60 Flywheel
Flexplate (016-004)
WARNING
WARNING
personal injury.
WARNING
Cummins Inc. does not recommend resurfacing of the
flexplate. Resurfacing the flexplate can cause
personal injury and property damage because the
flexplate is too thin.
CAUTION
Do not disassemble the flexplate assembly. Improper
assembly of the flexplate can cause engine damage.
Clean the flexplate with solvent and dry with compressed
air.
Check the ring gear for damaged or worn teeth. If the teeth
are damaged or worn the flexplate must be replaced.
Use the dye penetrant method to check the area of the
mounting holes for cracks. If the flexplate is cracked in the
mounting area the flexplate must be replaced.
Check the mounting pilot for damage. If the pilot is
damaged, the flexplate must be replaced.
Flywheel (016-005)
Preparatory Steps
WARNING
(-) battery cable first, and attach the negative (-)
battery cable last.
WARNING
• Disconnect the batteries. Refer to Procedure
013-009.
• Disconnect the air starter to prevent accidental
engine starting. Refer to Procedure 012-022.
• Remove the transmission, clutch, and all related
components. Refer to the OEM's instructions.
Flywheel QSK45 and QSK60
WARNING
battery cable last.
WARNING
013-009.
engine starting. Refer to Procedure 012-022.
Procedure 010-013.
• Remove the air cleaner support bracket. Refer to
Procedure 016-006.
WARNING
battery cable last.
WARNING
013-009.
engine starting. Refer to Refer Procedure 012-022.
• Remove the engine speed sensor. Refer to
Repair Manual Electronic Control System, QSK50
Remove
WARNING
Remove two capscrews, and install two guide studs.
Install the tee-handles.
Install the lifting straps.
Remove the remaining capscrews.
A mallet can be used to tap the flywheel if necessary.
Remove the flywheel.
WARNING
WARNING
WARNING
personal injury.
Use solvent or steam to clean the flywheel.
Use a wire brush to clean the crankshaft pilot bore.
Inspect the teeth of the ring gear for wear or damage.

If the teeth of the ring gear are worn or damaged, the ring
gear must be replaced. Refer to Procedure 016-008.
Use dye penetrant, Part Number 3375432, method to

check the area of the mounting capscrew holes for cracks.
There must not be any cracks in the flywheel mounting
area.
Inspect the pilot bearing mounting hole for damage. If the
pilot hole is damaged, the flywheel must be replaced.
WARNING
Cummins Inc., does not recommend resurfacing the
flywheel. Resurfacing the flywheel can cause it to be
too thin and cause personal injury, property damage,
or result in breakage.
Inspect the face of the flywheel for cracks or damage.
The flywheel must be replaced if cracked or damaged.
Install
Lubricate the flywheel mounting capscrew threads and
flange head surfaces with clean engine oil.
Install the washer onto the capscrew and lubricate the
washer (1).
WARNING
Install two guide studs, to prevent the flywheel from
rotating.
Install the flywheel.
Install the flywheel mounting capscrews.
Remove the two guide studs, and install the last two
flywheel mounting capscrews.
Tighten the flywheel mounting capscrews in the sequence

shown.
Step2 380 N•m [ 280 ft-lb ]
Step3 685 N•m [ 505 ft-lb ]
Measure the flywheel total indicator runout.

Flywheel Housing
Number 0 648 mm [ 25.5 in ]
Flywheel Bore Total Indicator Runout

mm in
Number 0 0.127 MAX 0.005
Number 00 0.127 MAX 0.005
The maximum allowed flywheel face runout is determined

by the distance from the center of the flywheel to the
contact point of measurement, divided by 1000.
Measure the flywheel face total runout.
Flywheel Face Total Indicator Runout

mm in
Number 0 (with a 254- 0.254 MAX 0.010
mm [10-in] center
distance)
Number 00 (with a 305- 0.305 MAX 0.012
mm [12-in] center
distance)
Finishing Steps
WARNING
WARNING
battery cable last.
• Install the drive unit and related components. Refer
to the OEM's instructions.
• Connect the batteries. Refer to Procedure 013-009.
• Connect the air to the air starter. Refer to Procedure
012-022.
WARNING
WARNING
battery cable last.
• Install the drive unit and related components. Refer
to the OEM's instructions.
• Install the air cleaner support bracket. Refer to
Procedure 016-006.
010-013.
012-022.
WARNING
battery cable last.
WARNING
• Install the engine speed sensor. Refer to Procedure
Modular Common Rail System Series Engines,
Bulletin 4021533.
• Install the transmission, clutch, and all related
012-022.
Flywheel Housing QSK45 and QSK60
Flywheel Housing (016-006)

Preparatory Steps
WARNING
possibility of personal injury, away ventilate the
battery cable last.
WARNING
WARNING
WARNING
ingestion, or prolonged contact with used engine oil.
If not reused, dispose of in accordance with local
• Disconnect the batteries to prevent accidental
starting. Refer to Procedure 013-009.
• Disconnect the air starter (if equipped) to prevent
accidental starting. Refer to OEM Service Manual.
• Remove the starting motor. Refer to Procedure
013-020.
components. Refer to the OEM Service Manuals.
• Remove the flywheel. Refer to Procedure 016-005.
• Drain the Engine Lubricating oil. Refer to Procedure
007-037.
• Remove the rear crankshaft seal. Refer to Procedure
001-024.
QSK45 and QSK60 Flywheel Housing
WARNING
WARNING
battery cable last.
WARNING
013-020.
• Remove the engine speed sensor. Refer to
• Remove the rear bank wiring harness. Refer to
• Remove the turbocharger oil drain lines. Refer to
Procedures 010-034 or 010-035.
• Drain the engine lubricating oil. Refer to Procedure
007-037.
001-024.
WARNING
battery cable last.
WARNING
WARNING
WARNING
013-020.
• Remove the turbocharger air inlet connections.
Procedure 010-013.
• Drain the engine lubricating oil. Refer to Procedure
007-037.
001-024.
Exploded View
Flywheel Housing
1. Flywheel housing 9. Pressure regulator spring
2. Transmission adapter locating roll pin 10. Capscrew (M6 x 1.00 x 12)
3. Capscrew (M12 x 1.75 x 50) 11. Flywheel housing locating dowel pin
4. Transmission adapter 12. Capscrew (M6 x 1.0 x 20)
5. Capscrew 13. Access hole cover
6. Pressure regulator plug 14. Rear crankshaft oil seal
7. O-ring seal 15. Flywheel housing mounting gasket.
8. Pressure regulator plunger for piston cooling nozzles
Remove
WARNING
Inspect the engine lifting brackets for damage or
cracks. Do not attempt to lift the engine if any cracks
or damage is visible. Using damaged lifting equipment
can cause serious personal injury and or property
damage.
WARNING
The QSK45 and QSK60 series engines can weigh as
much as 9980 kg [22,000 lb]. Use a properly rated
hoist and lifting fixture, Part Number 3163264 to lift
the engine. Rigging and lifting must be done by
trained, experienced personnel.
Install the engine lifting fixture.
Remove the capscrews from the engine mounts.
Use the engine lifting fixture to lift the engine up until the
engine mounts are free from the frame.
Remove the adapter cover plate or oil sump, whichever is

in the front position.
CAUTION
Put a wooden block the width of the oil pan adapter
between the jack stands and the oil pan adapter to
prevent damage to the engine. Use a minimum of four
jack stands to support the engine.
Each jack stand must be rated at a minimum of 2722 kg
[6,000 lbs].
Use the engine lifting fixture to lift the engine and support
the front and rear on both sides of the engine with a jack
stands and wooden blocks.
Remove the rear engine mounts from the flywheel

housing.
WARNING
Remove two capscrews, and install the guide studs.
Use a hoist, tee-handles, and a lifting sling to remove the
flywheel housing.
Install the lifting sling, and adjust the hoist until there is
tension in the lifting sling.
Remove the remaining flywheel housing mounting
capscrews.
Use a mallet, and tap the flywheel housing off the two
locating dowel pins.
Note the gasket orientation. Engine damage can occur if
the gasket is not properly installed when reinstalling the
flywheel housing.
Remove the gasket.
Remove the two capscrews securing the gasket in place

to the engine block and remove the gasket.
WARNING
The pressure regulator springs are under
compression. Use caution when removing. Personal
injury can occur.
Remove the pressure regulator from the flywheel housing.
Remove the plug (1), springs (4), and plunger (3) from the
flywheel housing. Remove and discard the o-ring (2) from
the plug.
WARNING
WARNING
WARNING
personal injury.
Use solvent or steam to clean the flywheel housing.
Inspect all surfaces for nicks, burrs, cracks, or damage.
Use a fine crocus cloth to remove small nicks and burrs.
Inspect all threaded capscrew holes for damage.

Repair or replace the housing if the capscrew holes are
damaged.
WARNING
WARNING
personal injury.
Use solvent to clean the lubricating oil pressure regulator
spool and spring. Dry with compressed air.
Inspect the spring for broken coils.
Inspect the spool for scuffing. Minor scuffs can be
removed with a fine crocus cloth.
The critical area of the spool is the seating area. Polished
areas are normal.
Use a spring tester, Part Number 3375182, to measure the

pressure regulator spring tension.
Compress the spring to 114.3 mm [4.50 in].
The force required to compress the pressure regulator
spring must be:
Force required to compress Pressure Regulator
Spring
N lbf
112.5 Assembled Length 25.3
If the pressure regulator spring does not meet this

specifications, it must be replaced.
Redowel
The tools needed to perform this procedure are:
Drill ream fixture, Part Number ST-1232, that contains:
1. Plate, Part Number ST-1232-1
2. Locator pin, Part Number 3375052
3. Spacer washer, Part Number ST-1232-2
4. Drill/ream actual sizes bushing set depend on the
dowel size
5. Drill adapter locally obtained; use to adapt open-
shank reamers to drill-chuck
6. Reamer locally obtained
7. Drill bit locally obtained.
Use a dowel pin extractor, Part Number ST-1134, or

equivalent. Remove the two dowels (9) from the block.
Measure a dowel pin that has been removed so an
oversize dowel pin can be determined.
WARNING
avoid personal injury, use a hoist or get assistance
when lifting this component.
Install the edge-molded gasket in the correct position.
Use guide bolts to help during alignment. Install the
flywheel housing and the capscrews.
Install the flywheel housing.
Do not tighten the capscrews. The flywheel housing will
have to be aligned.
Move the housing with a mallet until the bore is within

specifications. Make sure that the face of the housing is
in alignment.
Flywheel Housing Bore Diameter

mm in
Number 0 648 NOM 25.5
Flywheel Housing - Radial Runout

mm in
Number 0 0.25 MAX 0.010
Number 00 0.30 MAX 0.012
Measure the flywheel housing face runout.
Flywheel Housing - Face Runout

mm in
Number 0 0.25 MAX 0.010
Number 00 0.30 MAX 0.012
When the housing is in alignment, tighten the capscrews

in the sequence shown.
Step2 195 N•m [ 144 ft-lb ]
After the capscrews are tightened, check the alignment
again.
The graphic illustrates the location of the dowel holes on

QSK45 and QSK60 flywheel housings.
Using the appropriate capscrews, attach plate, Part

Number ST-1232-1, that is contained in the drill ream
fixture, Part Number ST-1232, to the crankshaft.
Do not completely tighten the capscrews, the plate must
be able to move.
Use the locator pin to align the plate with the hole for the
dowel pin.
The taper on the pin must engage the dowel pin hole.
The locator pin must rotate easily after the capscrews are
tightened.
Lock the crankshaft into position.
Make sure the locator pin is still in alignment and that the
locator pin can be rotated easily.
The crankshaft must not turn during the reaming process.
Measure the dowel pins to be installed.

Obtain a reamer (5) that is 0.013- to 0.025-mm [0.0005- to
0.001-in] smaller than the dowel.
The dowel must protrude from the block by one-half of the
flywheel housing wall thickness.
There are three oversize dowel pins available from
Cummins Inc.
Oversize Dowel Pin - Outer Diameter
Oversized 0.381 mm [0.01513.08 mm [ 0.515 in ]
in]
Install the appropriate drill bushings (4). The following

bushings are available from Cummins Inc.
Available Drill/Ream Bushing Sets

Part Number Bushing Sizes
1.230 mm [0.484 in], 1.270 mm [0.500 in],
3376495 13.106 mm [0.516 in], 13.487 mm [0.531
in], 13.868 mm [0.546 in]
14.300 mm [0.563 in], 14.681 mm [0.578
ST-1234 in], 15.088 mm [0.594 in], 15.487 mm
[0.694 in],
15.875 mm [0.625 in], 16.281 mm [0.640
ST-1235 in], 16.662 mm [0.656 in], 17.069 mm
[0.672 in]
17.475 mm [0.688 in], 17.856 mm [0.703
ST-1236 in], 18.263 mm [0.719 in], 18.644 mm
[0.734 in]
19.050 mm [0.750 in], 19.456 mm [0.766
ST-1237
in], 19.837 mm [0.781 in]
ST-1238 22.631 mm [0.891 in], 23.825 mm [0.938
in]
The drill bushing used must be the same size as the

reamer (or the drill) used.
WARNING
WARNING
personal injury.
CAUTION
Do not allow metal chips to enter the engine. Damage
to the engine will result.
When the new dowel pins are more than 0.38-mm [0.015-
in] larger than the old dowels, drill the hole to a size that
is slightly smaller than the reamer. The reamer will not
have to remove an excessive amount of material.
Ream the hole until the reamer touches the bottom of the
hole in the block.
Remove the reamer. Clean the hole with solvent. Dry with
compressed air. Push the reamer through the hole again.
The reamer must touch the bottom of the hole in the block.
After reaming one hole, turn the plate and align it with the
next dowel hole. Repeat the procedure in the next hole.
CAUTION
The dowel hole must not contain any metal chips.
Engine damage will result.
Remove the plate from the crankshaft.
Use a square-nose drift. Drive in each dowel pin until it
touches the bottom of the hole in the block.
After the dowels are installed, measure the bore and the
face alignment.
If not within specifications, repeat the alignment and
doweling procedure.
Install
Use clean engine oil to lubricate the oil pressure regulator
bores on the flywheel housing.
Instal the pressure regulator plunger (3) into the bore with
the flat face of the plunger first.
Check that the plunger has freedom of movement the
entire length of the bore.
Insert the regulator valve springs (4) into the bore.
Assemble a new o-ring (2) on the plug (1).
Lubricate the o-ring (2) and compress the pressure
regulator spring sufficiently to engage the plug to the
threads in the bore. Tighten the plug.
Torque Value:
Oil Pressure 60 N•m [ 44 ft-lb ]
Regulator Plug
CAUTION
The tab at the top of the flywheel housing gasket is to
provide indication of proper orientation of the gasket.
Failure to do so will cause excessive lubrication oil
temperatures which will lead to engine damage.
Install the flywheel housing gasket over the dowels (2) on
the engine block. Check the tab (1) on the gasket is
located on the same side as the lubricating oil filter head
assembly. The tab shows which of the two oil cooler rifles
will be covered to ensure oil is passed through the oil
coolers. Example: If the oil filter head is on the right bank
of the engine, then the right bank oil cooler rifle needs to
be covered. Therefore the tab (1) on the flywheel housing
gasket must be on the right bank side.
Secure the flywheel gasket in place with the two

capscrews located below the tab.
Torque Value:
Flywheel 9 N•m [ 80 in-lb ]
Gasket
Capscrews
WARNING
or get assistance when lifting this component.
Make sure the flywheel housing dowel pins have been
installed into the cylinder block.
Use guide bolts to help during alignment.
Install the flywheel housing and the capscrews.
Tighten the flywheel housing mounting capscrews in

sequence.
Step2 195 N•m [ 144 ft-lb ]
The bore and the face of the housing must align with the
crankshaft.
The indicator arm must be rigid for an accurate reading.
It must not sag.
Attach an indicator to the crankshaft as shown.
Position the indicator at the 12-o'clock position. Adjust the

dial until the needle points to zero. Rotate the crankshaft
one complete revolution, 360 degrees.
Record the total indicator runout.
The indicator must return to zero when returning to start
point.
The maximum allowable total indicator runout depends on

the diameter of the bore.

mm in

mm in
Number 0 0.25 MAX 0.010
Number 00 0.30 MAX 0.012
If the alignment is not within specifications and the bore
is round, the housing can be shifted.
If the alignment is not within specifications and the bore
is not round, the housing must be replaced.
When measuring the face runout, the crankshaft must be

pushed or pulled in the same direction each time a point
is measured.
Attach an indicator as shown. Position the indicator at the
12-o'clock position. Adjust the dial until the needle points
to zero.

mm in
Number 0 0.25 MAX 0.010
Number 00 0.30 MAX 0.012
Record the indicator reading at three different points; for

example, 3 o'clock, 6 o'clock, and 9 o'clock.
Turn backward to the original position. Make sure the
needle still points to zero. Determine the total indicator
runout.
Example of Total Indicator Run Out

Position Indicator Reading
3 o'clock 0.00 mm [0.00 in]
6 o'clock 0.08 mm [0.003 in]
9 o'clock 0.05 mm [0.002 in]
Total Indicator Run Out = 0.13 mm [0.005 in]
Install engine mounts to the front of the flywheel housing.
Install the adapter cover plate or oil sump, whichever is in

the front position.
Lift the engine. Remove the jack stands and supports, and
lower the engine.
Finishing Steps
WARNING
WARNING
battery cable last.
• Install the rear crankshaft seal. Refer to Procedure
001-024.
• Fill the engine with lubricating oil. Refer to Procedure
007-037.
• Install the flywheel. Refer to Procedure 016-005.
• Install the starting motor. Refer to Procedure
013-020.
• Connect the air starter (if equipped). Refer to OEM
Service Manual.
WARNING
WARNING
battery cable last.
001-024.
• Fill the engine with lubricating oil. Refer to Procedure
007-037.
013-020.
• Install the engine speed sensor. Refer to Procedure
Modular Common Rail System Series Engines,
Bulletin 4021533.
• Install the rear bank wiring harness. Refer to
• Install the turbocharger oil drain lines. Refer to
Procedures 010-034 or 010-035.
Service Manual.
QSK45 and QSK60 Flywheel Ring Gear
WARNING
WARNING
battery cable last.
001-024.
• Fill engine with lubricating oil. Refer to Procedure
007-037.
013-020.
• Install the turbocharger air inlet connections. Refer
010-013.
Service Manual.
Flywheel Ring Gear (016-008)

Disassemble
WARNING
protective gloves when removing the heated ring
gear.
WARNING
To reduce the possibility of severe eye damage, wear
eye protection when you drive the ring gear from the
flywheel.
CAUTION
Adjust the torch to a good heating flame. Do not use
a cutting flame (a blue flame) to heat the ring gear.
Damage to the flywheel can result.
Heat the ring gear with a torch.
Use a brass drift and a hammer to remove the hot ring
gear.
Flywheel Ring Gear QSK45 and QSK60
WARNING
To reduce the possibility of severe eye damage, wear
eye protection when you drive the ring gear from the
flywheel.
If a heating torch is not available, the ring gear can be
removed with a brass drift and hammer.
If this method is used to remove the ring gear from a
flexplate assembly, make sure a wooden block is used to
support the ring gear adapter.
Assemble
WARNING
CAUTION
Damage to the ring gear and the ring gear teeth can
result.
CAUTION
Do not attempt to install the ring gear without heating
it, the ring gear will be damaged or broken.
Adjust the oven temperature to 232°C [450°F]. Heat the
ring gear in the oven for a minimum of one hour, and a
maximum of six hours. The inner diameter of the ring gear
will become larger and simplify the installation of the ring
gear on the flywheel.
WARNING
Use a heating flame to heat the ring gear if an oven is
not available.
Use a Tempilstik® crayon or equivalent, to check the
temperature of the ring gear. Heat the ring gear to 232°C
[450°F].
QSK45 and QSK60 Flywheel Ring Gear
WARNING
CAUTION
Allow the ring gear to air cool. Do not use water or oil
to reduce the cooling time. Damage to the ring gear
can result.
Remove the ring gear from the oven.
The part number is on the same side as the bevel.
Position the ring gear so that the bevel is positioned
toward the crankshaft edge of the flywheel as shown.
Install the ring gear.
Flywheel Ring Gear QSK45 and QSK60
Notes
QSK45 and QSK60
Section 17 - Miscellaneous - Group 17 Page 17-a
Section 17 - Miscellaneous - Group 17

Section Contents
Page
Capscrew .........................................................................................................................................................17-1
Magnetic Crack Inspect...................................................................................................................................17-1
Cup Plug ..........................................................................................................................................................17-3
Install..............................................................................................................................................................17-4
Remove..........................................................................................................................................................17-3
Flexible Hose ...................................................................................................................................................17-5
Pipe Plug .........................................................................................................................................................17-5
Install..............................................................................................................................................................17-6
Remove..........................................................................................................................................................17-5
Straight Thread Plug .......................................................................................................................................17-6
Install..............................................................................................................................................................17-7
Remove..........................................................................................................................................................17-6
QSK45 and QSK60
Page 17-b Section 17 - Miscellaneous - Group 17

QSK45 and QSK60 Capscrew
Section 17 - Miscellaneous - Group 17 Page 17-1
Capscrew (017-001)
Magnetic Crack Inspect
This procedure describes the visual and magnetic particle
inspection of special and high strength capscrews for the:
• Cylinder head
• Main bearing cap
• Flywheel
• Connecting rod
• Crankshaft pulley or adapter
• Lifting bracket
• Crankshaft counterweight.
CAUTION
Prevent damage to the capscrews. Nicks in the body
of the capscrew can cause an area of stress that can
fail during engine operation. Damage to the threads
will cause torque values to be incorrect and will
damage the mating parts.
WARNING
WARNING
Wear eye and face protection when using compressed
air. Flying debris and dirt can cause personal injury.
If necessary, use a wire wheel to remove all rust,
corrosion, and dirt from the capscrews.
Use solvent to clean the capscrew and dry with
compressed air.
Check the capscrew. The capscrew must be replaced if:

• Threads are damaged
• Rust or corrosion has caused pitting in the body
• The body is nicked, galled, bent, or stretched.
Some capscrews (cylinder head, main bearing cap,
connecting rods) have threads that have been formed by
a rolling operation during manufacture. Repair of rolled
threads by use of a thread die is not recommended. The
thread die can create a sharp corner on the minor
diameter (root) of the threads. This sharp corner can
cause an area of increased stress.
Capscrew QSK45 and QSK60
Page 17-2 Section 17 - Miscellaneous - Group 17
Use a magnetic particle testing machine such as

Magnaflux.
Use the continuous method. Apply a head shot of 300 to
400 amperes VDC or rectified VAC.
Use an ultraviolet light. Check for indications of cracks.

The magnetic particles tend to form on sharp corners and
edges. Do not mistake these for cracks.
Any indications of cracks are not acceptable.
Prepare the machine for a coil shot.

Make sure the capscrew is near one side of the coil and
not in the center.
Apply 1000 to 1350 ampere-turns.
Use an ultraviolet light. Check for indications of cracks.

Any indications of cracks are not acceptable.
QSK45 and QSK60 Cup Plug
WARNING
WARNING
Wear eye and face protection when using compressed
air. Flying debris and dirt can cause personal injury.
Demagnetize the capscrew thoroughly.
Use solvent to clean the capscrew and dry with
compressed air.
Cup Plug (017-002)

Remove
CAUTION
Do not allow metal shavings to fall inside the engine
when drilling a hole in the cup plug. Damage to engine
components can occur.
Use a center punch to mark the cup plugs for drilling.
Drill a 3.20 mm [0.125 in] hole in the cup plug.
Use a dent puller to remove the cup plug.

Discard all used cup plugs.

Thoroughly clean the cup plug bore using Scotch-Brite™,
or equivalent.
Use spray cleaner, Part Number 3375433, or equivalent,
to clean the bore.
Cup Plug QSK45 and QSK60
Inspect the cup plug bores for damage.

Repair any damaged cup plug bores.
Install
CAUTION
Excessive sealant can run back into the engine and
cause damage to other components. Allow the sealant
to dry for a minimum of two hours before operating
the engine. The plug can come out of the bore if the
sealant is not dry.
Apply a 2 mm [1/6 in] bead of cup plug sealant, Part
Number 3375068, or equivalent, to the outside
circumference of the cup plug and the inside
circumference of the cup plug bore.
Do not install a used cup plug.
Install the cup plug with the appropriate cup plug driver.
CAUTION
Do not install the cup plug too deeply. If the cup plug
is not installed straight and flat, it must be replaced
with a new cup plug.
The cup plug must be installed with the edge of the cup
plug 0.5 to 1.0 mm [0.020 to 0.040 in] deeper than the
leading chamfer of the bore.
QSK45 and QSK60 Pipe Plug
Flexible Hose (017-005)

Inspect for Reuse
Inspect all flexible hoses and their connections for leaks
or deterioration.
Repair or replace the hose if damaged.
Pipe Plug (017-007)

Remove
Remove the pipe plug.

Use spray cleaner, Part Number 3375433, or equivalent
to clean the threads of the pipe plugs and threaded bores.
Inspect the threads of the pipe plug for damage.

Replace the pipe plug if damaged.
Inspect the threaded bore for damage.
Repair the threaded bore if damaged.
Straight Thread Plug QSK45 and QSK60
Install
Apply a film of pipe plug sealant, Part Number 3375066,
or equivalent to the pipe plug threads.

Refer to the chart in the graphic for torque values.
Straight Thread Plug (017-011)

Remove
Select the appropriate size allen wrench or socket and
remove the straight thread plug.

Use spray cleaner, Part Number 3375433, or equivalent
to clean the threads of the straight thread plug and
threaded bore.
QSK45 and QSK60 Straight Thread Plug
Inspect the threads of the straight thread plug for damage.

Replace the straight thread plug if damaged.
Inspect the threaded bore for damage.
Repair the bore if damaged.
Install
Install a new o-ring on the straight thread plug.
Lubricate the o-ring with clean 15W-40 oil.
Install the straight thread plug.
Tighten the straight thread plug.

Refer to the chart in the graphic for torque values.
Straight Thread Plug QSK45 and QSK60
Notes
Cummins Service Publications Electronic Books on CD-ROM
Enclosed, we’ve included on CD-ROM, an electronic copy of this publication in Adobe® Acrobat® format (PDF) for your
personal use and reference. Before you begin to use the CD-ROM, please read the “Cummins Service Publications
Electronic Books on CD-ROM Information” printed section, beginning on the next page. This section includes
information about this CD-ROM including System Requirements, Local Administrative Rights requirements, How to Use,
Helpful Support Tips and other information.
Cummins Service Publications Electronic Books on CD-ROM Information
The enclosed CD-ROM provides you with the capability to view this publication electronically as well as perform searches.
This CD-ROM is copy protected and will not allow Printing, Changing of Content, Extracting Content or Commenting /
Annotating of the PDF file.
This CD-ROM is read only, and you will not be able to copy files from the CD-ROM and have them open or function in any
manner. The only method to view the electronic publication is from the original CD-ROM.
This CD-ROM is intended for use by the owner of the printed publication only. Copying or distribution of content from this
CD-ROM is expressly prohibited. This CD-ROM will not function from a network server CD-ROM drive. It will function
only in a CD-ROM drive directly connected to your computer.
For Microsoft Windows NT 4.0, Microsoft Windows 2000 or Microsoft Windows XP, this CD-ROM requires that
you have Local Administrative rights in order to use. See the System requirements section for additional details.
System Requirements:
Use of the Cummins Service Publications Electronic Books on CD-ROM requires Adobe Acrobat, Adobe Acrobat Reader,
or Adobe Reader software to be pre-installed on your computer. This product has been tested for compatibility with
Adobe Acrobat software versions 5.0, 6.0 and 7.0. It may function properly with versions later than Adobe Acrobat 7.0,
but testing has not been performed. Acrobat Reader is available as a free download from www.adobe.com.
The Cummins Service Publications Electronic Books on CD-ROM product requires the following system
components:
• Microsoft Windows Auto-Play must be enabled on your computer (it is enabled by default when Windows is installed)
• CD-ROM Drive
• Color Monitor with at least 800x600 resolution graphics
• Microsoft Windows XP Professional or Microsoft Windows 2000 Professional. This CD-ROM may be compatible with
Microsoft Windows 98 SE, Microsoft Windows NT 4.0, or Microsoft Windows XP Home Edition, but testing has not
been performed.
• Recommended memory, processor speed and available hard-disk space is in accordance with respective Microsoft
Operating System Guidelines, as well as Adobe Acrobat system requirements listed later in these instructions.
Note: The Cummins Service Publications Electronic Books on CD-ROM product is not Macintosh compatible.
About required Local Administrative Rights:
The copy protection system used on this product requires direct access to CD-ROM drives in order to authenticate copy
protected discs.
In order to allow the software to enable direct access to CD-ROM drives rights under Microsoft Windows, if you are using
Microsoft Windows NT 4.0, Microsoft Windows 2000 or Microsoft Windows XP, your logon account/profile must have
Local Administrative Rights on the computer you will be using your Cummins Service Publications Electronic Book on CD-
ROM with. If this computer is set up in Restricted Mode, and your logon account/profile does not have Local
Administrative Rights, then, with approval of your I.T. department or the owner of your computer, you can choose from the
following options to allow the Cummins Service Publications Electronic Book on CD-ROM to function properly:
• Have your computer account enabled to have Local Administrative rights and then you can run the Cummins Service
Publications Electronic Book on CD-ROM - OR -
• Have a user with Local Administrative Rights logon to your computer and run the CD-ROM one time. By doing this,
the necessary files will be loaded to your computer and your computer will be enabled to have direct access to CD-
ROM drives. Then restart this computer. It is very important to restart the computer after you have done this. For all
future needs, you can run the Cummins Service Publications Electronic Book on CD-ROM under your own account,
without requiring your logon account/profile to have Local Administrative Rights. (Note: This needs to be done only
once for any Cummins Service Publications Electronic Book on CD-ROM and then does not need to be done again
for other Cummins Service Publications Electronic Book on CD-ROM titles you may own.)
(continued)
About the Copy Protection Software:
• This product may upgrade the proprietary copy protection software files it uses that are placed on your computer
system to a new version, if an older version exists on your computer. If you have CD-ROM copy protected items from
other companies and they use older versions of the same HexaLock copy protection software that the Cummins
Service Publications Electronic Books on CD-ROM uses, it may render them incompatible for use on your computer.
Adobe Acrobat Reader 5.0 system requirements:

• PC Compatible computer w/ Intel® Pentium® processor
• One of the following Microsoft® Windows Operating Systems:
Microsoft Windows 98 SE
Microsoft Windows Millennium Edition
Microsoft Windows NT® 4.0 with Service Pack 5
Microsoft Windows 2000
Microsoft Windows XP
• 64MB of RAM
• 24MB of available hard-disk space
• Additional 70MB of hard-disk space for Asian fonts (optional)
(Asian fonts are not required for Cummins Service Publications Electronic Books on CD-ROM product.)
Adobe Reader 6.0.1 system requirements:

• PC Compatible computer w/ Intel Pentium processor
• One of the following Microsoft Windows Operating Systems:
Microsoft Windows 98 SE
Microsoft Windows Millennium Edition
Microsoft Windows NT 4.0 with Service Pack 6
Microsoft Windows 2000 with Service Pack 2
Microsoft Windows XP Professional or Home Edition
Microsoft Windows XP Tablet PC Edition
• 32MB of RAM (64MB recommended)
• 60MB of available hard-disk space
• Microsoft Internet Explorer 5.0.1, 5.5, 6.0, or 6.1
Adobe Reader 7.0 system requirements:

• PC Compatible computer w/ Intel Pentium processor
• One of the following Microsoft Windows Operating Systems:
Microsoft Windows 2000 with Service Pack 2
Microsoft Windows XP Professional or Home Edition
Microsoft Windows XP Tablet PC Edition
• 128MB of RAM
• Up to 90MB of available hard-disk space
• Microsoft Internet Explorer 5.5 or higher
How to Use the Cummins Service Publications Electronic Book on CD-ROM:

To use the CD-ROM, simply insert the CD-ROM into your computer and it should automatically run, open Adobe Acrobat
and open the Electronic Book. (This happens with Microsoft Windows Auto-Play functionality, and Adobe Acrobat pre-
loaded by you on your computer).
(continued)
Helpful Support Tips:
• If Windows Auto-Play is not enabled, try re-enabling it, or navigate with Windows Explorer to your CD-ROM drive and
double click on the CD-ROM drive letter to open it. Then double-click on the program named “clickhere”. (Do not
attempt to directly open the PDF file by clicking on the PDF document.)
• In rare occasions, after inserting the CD-ROM you may receive a notice from Adobe Acrobat that it “could not open
the PDF because it is either not a supported file type or the file has been corrupted”. This can occur in rare occasions
due to application timing issues. If this occurs there are several options to remedy the situation: 1) Simply click OK on
the notice, eject the CD-ROM and re-insert it to have it restart the program, or 2) Click OK on the notice and navigate
with Windows Explorer to your CD-ROM drive and double click on the CD-ROM drive letter to open it. Then double-
click on the program named “clickhere”. (Do not attempt to directly open the PDF file by clicking on the PDF
document) or 3) Click OK on the notice, eject the CD-ROM, restart your computer and after the system has restarted,
re-insert the CD-ROM and have it automatically run.
• If the Cummins Service Publications Electronic Books on CD-ROM does not function, see the prior section on “About
required Local Administrative Rights:” in this documentation and verify you have Local Administrative Rights on your
computer in order to run the CD-ROM.
Electronic Book Technical Support:

Support for this product is available from Monday through Friday weekly, excluding Holidays, from 8 a.m. to 5 p.m.
You may call (502) 540-4981 for telephone support. For e-mail support, please e-mail ebooksupport@merrickind.com.
CD-ROM Media Replacement Options:

Up to 90 days from date of purchase:
Within the first 90 days from your date of purchase, if your copy of an Electronic Book on CD-ROM does not function, and
after a Cummins Electronic Book Technical Support Technician has confirmed the situation and authorized its
replacement by providing you an RMA#, you may send back the CD-ROM for a free replacement. To do so, you must
package the CD-ROM and ship/mail, with postage pre-paid by you, to the below address. You must also include a
photocopy of the original invoice for proof of purchase of the publication clearly indicating the bulletin # and the purchase
date. The RMA# must be on the address information of the package. If the proof of purchase copy of the invoice is not
enclosed, your request will not be able to be processed and will not be returned. Delivery of the replacement will be
shipped to you at no charge. Allow 3 to 4 weeks for your receipt of replacement copy. Note: Return only the non-
functional CD-ROM, do not return the entire printed publication. The replacement CD-ROM maintains the original
purchase/invoice date for the purposes of this replacement policy. This policy is subject to change at any time, without
notice. For a copy of the most current replacement options policy, please e-mail ebooksupport@merrickind.com with your
request.
Media Replacement Ship to Address:

Attn: Cummins Service Publications Electronic Books Technical Support
RMA#: XXXXXX (where XXXXXX is the RMA#)
808 E. Liberty Street
Louisville, KY 40204 U.S.A.
Cummins Service Publications Electronic Books on CD-ROM are Copyright © Cummins Inc.
Adobe Acrobat Reader is a registered trademark of Adobe Systems Incorporated.
Microsoft, Windows, and Windows NT are registered trademarks of Microsoft Corporation.
Intel and Pentium are trademarks of Intel Corporation.
HexaLock is Copyright © HexaLock, Ltd.
All other names and products used herein are trademarks for their respective owner.
QSK45 and QSK60
Section L - Service Literature Page L-a
Section L - Service Literature

Section Contents
Page
Additional Service Literature ............................................................................................................................L-1
General Information..........................................................................................................................................L-1
Cummins Customized Parts Catalog ................................................................................................................L-3
General Information..........................................................................................................................................L-3
Ordering the Customized Parts Catalog.............................................................................................................L-3
Ordering by Telephone...................................................................................................................................L-3
Ordering On-Line...........................................................................................................................................L-3
Service Literature Ordering Location ...............................................................................................................L-2
Contact Information...........................................................................................................................................L-2
QSK45 and QSK60
Page L-b Section L - Service Literature

QSK45 and QSK60 Additional Service Literature
Section L - Service Literature Page L-1
Additional Service Literature

General Information
The following publications can be purchased by contacting a Cummins Inc. Distributor:
Bulletin Title of Publication

3669001 Fuel for Cummins Engines
3810340 Cummins Engine Oil Recommendations
3666132 Cummins Coolant Requirements and Maintenance
3379000 Air For Your Engine
3387266 Cold Weather Operation
3666121 Holset® Air Compressor Master Repair Manual
3666393 Troubleshooting and Repair Manual, QSX15/QSK45/60 Generator-Drive Control System
3666394 Troubleshooting and Repair Manual, QSX15/QSK45/60 Generator Set Power Command
Control Version 3200
3666347 QSK45/60 Generator-Drive Control System Wiring Diagram
3666351 QSK45/60 Wiring Diagram
3666357 QSK45/60 CENSE™ Phase 1.0 Wiring Diagram
3666465 QSK45/60 PowerCommand® Control Version 3200 with Control Housing 1 Wiring Diagram
4021349 QSK60 Wiring Diagram
4021373 Shop Manual, QSK45 and QSK60 Series Engines
4021380 QSK45, QSK60, and QSK78 Generator-Drive Control System Wiring Diagram
4021406 QSK45 and QSK60 PowerCommand® Control 3200 with Control Housing 1 and Centinel™
Wiring Diagram
4021407 QSK45 and QSK60 PowerCommand® Control 3200 with Control Housing 2 Wiring Diagram
4021408 QSK45 and QSK60 PowerCommand® Control 3200 with Control Housing 2 and Centinel™
Wiring Diagram
4021410 QSK45 and QSK60 Phase 2.0 Industrial without CENSE™ Wiring Diagram
4021412 QSK60 Phase 2.0 Industrial with CENSE™ Wiring Diagram
4021413 QSK45 Phase 2.0 Industrial with CENSE™ Wiring Diagram
4021414 QSK60 CENSE™ Phase 1.5 Wiring Diagram
Service Literature Ordering Location QSK45 and QSK60
Page L-2 Section L - Service Literature
Service Literature Ordering Location

Contact Information
Region Ordering Location

United States and Canada Cummins Distributors
or
Credit Cards at 1-800-646-5609
or
Order online at www.powerstore.cummins.com
U.K., Europe, Mid-East, Africa, Cummins Distributors or Dealers
and Eastern European Countries
South and Central America Cummins Americas, Inc.
(excluding Brazil and Mexico) 16085 N.W. 52nd Avenue
Hialeah, FL 33104
Brazil and Mexico Cummins Inc.
International Parts Order Dept., MC 40931
Box 3005
Columbus, IN 47202-3005
Far East (excluding Cummins Diesel Sales Corp.
Australia and New Zealand) Literature Center
8 Tanjong Penjuru
Jurong Industrial Estate
Singapore
Australia and New Zealand Cummins
4 Dalmore Drive
Scoresby 3179
Victoria, Australia
QSK45 and QSK60 Cummins Customized Parts Catalog
Section L - Service Literature Page L-3
Cummins Customized Parts Catalog

General Information
Cummins is pleased to announce the availability of a parts catalog compiled specifically for you. Unlike the generic
versions of parts catalogs that support general high volume parts content; Cummins Customized catalogs contains
only the new factory parts that were used to build your engine.
The catalog cover, as well as the content, is customized with you in mind. You can use it in your shop, at your worksite,
or as a coffee table book in your RV or boat. The cover contains your name, company name, address, and telephone
number. Your name and engine model identification even appears on the catalog spine. Everybody will know that
Cummins created a catalog specifically for you.
This new catalog was designed to provide you with the exact information you need to order parts for your engine. This
will be valuable for customers that do not have easy access to the Cummins Electronic Parts Catalog or the Cummins
Parts Microfilm System.
Additional Features of the Customized Catalog include:
• Engine Configuration Data
• Table of Contents
• Separate Option and Parts Indexes
• Service Kits (when applicable)
• ReCon Part Numbers (when applicable)
Ordering the Customized Parts Catalog
Ordering by Telephone
North American customers can contact their Cummins Distributor or call Gannett Direct Marketing Services at
1-800-646-5609 and order by credit card. Outside North America order on-line or make an International call to Gannett
at (++)502-454-6660.
Ordering On-Line
The Customized Parts Catalog can be ordered On-Line from the Cummins Powerstore by credit card. Contact the
Powerstore at WWW.POWERSTORE.CUMMINS.COM
Contact GDMS or the CUMMINS POWERSTORE for the current price; Freight may be an additional expense.
Information we need to take your Customized Parts Catalog Order. This information drives the cover content of the
CPC.
• Customer Name
• Street Address
• Company Name (optional)
• Telephone no.
• Credit Card No.
• Cummins Engine Serial Number (located on the engine data plate)
• Please identify the required media: Printed Catalog, CD-ROM, or PDF File
Unfortunately not all Cummins Engines can be supported by this parts catalog. Engines older than 1984 or newer
than 3 months may not have the necessary parts information to compile a catalog. We will contact you if this occurs
and explain why we are unable to fill your order.
Customized Parts Catalogs are produced specifically for a single customer. This means they are not returnable for a
refund. If we make an error and your catalog is not useable, we will correct that error by sending you a new catalog.
Cummins Customized Parts Catalog QSK45 and QSK60
Page L-4 Section L - Service Literature
Notes
QSK45 and QSK60
Section M - Component Manufacturers Page M-a
Section M - Component Manufacturers

Section Contents
Page
Component Manufacturers' Addresses ...........................................................................................................M-1
Air Compressors..............................................................................................................................................M-1
Air Cylinders....................................................................................................................................................M-1
Air Heaters.......................................................................................................................................................M-1
Air Starting Motors...........................................................................................................................................M-1
Alternators.......................................................................................................................................................M-1
Auxiliary Brakes...............................................................................................................................................M-1
Belts................................................................................................................................................................M-1
Catalytic Converters.........................................................................................................................................M-1
Coolant Level Switches....................................................................................................................................M-1
Clutches..........................................................................................................................................................M-1
Coolant Heaters...............................................................................................................................................M-2
Drive Plates.....................................................................................................................................................M-2
Electric Starting Motors....................................................................................................................................M-2
Electronic Switches..........................................................................................................................................M-2
Engine Protection Controls...............................................................................................................................M-2
Fan Clutches....................................................................................................................................................M-2
Fans................................................................................................................................................................M-2
Fault Lamps.....................................................................................................................................................M-2
Filters...............................................................................................................................................................M-2
Flexplates........................................................................................................................................................M-2
Fuel Coolers....................................................................................................................................................M-2
Fuel Pumps......................................................................................................................................................M-2
Fuel Warmers..................................................................................................................................................M-2
Gauges............................................................................................................................................................M-3
Governors........................................................................................................................................................M-3
Heat Sleeves....................................................................................................................................................M-3
Hydraulic and Power Steering Pumps..............................................................................................................M-3
In-Line Connectors...........................................................................................................................................M-3
Oil Heaters.......................................................................................................................................................M-3
Prelubrication Systems.....................................................................................................................................M-3
Radiators.........................................................................................................................................................M-3
Throttle Assemblies..........................................................................................................................................M-3
Torque Converters...........................................................................................................................................M-3
QSK45 and QSK60
Page M-b Section M - Component Manufacturers

QSK45 and QSK60 Component Manufacturers' Addresses
Section M - Component Manufacturers Page M-1
Component Manufacturers' Addresses (203-001)

NOTE: The following list contains addresses and telephone numbers of suppliers of accessories used on Cummins
engines. Suppliers can be contacted directly for any specifications not covered in this manual.
Air Compressors Ingersoll-Rand Engine Belts
Starting Systems
Bendix Heavy Vehicles Systems T.B.A. Belting Ltd.
888 Industrial Drive
Div. of Allied Automotive P.O. Box 77
901 Cleveland Street Elmhurst, IL 60126 Wigan
Telephone: (708) 530-3875
Elyria, OH 44036 Lancashire
Telephone: (216) 329-9000 StartMaster WN2 4XQ
Holset Engineering Co., Inc. Air Starting Systems England
A Division of Sycon Corporation Telephone: (0)1942-259221
1320 Kemper Meadow Drive
Suite 500 9595 Cheney Avenue Dayco Mfg.
Cincinnati, OH 45240 P. O. Box 491 Belt Technical Center
Telephone: (513) 825-9600 Marion, OH 43302 1955 Enterprize
Telephone: (614) 382-5771 Rochester Hills, MI 48309
Midland-Grau
Alternators Telephone: (810) 853-8300
Heavy Duty Systems
Heavy Duty Group Headquarters Robert Bosch Ltd. Gates Rubber Company
10930 N. Pamona Avenue P.O. Box 98 900 S. Broadway
Kansas City, MO 64153 Broadwater Park Denver, CO 80217
Telephone: (816) 891-2470 North Orbital Road
Goodyear Tire and
Air Cylinders Denham
Rubber Company
Uxbridge Industrial Products Div.
Bendix Ltd. Middlesex UD9 5HG
Douglas Road 2601 Fortune Circle East
England
Kingswood Indianapolis, IN 46241
Telephone: (0)1895-838383
Bristol Telephone: (317) 898-4170
Prestolite Electrics Catalytic Converters
England
Telephone: 0117-671881 Cleveland Road
Leyland Donaldson Company, Inc.
Catching Engineering PR5 1XB 1400 West 94th Street
1733 North 25th Avenue England P.O. Box 1299
Melrose Park, IL 60160 Telephone: (0)1772-421663 Minneapolis, MN 55440
Telephone: (708) 344-2334 Telephone: (612) 887-3835
C. E. Niehoff & Co.
TEC - Hackett Inc. 2021 Lee Street Nelson Division
8909 Rawles Avenue Evanston, IL 60202 Exhaust and Filtration Systems
Indianapolis, IN 46219 Telephone: (708) 866-6030 1801 U.S. Highway 51 P.O. Box 428
Telephone: (317) 895-3670 Stoughton, WI 53589
Delco-Remy America
Air Heaters Telephone: (608) 873-4200
2401 Columbus Avenue
Fleetguard, Inc. P.O. Box 2439 Walker Manufacturing
1200 Fleetguard Road Anderson, IN 46018 3901 Willis Road
Telephone: (317) 646-3528 P.O. Box 157
Cookeville, TN 38502
Grass Lake, MI 49240
Telephone: (615) 526-9551 Leece-Neville Corp.
Telephone: (517) 522-5500
Kim Hotstart Co. 400 Main Street
Arcade, NY 14009 Coolant Level Switches
P.O. Box 11245
Spokane, WA 99211-0245 Telephone: (716) 492-1700 Robertshaw Controls Company
Telephone: (509) 534-6171 Auxiliary Brakes P.O. Box 400
Air Starting Motors Knoxville, TN 37901
The Jacobs Manufacturing Company Telephone: (216) 885-1773
Ingersoll Rand Vehicle Equipment Division
22 East Dudley Town Road Clutches
Chorley New Road
Horwich Bloomfield, CT 06002 Twin Disc International S.A.
Bolton Telephone: (203) 243-1441 Chaussee de Namur
Lancashire Nivelles
England Belguim
BL6 6JN Telephone: 067-224941
Telephone: 01204-65544 Twin Disc Incorporated
1328 Racine Street
Racine, WI 53403
Telephone: (414) 634-1981
Component Manufacturers' Addresses QSK45 and QSK60
Page M-2 Section M - Component Manufacturers
Coolant Heaters Fan Clutches Fault Lamps

Fleetguard, Inc. Kysor Cooling Systems N.A. Cutler-Hammer Products
1200 Fleetguard Road 6040 West 62nd Street Eaton Corporation
Cookeville, TN 38502 Indianapolis, IN 46278 4201 N. 27th Street
Telephone: (615) 526-9551 Telephone: (317) 328-3330 Milwaukee, WI 53216
Drive Plates Holset Engineering Co. Ltd. Telephone: (414) 449-6600
ST Andrews Road Filters
Detroit Diesel Allison
Division of General Motors Huddersfield, West Yorkshire Fleetguard International Corp.
England HD1 6RA
Corporation Cavalry Hill Industrial Park
Telephone: (0)1484-22244
P.O. Box 894 Weedon
Indianapolis, IN 46206-0894 Horton Industries, Inc. Northampton NN7 4TD
Telephone: (317) 242-5000 P.O. Box 9455 England
Electric Starting Motors Minneapolis, MN 55440 Telephone: 01327-341313
Telephone: (612) 378-6410 Fleetguard, Inc.
Prestolite Electrics
Rockford Clutch Company 1200 Fleetguard Road
Cleveland Road
Leyland 1200 Windsor Road Cookeville, TN 38502
PR5 1XB P.O. Box 2908 Telephone: 1-800-22-Filters
England Rockford, IL 61132-2908 (1-800-223-4583)
Telephone: 01772-421663 Telephone: (815) 633-7460 Flexplates
Fans
Delco-Remy America Corrugated Packing and
2401 Columbus Avenue Truflo Ltd. Sheet Metal
P.O. Box 2439 Westwood Road Hamsterley
Anderson, IN 46018 Birmingham Newcastle Upon Tyne
Telephone: (317) 646-3528 B6 7JF England
Leece-Neville Corp. England Telephone: (0)1207-560-505
400 Main Street Telephone: (0)121-3283041 Allison Transmission
Arcade, NY 14009 Hayes-Albion Corporation Division of General Motors
Telephone: (716) 492-1700 Jackson Manufacturing Plant Corporation
1999 Wildwood Avenue P.O. Box 894
Nippondenso Inc.
Jackson, MI 49202 Indianapolis, IN 46206-0894
2477 Denso Drive
P.O. Box 5133 Telephone: (517) 782-9421 Telephone: (317) 242-5000
Southfield, MI 48086 Engineered Cooling Systems, Inc. Midwest Mfg. Co.
Telephone: (313) 350-7500 201 W. Carmel Drive 29500 Southfield Road, Suite 122
Electronic Switches Carmel, IN 46032 Southfield, MI 48076
Cutler-Hammer Products
Eaton Corporation Brookside Corporation Wohlert Corporation
4201 N. 27th Street P.O. Box 30 708 East Grand River Avenue
Milwaukee, WI 53216 McCordsville, IN 46055 P.O. Box 20217
Telephone: (414) 449-6600 Telephone: (317) 335-2014 Lansing, MI 48901
TCF Aerovent Company Telephone: (517) 485-3750
Engine Protection Controls
9100 Purdue Rd., Suite 101 Fuel Coolers
Flight Systems Headquarters Indianapolis, IN 46268-1190
Hempt Road Hayden, Inc.
Telephone: (317) 872-0030
P.O. Box 25 1531 Pomona Road
Mechanicsburg, PA 17055 Kysor-Cadillac P.O. Box 848
Telephone: (717) 697-0333 1100 Wright Street Corona, CA 91718-0848
Cadillac, MI 49601 Telephone: (909) 736-2665
The Nason Company Telephone: (616) 775-4681 Fuel Pumps
2810 Blue Ridge Blvd.
Schwitzer
West Union, SC 29696 Robert Bosch Corp.
6040 West 62nd Street
Telephone: (803) 638-9521 Automotive Group
P.O. Box 80-B 2800 South 25th Ave.
Teddington Industrial Indianapolis, IN 46206
Equipment Broadview, IL 60153
Telephone: (317) 328-3010
Windmill Road Fuel Warmers
Sunbury on Thames
Fleetguard, Inc.
Middlesex 1200 Fleetguard Road
TW16 7HF Cookeville, TN 38502
England Telephone: (615) 526-9551
Telephone: (0)9327-85500
QSK45 and QSK60 Component Manufacturers' Addresses
Section M - Component Manufacturers Page M-3
Gauges Sperry Vickers The G&O Manufacturing Company

P.O. Box 302 100 Gando Drive
Grasslin U.K. Ltd.
Troy, MI 48084 P.O. Box 1204
Vale Rise
Tonbridge Telephone: (313) 280-3000 New Haven, CT 06505-1204
Telephone: (203) 562-5121
Kent Z.F.
TN9 1TB P.O. Box 1340 Young Radiator Company
England Grafvonsoden Strasse 2825 Four Mile Road
Telephone: (0)1732-359888 5-9 D7070 Racine, WI 53404
Datcon Instruments Schwaebisch Gmuend Telephone: (910) 271-2397
P.O. Box 128 Germany L and M Radiator, Inc.
East Petersburg, PA 17520 Telephone: 7070-7171-31510 1414 East 37th Street
Telephone: (717) 569-5713 In-Line Connectors Hibbing, MN 55746
Rochester Gauges, Inc. Pioneer-Standard Electronics, Inc. Telephone: (218) 263-8993
11616 Harry Hines Blvd. 5440 Neiman Parkway Throttle Assemblies
P.O. Box 29242 Solon, OH 44139 Williams Controls, Inc.
Dallas, TX 75229 Telephone: (216) 349-1300 14100 SW 72nd Avenue
Telephone: (214) 241-2161
Deutsch Portland, OR 97224
Governors Industrial Products Division Telephone: (503) 684-8600
Woodward Governor Co. 37140 Industrial Avenue Torque Converters
P.O. Box 1519 Hemet, CA 92343
Telephone: (714) 929-1200 Twin Disc International S.A.
Fort Collins, CO 80522
Chaussee de Namur
Telephone: (303) 482-5811 Oil Heaters
Nivelles
(800) 523-2831 Fleetguard, Inc. Belgium
Barber Colman Co. 1200 Fleetguard Road Telephone: 067-224941
1354 Clifford Avenue Cookeville, TN 38502 Twin Disc Incorporated
Loves Park, IL 61132 Telephone: (615) 526-9551 1328 Racine Street
Telephone: (815) 637-3000
Kim Hotstart Co. Racine, WI 53403-1758
United Technologies P.O. Box 11245 Telephone: (414) 634-1981
Diesel Systems Spokane, WA 99211-0245
Rockford Powertrain, Inc.
1000 Jorie Blvd. Telephone: (509) 534-6171
Off-Highway Systems
Suite 111 Prelubrication Systems 1200 Windsor Road
Oak Brook, IL 69521 P.O. Box 2908
Telephone: (312) 325-2020 RPM Industries, Inc.
Suite 109 Rockford, IL 61132-2908
Heat Sleeves 55 Hickory Street Telephone: (815) 633-7460
Bentley Harris Manufacturing Co. Washington, PA 15301 Modine Mfg. Co.
100 Bentley Harris Way Telephone: (412) 228-5130 1500 DeKoven Avenue
Gordonville, TN 38563 Radiators Racine, WI 53401
JB Radiator Specialties, Inc.
Hydraulic and Power Steering
P.O. Box 292087
Pumps
Sacramento, CA 95829-2087
Honeywell Control Systems Ltd. Telephone: (916) 381-4791
Honeywell House
Arlington Business Place
Bracknell
Berks RG12 1EB
Telephone: (0)1344-656000
Component Manufacturers' Addresses QSK45 and QSK60
Page M-4 Section M - Component Manufacturers
Notes
QSK45 and QSK60
Section V - Specifications Page V-a
Section V - Specifications
Section Contents
Page
Air Intake System ..........................................................................................................................................V-121
Specifications...............................................................................................................................................V-121
Air Intake System - Group 10 - Specifications ...............................................................................................V-77
Air Intake Restriction................................................................................................................................................V-77
Turbocharger............................................................................................................................................................V-77
Air Intake System - Group 10 - Torque Values ..............................................................................................V-79
Aftercooler Assembly............................................................................................................................................... V-79
Aftercooler Element..................................................................................................................................................V-81
Air Cleaner Assembly (Engine-Mounted).................................................................................................................V-81
Air Leaks, Air Intake and Exhaust Systems............................................................................................................. V-82
Frame, Two-Stage Turbocharger.............................................................................................................................V-95
Intercooler Assembly................................................................................................................................................V-97
Intercooler Element..................................................................................................................................................V-99
Turbocharger............................................................................................................................................................V-83
Turbocharger Coolant Hoses...................................................................................................................................V-88
Turbocharger Heat Shield........................................................................................................................................V-94
Turbocharger Inlet Connections.............................................................................................................................V-100
Turbocharger Oil Drain Line.....................................................................................................................................V-90
Turbocharger Oil Supply Line...................................................................................................................................V-90
Turbocharger, High Pressure...................................................................................................................................V-84
Turbocharger, Low Pressure....................................................................................................................................V-87
Capscrew Markings and Torque Values .......................................................................................................V-126
Capscrew Markings and Torque Values - Metric............................................................................................V-126
Capscrew Markings and Torque Values - U.S. Customary.............................................................................V-126
General Information......................................................................................................................................V-126
Compressed Air System ...............................................................................................................................V-124
Compressed Air System - Group 12 - Specifications ..................................................................................V-106
Air Compressor......................................................................................................................................................V-106
Compressed Air System - Group 12 - Torque Values ..................................................................................V-107
Air Compressor......................................................................................................................................................V-107
Air Compressor Unloader and Valve Assembly.....................................................................................................V-107
Cooling System .............................................................................................................................................V-120
QSK45 Engines..........................................................................................................................................V-120
QSK60 Engines..........................................................................................................................................V-120
Cooling System — Group 08 - Specifications ................................................................................................V-54
Coolant Thermostat..................................................................................................................................................V-54
Cooling System Diagnostics.....................................................................................................................................V-54
Fan Drive Idler Arm Assembly..................................................................................................................................V-54
Fan Drive Idler Pulley Assembly.............................................................................................................................. V-54
Fan Hub, Belt Driven................................................................................................................................................V-55
Water Pump............................................................................................................................................................. V-55
Cooling System — Group 08 - Torque Values ...............................................................................................V-56
Coolant Filter Head.................................................................................................................................................. V-56
Coolant Thermostat..................................................................................................................................................V-56
Coolant Thermostat Housing Support......................................................................................................................V-57
Cooling System........................................................................................................................................................V-59
Drive Belt, Cooling Fan............................................................................................................................................ V-56
ECM Cooling Plate...................................................................................................................................................V-68
ECM Cooling Plate Lines......................................................................................................................................... V-69
Expansion Tank........................................................................................................................................................V-63
Fan Drive Idler Arm Assembly..................................................................................................................................V-59
Fan Drive Idler Pulley Assembly.............................................................................................................................. V-60
Fan Hub, Belt Driven................................................................................................................................................V-60
Heat Exchanger........................................................................................................................................................V-63
Low-Temperature Aftercooler (LTA) Water Pump....................................................................................................V-67
QSK45 and QSK60
Page V-b Section V - Specifications
Marine Gear Oil Cooler............................................................................................................................................ V-62

Radiator Hoses.........................................................................................................................................................V-62
Right Bank Number 8 Coolant Loop.........................................................................................................................V-67
Sea Water Pump......................................................................................................................................................V-64
Water Manifold.........................................................................................................................................................V-64
Water Pump............................................................................................................................................................. V-65
Cylinder Block — Group 01 - Specifications ....................................................................................................V-1
Bearings, Connecting Rod.........................................................................................................................................V-1
Bearings, Main...........................................................................................................................................................V-1
Bearings, Thrust.........................................................................................................................................................V-1
Camshaft....................................................................................................................................................................V-2
Camshaft Bushings....................................................................................................................................................V-2
Camshaft Gear (Camshaft Installed)..........................................................................................................................V-2
Camshaft Gear (Camshaft Removed)........................................................................................................................V-3
Camshaft Thrust Bearing......................................................................................................................................... V-11
Crankshaft Adapter....................................................................................................................................................V-3
Crankshaft Gear, Front (Crankshaft Removed).........................................................................................................V-3
Cylinder Block............................................................................................................................................................V-4
Cylinder Block and Liner Seats..................................................................................................................................V-5
Cylinder Liner.............................................................................................................................................................V-5
Cylinder Liner Protrusion..........................................................................................................................................V-11
Gear Cover, Front......................................................................................................................................................V-6
Gear Train Backlash, Front......................................................................................................................................V-11
Idler Gear, Camshaft (Left Bank)...............................................................................................................................V-7
Idler Gear, Camshaft (Right Bank).............................................................................................................................V-7
Idler Gear, Hydraulic Pump........................................................................................................................................V-8
Idler Gear, Water Pump.............................................................................................................................................V-9
Piston.........................................................................................................................................................................V-9
Piston and Connecting Rod Assembly.....................................................................................................................V-10
Piston Rings.............................................................................................................................................................V-10
Vibration Damper, Viscous.......................................................................................................................................V-10
Cylinder Block — Group 01 - Torque Values .................................................................................................V-12
Accessory Drive Seal...............................................................................................................................................V-12
Alternator Drive Seal................................................................................................................................................V-12
Bearings, Connecting Rod....................................................................................................................................... V-12
Bearings, Main......................................................................................................................................................... V-12
Camshaft..................................................................................................................................................................V-12
Crankshaft Adapter.................................................................................................................................................. V-13
Crankshaft Seal, Front............................................................................................................................................. V-13
Crankshaft Seal, Rear..............................................................................................................................................V-13
Gear Cover, Front.................................................................................................................................................... V-13
Gear Housing, Front.................................................................................................................................................V-14
Hand Hole Cover......................................................................................................................................................V-14
Idler Gear, Camshaft (Left Bank)............................................................................................................................. V-14
Idler Gear, Camshaft (Right Bank)...........................................................................................................................V-15
Idler Gear, Hydraulic Pump......................................................................................................................................V-15
Idler Gear, Water Pump........................................................................................................................................... V-15
Piston and Connecting Rod Assembly.....................................................................................................................V-15
Piston Cooling Nozzle..............................................................................................................................................V-15
Vibration Damper, Viscous.......................................................................................................................................V-15
Cylinder Head — Group 02 - Specifications .................................................................................................. V-16
Cylinder Head...........................................................................................................................................................V-16
Cylinder Head — Group 02 - Torque Values ..................................................................................................V-18
Cylinder Head...........................................................................................................................................................V-18
Drive Belt Tension ........................................................................................................................................V-125
Tension Chart...............................................................................................................................................V-125
Drive Units — Group 09 - Specifications .......................................................................................................V-70
Accessory Drive....................................................................................................................................................... V-70
Accessory Drive Pulley.............................................................................................................................................V-71
Fuel Pump Drive.......................................................................................................................................................V-71
Hydraulic Pump Drive...............................................................................................................................................V-73
Water Pump Drive....................................................................................................................................................V-73
Drive Units — Group 09 - Torque Values .......................................................................................................V-75
QSK45 and QSK60
Section V - Specifications Page V-c
Accessory Drive....................................................................................................................................................... V-75

Engine Barring Device..............................................................................................................................................V-76
Fuel Pump Drive.......................................................................................................................................................V-75
Hydraulic Pump Drive...............................................................................................................................................V-75
Water Pump Drive....................................................................................................................................................V-75
Electrical Equipment — Group 13 - Specifications ......................................................................................V-109
Belt Tensioner, Automatic (Alternator)...................................................................................................................V-109
Electrical Equipment — Group 13 - Torque Values .....................................................................................V-110
Alternator................................................................................................................................................................V-110
Belt Tensioner, Automatic (Alternator)...................................................................................................................V-110
Drive Belt, Alternator..............................................................................................................................................V-110
Starting Motor.........................................................................................................................................................V-110
Electrical System ..........................................................................................................................................V-123
Batteries (Specific Gravity)............................................................................................................................V-123
Engine Testing — Group 14 - Specifications ...............................................................................................V-111
Engine Run-in (Engine Dynamometer)..................................................................................................................V-111
Engine Testing (Chassis Dynamometer)................................................................................................................V-111
Engine Testing (Engine Dynamometer).................................................................................................................V-111
Engine Testing — Group 14 - Torque Values ..............................................................................................V-112
Engine Compression..............................................................................................................................................V-112
Engine Run-in (Without Dynamometer).................................................................................................................V-112
Engine Testing (Engine Dynamometer).................................................................................................................V-112
Exhaust System ............................................................................................................................................V-122
Exhaust System — Group 11 - Specifications .............................................................................................V-101
Exhaust Restriction................................................................................................................................................V-101
Exhaust System — Group 11 - Torque Values .............................................................................................V-102
Exhaust Connection Pipe.......................................................................................................................................V-102
Exhaust Connection Pipe (Turbocharger to Turbocharger)...................................................................................V-102
Exhaust Manifold Heat Shield................................................................................................................................V-104
Exhaust Manifold, Dry............................................................................................................................................V-102
Fraction, Decimal, Millimeter Conversions ..................................................................................................V-128
Conversion Chart..........................................................................................................................................V-128
Fuel System ..................................................................................................................................................V-118
with Electronically Actuated Injector...........................................................................................................V-118
with Mechanically Actuated Injector............................................................................................................V-118
Fuel System — Group 05 - Specifications .....................................................................................................V-29
Fuel Pump................................................................................................................................................................V-29
Fuel System — Group 05 - Torque Values .....................................................................................................V-30
Fuel Lift Pump..........................................................................................................................................................V-32
Fuel Pump................................................................................................................................................................V-30
Fuel Shutoff Valve....................................................................................................................................................V-32
General Engine ..............................................................................................................................................V-115
General Specifications..................................................................................................................................V-115
QSK45 Engines..........................................................................................................................................V-115
QSK60 Engines..........................................................................................................................................V-116
Group 04 - Specifications ...............................................................................................................................V-27
Cam Follower Assembly...........................................................................................................................................V-27
Group 04 - Torque Values ..............................................................................................................................V-28
Cam Follower Assembly...........................................................................................................................................V-28
Cam Follower Cover.................................................................................................................................................V-28
Injectors and Fuel Lines — Group 06 - Specifications ..................................................................................V-34
Fuel Drain Line Restriction.......................................................................................................................................V-34
Fuel Inlet Restriction.................................................................................................................................................V-34
Injectors and Fuel Lines — Group 06 - Torque Values .................................................................................V-35
Air in Fuel.................................................................................................................................................................V-35
Fuel Connection Block (Manifold-Mounted).............................................................................................................V-35
Fuel Control Valve Body Assembly..........................................................................................................................V-41
Fuel Cooler...............................................................................................................................................................V-42
Fuel Drain Line Restriction.......................................................................................................................................V-35
Fuel Drain Lines.......................................................................................................................................................V-35
QSK45 and QSK60
Page V-d Section V - Specifications
Fuel Filter Head........................................................................................................................................................V-37

Fuel Inlet Restriction.................................................................................................................................................V-38
Fuel Manifold (Drain)................................................................................................................................................V-38
Fuel Manifold (Supply).............................................................................................................................................V-39
Fuel Supply Lines.....................................................................................................................................................V-40
Injector......................................................................................................................................................................V-41
Injector Supply Lines (High Pressure)......................................................................................................................V-42
Lubricating Oil System .................................................................................................................................V-119
Lubricating Oil System — Group 07 - Specifications ....................................................................................V-43
Lubricating Oil Filter Head........................................................................................................................................V-43
Lubricating Oil Pressure Regulator (Main Rifle).......................................................................................................V-43
Lubricating Oil Pressure Regulator (Piston Cooling)................................................................................................V-43
Lubricating Oil Pump................................................................................................................................................V-43
Lubricating Oil System — Group 07 - Torque Values ...................................................................................V-45
Eliminator Filter........................................................................................................................................................V-51
Lubricating Oil Cooler Cover....................................................................................................................................V-50
Lubricating Oil Dipstick.............................................................................................................................................V-45
Lubricating Oil Dipstick Tube....................................................................................................................................V-45
Lubricating Oil Fill Tube............................................................................................................................................V-51
Lubricating Oil Filter (Spin-On).................................................................................................................................V-46
Lubricating Oil Filter Head........................................................................................................................................V-46
Lubricating Oil Filter Head Adapter..........................................................................................................................V-47
Lubricating Oil High Pressure Relief Valve..............................................................................................................V-47
Lubricating Oil Pan...................................................................................................................................................V-47
Lubricating Oil Pan Adapter.....................................................................................................................................V-48
Lubricating Oil Pan Adapter Cover Plate..................................................................................................................V-48
Lubricating Oil Pressure Regulator (Main Rifle).......................................................................................................V-48
Lubricating Oil Pressure Regulator (Piston Cooling)................................................................................................V-48
Lubricating Oil Pump................................................................................................................................................V-48
Lubricating Oil Suction Tube (Block-Mounted).........................................................................................................V-49
Lubricating Oil Temperature Gauge.........................................................................................................................V-49
Lubricating Oil Transfer Tube...................................................................................................................................V-49
Pre-Lubricating Oil Pump.........................................................................................................................................V-50
Mounting Adaptations — Group 16 - Specifications ....................................................................................V-113
Engine Support Bracket, Front...............................................................................................................................V-113
Flywheel.................................................................................................................................................................V-113
Flywheel Housing...................................................................................................................................................V-113
Mounting Adaptations — Group 16 - Torque Values ...................................................................................V-114
Engine Support Bracket, Front...............................................................................................................................V-114
Flywheel.................................................................................................................................................................V-114
Flywheel Housing...................................................................................................................................................V-114
Newton-Meter to Foot-Pound Conversions ..................................................................................................V-129
Pipe Plug Torque Values ..............................................................................................................................V-130
Torque Table................................................................................................................................................V-130
Rocker Levers — Group 03 - Specifications ..................................................................................................V-19
Overhead Set (OBC)................................................................................................................................................V-19
Rocker Lever Assembly...........................................................................................................................................V-19
Rocker Levers — Group 03 - Torque Values .................................................................................................V-20
Crankcase Breather (External).................................................................................................................................V-20
Overhead Set (OBC)................................................................................................................................................V-23
Rocker Lever Assembly...........................................................................................................................................V-24
Rocker Lever Cover.................................................................................................................................................V-24
Rocker Lever Housing..............................................................................................................................................V-26
Tap-Drill Chart - U.S. Customary and Metric ................................................................................................V-131
General Information......................................................................................................................................V-131
Weights and Measures - Conversion Factors ..............................................................................................V-132
QSK45 and QSK60 Cylinder Block — Group 01 - Specifications
Section V - Specifications Page V-1
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Cylinder Block — Group 01 - Specifications

Bearings, Connecting Rod (001-005)
Connecting Rod Bearing Thickness
Standard 3.106 MIN 0.122
3.157 MAX 0.124
Oversized 0.254 mm [0.010 in] 3.233 MIN 0.127
3.284 MAX 0.129
3.411 MAX 0.134
3.538 MAX 1.139
3.665 MAX 0.144
Connecting Rod Side Clearance 0.30 mm MIN 0.012 in
0.51 mm MAX 0.020 in
Bearings, Main (001-006)

Main Bearing Thickness
4.336 MAX 0.171
4.463 MAX 0.176
4.590 MAX 0.181
4.717 MAX 0.186
4.844 MAX 0.191
Crankshaft End Clearance 0.13 mm MIN 0.005 in
0.51 mm MAX 0.020 in
Bearings, Thrust (001-007)

Thrust Bearing Thickness
7.31 MAX 0.288
7.57 MAX 0.298
7.82 MAX 0.308
8.08 MAX 0.318
8.33 MAX 0.328
Cylinder Block — Group 01 QSK45 and QSK60
Page V-2 Section V - Specifications
Ref.No./
Steps
.
Crankshaft End Clearance 0.13 mm MIN 0.005 in

0.52 mm MAX 0.020 in
Camshaft (001-008)
Camshaft Thrust End Clearance 0.15 mm MIN 0.006 in
0.33 mm MAX 0.013 in
Camshaft Bushing Journal Diameter 104.987 MIN 4.133 in

mm
105.013 MAX 4.134 in
mm
Camshaft End Clearance 0.15 mm MIN 0.006 in

0.33 mm MAX 0.013 in
Camshaft Bushings (001-010)

Camshaft Bushing Bore Diameter 111.975 MIN 4.409 in
mm
112.025 MAX 4.410 in
mm
Camshaft Gear (Camshaft Installed) (001-012)

Camshaft Outside Diameter (Gear Location) 86.90 mm MIN 3.421 in
86.99 mm MAX 3.425 in
Camshaft Gear Inside Diameter 86.88 mm MIN 3.420 in

86.90 mm MAX 3.421 in
QSK45 and QSK60 Cylinder Block — Group 01
Ref.No./
Steps
.
Camshaft Thrust Bearing Thickness 13.95 mm MIN 0.549 in

14.05 mm MAX 0.553 in
Camshaft End Clearance 0.15 mm MIN 0.006 in

0.33 mm MAX 0.013 in
Camshaft Gear (Camshaft Removed) (001-013)

Camshaft Outside Diameter (Gear Location) 86.90 mm MIN 3.421 in
86.99 mm MAX 3.425 in
Camshaft Gear Inside Diameter 86.88 mm MIN 3.420 in

86.90 mm MAX 3.421 in

14.05 mm MAX 0.553 in
Crankshaft Adapter (001-017)

Crankshaft Adapter Roll Pin Protrusion 21.0 mm MIN 0.83 in
23.0 mm MAX 0.91 in
Crankshaft Gear, Front (Crankshaft Removed) (001-019)

Crankshaft Outside Diameter (Front Gear 184.12 mm MIN 7.249 in
Location)
184.16 mm MAX 7.251 in
Ref.No./
Steps
.
Front Crankshaft Gear Inside Diameter 183.97 mm MIN 7.243 in

184.10 mm MAX 7.248 in
Cylinder Block (001-026)

Cylinder Liner Protrusion 0.15 mm MIN 0.006 in
0.20 mm MAX 0.008 in
Counterbore Inside Diameter (Upper Press 190.28 mm MIN 7.491 in

Fit)
190.34 mm MAX 7.494 in
Counterbore Inside Diameter (Lower Press 181.47 mm MIN 7.144 in

Fit)
181.80 mm MAX 7.157 in
Packing Ring Bore 177.32 mm MIN 6.981 in

177.48 mm MAX 6.987 in
Counterbore Depth 13.684 mm MIN 0.539 in

13.734 mm MAX 0.541 in
Cylinder Block Height (18)

Standard Head Gasket 529.527 MIN 20.848
526.679 MAX 20.854
529.171 MAX 20.834
Cylinder Block Height Main Bearing
Saddle (19)
Standard Head Gasket 433.05 MIN 17.049
433.22 MAX 17.056
432.72 MAX 17.036
Ref.No./
Steps
.
Camshaft Bushing Inside Diameter 76.200 mm MIN 3.000 in

76.289 mm MAX 3.004 in
Main Bearing Bore Inside Diameter 192.926 MIN 7.595 in

(Capscrews Tightened to Specifications) mm
192.951 MAX 7.596 in
mm
Cylinder Block and Liner Seats (001-027)

Counterbore Depth 13.684 mm MIN 0.539 in
13.734 mm MAX 0.541 in
Counterbore Diameter - Upper Press Fit 190.28 mm MIN 7.491 in

Diameter
190.34 mm MAX 7.494 in
Counterbore Diameter - Lower Press Fit 181.47 mm MIN 7.144 in

Diameter
181.80 mm MAX 7.157 in
Packing Ring Bore 177.32 mm MIN 6.981 in

177.48 mm MAX 6.987 in
Cylinder Liner (001-028)

Cylinder Liner Inside Diameter
Position 1, 20 mm [0.8 in] from top of liner 158.65 MIN 6.246
158.75 MAX 6.25
158.785 MAX 6.2513
158.785 MAX 6.2513
Ref.No./
Steps
.
Upper Press-Fit Cylinder Liner Flange

Diameter
190.36 MAX 7.495
Lower Press-Fit Area Outside Diameter

181.86 MAX 7.160
Cylinder Liner Flange Thickness 13.35 mm MIN 0.525 in

13.40 mm MAX 0.527 in

0.20 mm MAX 0.008 in
New Cylinder Liner Inner Diameter 158.75 mm MIN 6.250 in

158.78 mm MAX 6.251 in
Gear Cover, Front (001-031)

Accessory Drive and Water Pump Drive 43.99 mm MIN 1.732 in
Bushing Inside Diameter
44.07 mm MAX 1.735 in
Hydraulic Pump Drive Bushing Inside 43.99 mm MIN 1.732 in

Diameter
44.07 mm MAX 1.735 in
Ref.No./
Steps
.
Fuel Pump Drive Bushing Inside Diameter 43.99 mm MIN 1.732 in

44.07 mm MAX 1.735 in
Hydraulic Pump Drive Bushing Inside 43.99 mm MIN 1.732 in

Diameter
44.07 mm MAX 1.735 in
Idler Gear, Camshaft (Left Bank) (001-037)

Left Bank Camshaft Idler Gear Inside 73.035 mm MIN 2.875 in
Diameter
73.065 mm MAX 2.877 in
Left Bank Camshaft Idler Gear Shaft

Outside Diameter
(1) 88.75 MIN 3.494
89.05 MAX 3.506
(2) 21.75 MIN 0.856
22.25 MAX 0.876
(3) 72.96 MIN 2.872
72.98 MAX 2.873
Left Bank Camshaft Idler Gear Thrust 2.337 mm MIN 0.092 in
Bearing Thickness
2.387 mm MAX 0.094 in
Left Bank Camshaft Idler Gear End 0.15 mm MIN 0.006 in

Clearance
0.33 mm MAX 0.013 in
Idler Gear, Camshaft (Right Bank) (001-038)

Right Bank Camshaft Idler Gear Inside 73.035 mm MIN 2.875 in
Diameter
73.065 mm MAX 2.877 in
Ref.No./
Steps
.
Right Bank Camshaft Idler Gear Shaft

Outside Diameter
(1) 88.75 MIN 3.494
89.05 MAX 3.506
(2) 21.75 MIN 0.856
22.25 MAX 0.876
(3) 72.96 MIN 2.872
72.98 MAX 2.873
Right Bank Camshaft Idler Gear Thrust 2.337 mm MIN 0.092 in
Bearing Thickness
2.387 mm MAX 0.094 in
Right Bank Camshaft Idler Gear End 0.15 mm MIN 0.006 in

Clearance
0.33 mm MAX 0.013 in
Front Gear Train Backlash 0.07 mm MIN 0.003 in

0.51 mm MAX 0.020 in
Idler Gear, Hydraulic Pump (001-039)

Hydraulic Pump Drive Idler Gear Inside 73.035 mm MIN 2.875 in
Diameter
73.065 mm MAX 2.877 in
Hydraulic Pump Drive Idler Gear Shaft

Outside Diameter
(1) 88.75 MIN 3.494
89.05 MAX 3.506
(2) 21.75 MIN 0.856
22.25 MAX 0.876
(3) 72.96 MIN 2.872
72.98 MAX 2.873
Hydraulic Pump Idler Gear Thrust Bearing 2.337 mm MIN 0.092 in
Thickness
2.387 mm MAX 0.094 in
Ref.No./
Steps
.
Hydraulic Pump Idler Gear - End Clearance 0.15 mm MIN 0.006 in

0.33 mm MAX 0.013 in
Idler Gear, Water Pump (001-040)

Water Pump Drive Idler Gear Inside 73.035 mm MIN 2.875 in
Diameter
73.065 mm MAX 2.877 in
Water Pump Drive Idler Gear Shaft

Outside Diameter
(1) 88.75 MIN 3.494
89.05 MAX 3.506
(2) 21.75 MIN 0.856
22.25 MAX 0.876
(3) 72.96 MIN 2.872
72.98 MAX 2.873
Water Pump Idler Gear Thrust Bearing 2.337 mm MIN 0.092 in
Thickness
2.387 mm MAX 0.094 in
Piston (001-043)
Ring Groove Wear Limits (Diameter Over
Pins)
Top Ring 158.08 MIN 6.224
Second Ring 159.41 MIN 6.276
Piston Oil Ring Groove Width 4.788 mm MIN 0.1885 in

4.851 mm MAX 0.1910 in
Piston Pin Bore Inside Diameter 65.00 mm MIN 2.559 in

65.10 mm MAX 2.563 in
Ref.No./
Steps
.
Piston Skirt Outside Diameter

(1) 158.631 MIN 6.245
158.671 MAX 6.247
(2) 158.631 MIN 6.245
158.651 MAX 6.246
Piston Pin
Outside Diameter 64.997 MIN 2.5589
65.003 MAX 2.5591
Length 118.56 MIN 4.668
118.80 MAX 4.677
Piston Rings (001-047)

Piston Ring Gap
Top 0.56 MIN 0.022
0.76 MAX 0.030
Intermediate 0.63 MIN 0.025
1.02 MAX 0.040
Oil 0.38 MIN 0.015
0.59 MAX 0.023
Vibration Damper, Viscous (001-052)
Maximum Vibration Damper Thickness 65.66 mm MAX 2.585 in
Vibration Damper Eccentricity 0.46 mm MAX 0.018 in
Vibration Damper Face Runout 0.56 mm MAX 0.022 in
Piston and Connecting Rod Assembly (001-054)

Connecting Rod and Crankshaft Side 0.30 mm MIN 0.012 in
Clearance
0.52 mm MAX 0.020 in
Ref.No./
Steps
.
Gear Train Backlash, Front (001-055)

Gear Train Backlash 0.07 mm MIN 0.003 in
0.51 mm MAX 0.020 in
Camshaft Thrust Bearing (001-056)

14.05 mm MAX 0.553 in
Cylinder Liner Protrusion (001-064)

0.20 mm MAX 0.008 in
Cylinder Block — Group 01 - Torque Values QSK45 and QSK60
Ref.No./
Steps
.
Cylinder Block — Group 01 - Torque Values

Alternator Drive Seal (001-001)
Alternator Drive Seal Mounting Capscrews 10 N•m [ 89 in-lb ]
Accessory Drive Seal (001-003)

Accessory Drive Seal Mounting Capscrews 10 N•m [ 89 in-lb ]
Bearings, Connecting Rod (001-005)

Connecting Rod Cap Capscrews 1 85 N•m [ 63 ft-lb ]
2 Loosen
3 85 N•m [ 63 ft-lb ]
4 Turn 60 degrees
Bearings, Main (001-006)

Qsk45 Main Bearing Capscrews 1 195 N•m [ 144 ft-lb ]
2 420 N•m [ 310 ft-lb ]
3 Loosen all
4 200 N•m [ 148 ft-lb ]
5 420 N•m [ 310 ft-lb ]
6 Rotate 90 degrees
Qsk60 Main Bearing Capscrews 1 195 N•m [ 144 ft-lb ]

2 420 N•m [ 310 ft-lb ]
3 Loosen all
4 200 N•m [ 148 ft-lb ]
5 420 N•m [ 310 ft-lb ]
6 Rotate 90 degrees
390 N•m [ 288 ft-lb ]
Camshaft (001-008)
Camshaft Thrust Bearing Capscrew 45 N•m [ 33 ft-lb ]
Ref.No./
Steps
.
Crankshaft Adapter (001-017)

Crankshaft Adapter Capscrews 1 200 N•m [ 148 ft-lb ]
2 380 N•m [ 280 ft-lb ]
3 685 N•m [ 505 ft-lb ]
Crankshaft Seal, Front (001-023)

Front Crankshaft Seal Mounting Capscrews 10 N•m [ 89 in-lb ]
Crankshaft Seal, Rear (001-024)

Rear Crankshaft Seal Mounting Capscrews 10 N•m [ 89 in-lb ]
Gear Cover, Front (001-031)

Front Gear Cover Mounting Capscrews 80 N•m [ 59 ft-lb ]
Front Gear Cover Mounting Capscrews
M16 Capscrews
Oil Pan Adapter Mounting Capscrews 45 N•m [ 33 ft-lb ]
Hydraulic Pump Drive Mounting Capscrews 45 N•m [ 33 ft-lb ]
Front Gear Cover Mounting Capscrews 80 N•m [ 59 ft-lb ]

Front Gear Cover Mounting Capscrews
M16 Capscrews
Ref.No./
Steps
.
Oil Pan Adapter Mounting Capscrews 45 N•m [ 33 ft-lb ]
Gear Housing, Front (001-033)

Front Gear Housing Capscrews 80 N•m [ 59 ft-lb ]
Hand Hole Cover (001-035)

45 N•m [ 33 ft-lb ]
45 N•m [ 33 ft-lb ]
45 N•m [ 33 ft-lb ]
Idler Gear, Camshaft (Left Bank) (001-037)

Left Bank Camshaft Idler Gear Mounting 1 80 N•m [ 59 ft-lb ]
Capscrews 2 165 N•m [ 122 ft-lb ]
3 280 N•m [ 207 ft-lb ]
Ref.No./
Steps
.
Idler Gear, Camshaft (Right Bank) (001-038)

Right Bank Idler Shaft Mounting Capscrews 1 80 N•m [ 59 ft-lb ]
2 165 N•m [ 122 ft-lb ]
3 280 N•m [ 207 ft-lb ]
Idler Gear, Hydraulic Pump (001-039)

1 80 N•m [ 59 ft-lb ]
2 165 N•m [ 122 ft-lb ]
3 280 N•m [ 207 ft-lb ]
Idler Gear, Water Pump (001-040)

Idler Shaft Mounting Capscrews 1 80 N•m [ 59 ft-lb ]
2 165 N•m [ 122 ft-lb ]
3 280 N•m [ 207 ft-lb ]
Piston Cooling Nozzle (001-046)

Piston Cooling Nozzle Mounting Capscrews 80 N•m [ 59 ft-lb ]
12 Mm Capscrew 45 N•m [ 33 ft-lb ]
Piston Cooling Nozzle Mounting Capscrews
10 Mm Capscrew
Vibration Damper, Viscous (001-052)

Vibration Damper Mounting Capscrews 1 125 N•m [ 92 ft-lb ]
2 165 N•m [ 122 ft-lb ]
Piston and Connecting Rod Assembly (001-054)

Connecting Rod Capscrews 1 85 N•m [ 63 ft-lb ]
2 Loosen
3 85 N•m [ 63 ft-lb ]
4 Turn 60 degrees
Cylinder Head — Group 02 - Specifications QSK45 and QSK60
Ref.No./
Steps
.
Cylinder Head — Group 02 - Specifications

Cylinder Head (002-004)
Allowable Valve Depth From the Combustion 0.00 mm MIN 0.000 in
Face
0.51 mm MAX 0.020 in
Injector Bore Allowable Crack Length 6.4 mm MAX 0.252 in
Minimum Head Thickness (1) 152.4 mm MIN 6 in
Cylinder Head Capscrew Free Length 207.3 mm MAX 8.161 in
Injector Protrusion 2.2 mm MIN 0.087 in

2.7 mm MAX 0.106 in
Valve Seat Bore Measurements

Intake diameter 60.37 MIN 2.377
60.40 MAX 2.378
Intake depth 13.00 MIN 0.512
13.13 MAX 0.517
Exhaust diameter 60.37 MIN 2.377
60.40 MAX 3.378
Exhaust depth 12.50 MIN 0.492
12.62 MAX 0.497
Valve Stem Outside Diameter 10.490 mm MIN 0.4130 in
10.510 mm MAX 0.4138 in
QSK45 and QSK60 Cylinder Head — Group 02
Ref.No./
Steps
.
Valve Head Thickness (At the Outside 3.94 mm MIN 0.155 in

Diameter)
Valve Guide Bore Inside Diameter 21.438 mm MIN 0.8440 in

21.463 mm MAX 0.8450 in
Cylinder Head Pressure Test: Air Pressure 552 kPa MAX 80 psi
Valve Guide Height

To spring pocket 37.97 MIN 1.495
38.48 MAX 1.515
To top of head 13.97 MIN 0.550
14.47 MAX 0.570
Valve Guide Inside Diameter (Installed) 10.551 mm MIN 0.4154 in

10.589 mm MAX 0.4169 in
Valve Insert Seat Width

Intake 3.05 MIN 0.120
3.55 MAX 0.140
Exhaust 1.52 MIN 0.060
2.54 MAX 0.100
Valve Insert Seat to Guide Concentricity 0.05 mm MAX 0.002 in

Cylinder Head — Group 02 - Torque Values QSK45 and QSK60
Ref.No./
Steps
.
Cylinder Head — Group 02 - Torque Values

Cylinder Head (002-004)
Injector Hold Down Capscrew 16 N•m [ 142 in-lb ]
Clamp Capscrew 20 N•m [ 177 in-lb ]
Clamp Capscrew 54 N•m [ 40 ft-lb ]
Cylinder Head Capscrews 1 70 N•m [ 52 ft-lb ]

2 200 N•m [ 148 ft-lb ]
3 300 N•m [ 221 ft-lb ]
4 Turn another 90 degrees
(clockwise)
QSK45 and QSK60 Rocker Levers — Group 03 - Specifications
Ref.No./
Steps
.
Rocker Levers — Group 03 - Specifications

Overhead Set (OBC) (003-006)
Valve Clearances - Initial Set
Exhaust Valves (A) 0.81 MAX 0.032
Intake Valves (B) 0.36 MAX 0.014
Valve Clearances - Recheck
Exhaust Valves (A) 0.74 MIN 0.029
0.89 MAX 0.035
Intake Valves (B) 0.28 MIN 0.011
0.43 MAX 0.017
Valve Clearances - Initial Set
Exhaust Valves (A) 0.81 MAX 0.032
Intake Valves (B) 0.36 MAX 0.014
Valve Clearances - Recheck
Exhaust Valves (A) 0.74 MIN 0.029
0.89 MAX 0.035
Intake Valves (B) 0.28 MIN 0.011
0.43 MAX 0.017
Rocker Lever Assembly (003-009)
Rocker Lever Bore Inside Diameter (Bushing 47.66 mm MIN 1.876 in
Installed)
47.73 mm MAX 1.879 in
Rocker Lever Bushing Bore Inner Diameter 47.66 mm MIN 1.876 in

(Bushing Installed)
47.73 mm MAX 1.879 in
Rocker Lever Bore Inside Diameter (Bushing 49.246 mm MIN 1.939 in

Removed)
49.270 mm MAX 1.940 in
Rocker Arm Shaft Outside Diameter 47.592 mm MIN 1.874 in

47.634 mm MAX 1.875 in
Rocker Levers — Group 03 - Torque Values QSK45 and QSK60
Ref.No./
Steps
.
Rocker Levers — Group 03 - Torque Values

Crankcase Breather (External) (003-001)
Cam Follower Cover Bracket Capscrews 45 N•m [ 35 ft-lb ]
Breather Box Mounting Capscrews 45 N•m [ 35 ft-lb ]
Breather Outlet Hose Clamps 6 N•m [ 53 in-lb ]
Breather Box Hose Clamps 6 N•m [ 53 in-lb ]

QSK45 and QSK60 Rocker Levers — Group 03
Ref.No./
Steps
.
Reducer Hose And Blowby Sensor Hose 6 N•m [ 53 in-lb ]

Clamps
Blowby Sensor Outlet Hose Clamps 6 N•m [ 53 in-lb ]
Reducer And Blowby Sensor Hose Clamp 6 N•m [ 53 in-lb ]
Hose Brace Capscrew 45 N•m [ 35 ft-lb ]
Outlet Hose Mounting Capscrew 45 N•m [ 35 ft-lb ]
Breather Box Mounting Capscrews 45 N•m [ 35 ft-lb ]
Oil Pan Elbow 74 N•m [ 55 ft-lb ]

183 N•m [ 135 ft-lb ]
130 N•m [ 96 ft-lb ]
130 N•m [ 96 ft-lb ]
100 N•m [ 74 ft-lb ]
Two Piece Hose Clamp Capscrew 80 N•m [ 59 ft-lb ]

Rocker Levers — Group 03 QSK45 and QSK60
Ref.No./
Steps
.
Blowby Y Support Brace Capscrew 45 N•m [ 35 ft-lb ]

45 N•m [ 35 ft-lb ]
Crakcase Outlet Hose Clamps 6 N•m [ 53 in-lb ]
Blowby Hose Brace Capscrew 45 N•m [ 35 ft-lb ]

45 N•m [ 35 ft-lb ]
Crankcase Capscrews 45 N•m [ 35 ft-lb ]
Oil Drain Pipe Capscrews 45 N•m [ 35 ft-lb ]
Drain Hose Clamps 8 N•m [ 70 in-lb ]
Molded Hose Clamps 8 N•m [ 70 in-lb ]
Breather Hose Clamps 8 N•m [ 70 in-lb ]

Ref.No./
Steps
.
Flexible Hose Clamps 8 N•m [ 70 in-lb ]
Flexible Hose P-Clip Capscrews 45 N•m [ 35 ft-lb ]
Overhead Set (OBC) (003-006)

Valve Adjusting Screw 0.7 N•m [ 6 in-lb ]
Valve Set - Torque Wrench Method With 48 N•m [ 35 ft-lb ]

Adapter 60 N•m [ 44 ft-lb ]
Valve Set - Torque Wrench Method Without
Adapter

Adapter
Injector Adjusting Screw Preload 28 N•m [ 248 in-lb ]

19 N•m [ 168 in-lb ]
Valve Adjusting Screw Locknut With 48 N•m [ 35 ft-lb ]

Valve Adjusting Screw Locknut Without
Adapter
Ref.No./
Steps
.
Valve Adjusting Screw 0.7 N•m [ 6 in-lb ]

Adapter

Adapter
Rocker Lever Assembly (003-009)

Rocker Lever Mounting Capscrews 280 N•m [ 207 ft-lb ]
Rocker Lever Mounting Capscrews 280 N•m [ 207 ft-lb ]
Rocker Lever Cover (003-011)

Rocker Lever Capscrews 45 N•m [ 33 ft-lb ]
Rocker Lever Cover Capscrews 40 N•m [ 30 ft-lb ]

Ref.No./
Steps
.
Rocker Lever Cover Plate Capscrews 40 N•m [ 30 ft-lb ]
Turbocharger Speed Sensor Bracket 20 N•m [ 180 in-lb ]

Capscrews
Exhaust Gas Temperature Sensor P-Clip 20 N•m [ 180 in-lb ]

Capscrews
Sensor Bracket Capscrews 20 N•m [ 180 in-lb ]
P-Clip Capscrews 20 N•m [ 180 in-lb ]
Aftercooler Connection Tee Mounting 45 N•m [ 33 ft-lb ]

Capscrews 9 N•m [ 80 in-lb ]
Intake Air System Hose Clamps 9 N•m [ 80 in-lb ]
Air Crossover Mounting Capscrews 45 N•m [ 33 ft-lb ]

Ref.No./
Steps
.
Rocker Lever Housing (003-013)

Rocker Lever Housing Capscrews 115 N•m [ 85 ft-lb ]
QSK45 and QSK60 Group 04 - Specifications
Ref.No./
Steps
.
Group 04 - Specifications
Cam Follower Assembly (004-001)
Cam Follower Shaft Outside Diameter 39.975 mm MIN 1.574 in
40.013 mm MAX 1.575 in
Cam Follower Roller Side Clearance

Reference Point 1 0.230 MIN 0.009
0.610 MAX 0.024
0.114 MAX 0.005
Cam Follower Shaft Bore Inside Diameter 40.023 mm MIN 1.576 in

40.073 mm MAX 1.578 in
Cam Follower Shaft Outside Diameter 39.975 mm MIN 1.574 in

40.013 mm MAX 1.575 in
Cam Follower Roller Side Clearance

0.610 MAX 0.024
0.114 MAX 0.005
Cam Follower Shaft Bore Inside Diameter 40.023 mm MIN 1.576 in

40.073 mm MAX 1.578 in
Group 04 - Torque Values QSK45 and QSK60
Ref.No./
Steps
.
Group 04 - Torque Values

Cam Follower Assembly (004-001)
Cam Follower Mounting Capscrews 1 35 N•m [ 26 ft-lb ]
2 140 N•m [ 103 ft-lb ]
3 280 N•m [ 207 ft-lb ]
Cam Follower Mounting Capscrews 1 35 N•m [ 26 ft-lb ]

2 140 N•m [ 103 ft-lb ]
3 280 N•m [ 207 ft-lb ]
Cam Follower Cover (004-002)

Cam Follower Cover Capscrews 45 N•m [ 33 ft-lb ]
Cam Follower Cover Capscrews 45 N•m [ 33 ft-lb ]

QSK45 and QSK60 Fuel System — Group 05 - Specifications
Ref.No./
Steps
.
Fuel System — Group 05 - Specifications

Fuel Pump (005-016)
Engine Cranking Fuel Pressure 241 kPa MIN 35 psi
Fuel Pressure
1500 rpm (50 Hz) 1572 MIN 228
1800 rpm (60 Hz) 1820 MIN 264
1900 rpm 1896 MIN 275
2070 rpm 1896 MIN 275
Fuel System — Group 05 - Torque Values QSK45 and QSK60
Ref.No./
Steps
.
Fuel System — Group 05 - Torque Values

Fuel Pump (005-016)
Fuel Pump Capscrews 68 N•m [ 50 ft-lb ]
Fuel Pump Gear Housing Capscrews 54 N•m [ 40 ft-lb ]
Pressure Relief Valve Plug 14 ± 1 [ 124 ± 9

N•m in-lb ]
Control Orifice Plug 1 N•m [ 9 in-lb ]

14 ± 1 [ 124 ± 9
N•m in-lb ]
Filter Screen Cap 14 ± 1 [ 124 ± 9

N•m in-lb ]
QSK45 and QSK60 Fuel System — Group 05
Ref.No./
Steps
.
Regulator Mounting Capscrews 47 ± 5 [ 35 ± 4 ft-

N•m lb ]
Gerotor Capscrews 19 N•m [ 14 ft-lb ]

8 N•m [ 70 in-lb ]
100 N•m [ 74 ft-lb ]
135 N•m [ 100 ft-lb ]
Fuel Pump Mounting Capscrews 45 N•m [ 33 ft-lb ]

80 N•m [ 59 ft-lb ]
80 N•m [ 59 ft-lb ]
Fuel Pump Inlet And Supply Hoses Fuel 120 N•m [ 89 ft-lb ]
Pump Inlet Hose 120 N•m [ 89 ft-lb ]
Fuel Pump Inlet And Supply Hoses Fuel
Supply Hose
Fuel Pump Mounting Capscrews 117 N•m [ 86 ft-lb ]
Intake Manifold Capscrews 68 N•m [ 50 ft-lb ]
Capscrew To Camshaft Cover 180 N•m [ 133 ft-lb ]

Fuel System — Group 05 QSK45 and QSK60
Ref.No./
Steps
.
Support Bracket Capscrew To Fuel Pump 113 N•m [ 83 ft-lb ]
Fuel Shutoff Valve (005-043)

Electronic Control Valve Body Capscrews 8 N•m [ 71 in-lb ]
Eelctronic Control Valve Body Capscrews 8 N•m [ 71 in-lb ]
Fuel Shutoff Valve Coil Nut 2 N•m [ 18 in-lb ]
Ecm Mounting Capscrews 8 N•m [ 71 in-lb ]
Ecm Connector Capscrews 3 N•m [ 27 in-lb ]
Fuel Lift Pump (005-045)

Fuel Lift Pump Mounting Capscrews 15 N•m [ 133 in-lb ]
QSK45 and QSK60 Fuel System — Group 05
Ref.No./
Steps
.
Fuel Tubes Fittings 54 N•m [ 40 ft-lb ]

Injectors and Fuel Lines — Group 06 - Specifications QSK45 and QSK60
Ref.No./
Steps
.
Injectors and Fuel Lines — Group 06 - Specifications

With check valve 228 MAX 9
Without check valve 177 MAX 7

Stage 1 Filter Restriction 76 mm Hg MIN 3 in Hg
152 mm MAX 6 in Hg
Hg
Stage 2 Filter Restriction (clean filter) 28 kPa MAX 4 psi

Stage 2 Filter Restriction (dirty filter) 138 kPa MAX 20 psi
QSK45 and QSK60 Injectors and Fuel Lines — Group 06 - Torque Values
Ref.No./
Steps
.
Injectors and Fuel Lines — Group 06 - Torque Values

Air in Fuel (006-003)
Fuel Inlet Hose 120 N•m [ 89 ft-lb ]
Fuel Inlet Hose 120 N•m [ 89 ft-lb ]
Fuel Connection Block (Manifold-Mounted) (006-010)

Fuel Transfer Manifold Block Capscrews 9 N•m [ 79 in-lb ]
Fuel Transfer Deck Capscrews 23 N•m [ 17 ft-lb ]

72 N•m [ 53 ft-lb ]

Fuel Line 120 N•m [ 89 ft-lb ]
Fuel Drain Lines (006-013)

Fuel Drain Line To Fuel Manifold 45 N•m [ 33 ft-lb ]
Connection
Fuel Drain Line Hold Down Capscrews 9 N•m [ 80 in-lb ]

Injectors and Fuel Lines — Group 06 QSK45 and QSK60
Ref.No./
Steps
.
Fuel Drain Line To Fuel Tank Connection 45 N•m [ 33 ft-lb ]
Fuel Drain Manifold Capscrews 30 N•m [ 22 ft-lb ]
Fuel Drain Manifold 40 N•m [ 30 ft-lb ]
P-Clip Capscrew 22 N•m [ 195 in-lb ]

Fuel Drain Line Banjo Capscrew 48 N•m [ 35 ft-lb ]
P-Clip Capscrew 22 N•m [ 195 in-lb ]

QSK45 and QSK60 Injectors and Fuel Lines — Group 06
Ref.No./
Steps
.
Fuel Filter Head (006-017)

Filter Head Adapter 102 N•m [ 75 ft-lb ]
Straight Thread O-Ring Plugs 102 N•m [ 75 ft-lb ]
Check Valve Plug 62 N•m [ 46 ft-lb ]
Threaded Plugs 30 N•m [ 22 ft-lb ]
Elbow Fitting 62 N•m [ 46 ft-lb ]
Union Fitting 54 N•m [ 40 ft-lb ]

Ref.No./
Steps
.
Fuel Filter Supply And Return Hoses 55 N•m [ 40 ft-lb ]
Fuel Filter Head Mounting Nut And 65 N•m [ 50 ft-lb ]

Capscrews

Threaded O-Ring Plugs 27 N•m [ 20 ft-lb ]
Air Bleed Check Valve 55 N•m [ 41 ft-lb ]

Threaded O-Ring Plugs 27 N•m [ 20 ft-lb ]
Fuel Manifold (Drain) (006-021)

Drain Manifold Block Capscrews 20 N•m [ 177 in-lb ]
Ref.No./
Steps
.
Fuel Drain Union To Fuel Tank 170 N•m [ 125 ft-lb ]

Fuel Drain Union To Fuel Block Manifold 70 N•m [ 52 ft-lb ]
Check Valve/Union 55 N•m [ 40 ft-lb ]
Fuel Block Manifold Capscrews 45 N•m [ 33 ft-lb ]
Fuel Drain Union 70 N•m [ 52 ft-lb ]
Fuel Manifold (Supply) (006-022)

Fuel Manifold O-Ring Plugs M10 Plug 6 N•m [ 53 in-lb ]
Fuel Manifold O-Ring Plugs M12 Plug 8 N•m [ 71 in-lb ]
Fuel Manifold O-Ring Plugs M27 Plug 47 N•m [ 35 ft-lb ]
Fuel Manifold To Head Mounting 9 N•m [ 79 in-lb ]

Capscrews - Qsk45 Engines
Fuel Manifold To Head Mounting 9 N•m [ 79 in-lb ]

Capscrews - Qsk60 Engines
Ref.No./
Steps
.
Fuel Supply Lines (006-024)

Fuel Pump Inlet Hose 120 N•m [ 89 ft-lb ]
Fuel Supply Tube 120 N•m [ 89 ft-lb ]
Gerotor Pump Outlet Union 100 N•m [ 74 ft-lb ]
Fuel Supply Line 65 N•m [ 48 ft-lb ]
Tee Fitting Locknut 100 N•m [ 74 ft-lb ]
Fuel Pump Inlet To Actuator Union 170 N•m [ 125 ft-lb ]
Gerotor Fuel Supply Line 91 N•m [ 68 ft-lb ]
Fuel Line From Filter To Gerotor Pump Inlet 91 N•m [ 68 ft-lb ]

Ref.No./
Steps
.
Fuel Line From Filter To Inlet Actuator 65 N•m [ 48 ft-lb ]
Injector (006-026)
45 N•m [ 35 ft-lb ]
Injector Hold Down Capscrew 75 N•m [ 55 ft-lb ]
Injector Hold Down Clamp Capscrew 1 68 N•m [ 50 ft-lb ]

2 Loosen capscrew completely.
3 20 N•m [ 177 in-lb ]
4 Rotate the capscrew 60 degrees.
Fuel Control Valve Body Assembly (006-049)

Timing Actuator 25 N•m [ 18 ft-lb ]
25 N•m [ 18 ft-lb ]
Timing Rail Pressure Sensor 14 N•m [ 124 in-lb ]

15 N•m [ 133 in-lb ]
14 N•m [ 124 in-lb ]
23 N•m [ 17 ft-lb ]
Fuel Control Valve Body Capscrew 45 N•m [ 33 ft-lb ]

Ref.No./
Steps
.
Fuel Shutoff Valve Electrical Connection 2 N•m [ 18 in-lb ]
Control Valve Fuel Hose 120 N•m [ 89 ft-lb ]
Injector Supply Lines (High Pressure) (006-051)

Injector Plug 45 N•m [ 34 ft-lb ]
Injector Connector Nuts 45 N•m [ 34 ft-lb ]

45 N•m [ 34 ft-lb ]
Fuel Cooler (006-062)

Fuel Cooler Front Bracket Mounting 45 N•m [ 33 ft-lb ]
Capscrews
Fuel Cooler Fuel And Coolant Lines 27 N•m [ 20 ft-lb ]

QSK45 and QSK60 Lubricating Oil System — Group 07 - Specifications
Ref.No./
Steps
.
Lubricating Oil System — Group 07 - Specifications

Free Length 93.65 mm MIN 3.687 in
96.85 mm MAX 3.813 in
Load 409.2 N MIN 91.99 lbf
480.4 N MAX 107.99 lbf
Lubricating Oil Pressure Regulator (Main Rifle) (007-029)

70.1 mm [ 2.76 in ]
Spring Force 230 N MIN 52 lb
255 N MAX 57 lb
Lubricating Oil Pressure Regulator (Piston Cooling) (007-030)

Lubricating Oil Pressure Regulator (Piston 106.87 N MIN 24.02 lbf
Cooling) Spring
118.12 N MAX 26.55 lbf

Lubricating Oil Pump Idler Gear Backlash 0.21 mm MIN 0.008 in
0.39 mm MAX 0.015 in
Lubricating Oil Pump Pressure Regulator 230 N MIN 52 lbf

Spring Force at Working Height
255 N MAX 57 lbf
Lubricating Oil Pump Pressure Relief Valve 658 N MIN 148 lbf
Spring Force at Working Height
725 N MAX 163 lbf
Lubricating Oil Pump Idler Gear Bushing 60.045 mm MIN 2.364 in

Bore Inside Diameter
60.100 mm MAX 2.366 in
Lubricating Oil System — Group 07 QSK45 and QSK60
Ref.No./
Steps
.
Lubricating Oil Pump Idler Gear Shaft 59.975 mm MIN 2.361 in

Outside Diameter
60.006 mm MAX 2.363 in
Lubricating Oil Pump Ring Dowel Outside 19.217 mm MIN 0.757 in

Diameter
19.243 mm MAX 0.758 in
Lubricating Oil Pump Idler Thrust Washer 2.400 mm MIN 0.095 in

Thickness
2.470 mm MAX 0.097 in
Lubricating Oil Pump Idler Gear End 0.080 mm MIN 0.003 in

Clearance
0.360 mm MAX 0.014 in
Lubricating Oil Pump Idler Gear Backlash 0.021 mm MIN 0.008 in

0.039 mm MAX 0.015 in
Backlash - Lubricating Oil Pump Idler Gear 0.21 mm MIN 0.008 in

to Crankshaft Gear
0.39 mm MAX 0.015 in
Lubricating Oil Pump Idler Gear to 0.21 mm MIN 0.008 in

Crankshaft Gear Backlash
0.39 mm MAX 0.015 in
QSK45 and QSK60 Lubricating Oil System — Group 07 - Torque Values
Ref.No./
Steps
.
Lubricating Oil System — Group 07 - Torque Values

Lubricating Oil Dipstick (007-009)
Oil Pan Weep Hole Plug 47 N•m [ 35 ft-lb ]
Lubricating Oil Dipstick Tube (007-011)

Lubricating Oil Dipstick Capscrews 45 N•m [ 33 ft-lb ]
Dipstick Hand Hole Cover Capscrews 45 N•m [ 33 ft-lb ]

6 N•m [ 53 in-lb ]
Lower Dipstick Tube Supporting Bracket 45 N•m [ 33 ft-lb ]

Capscrew
Upper Dipstick Tube Supporting Bracket 45 N•m [ 33 ft-lb ]

Capscrew
Dipstick Capscrews 45 N•m [ 35 ft-lb ]
Dipstick P-Clip Nut And Bolt 45 N•m [ 35 ft-lb ]

Ref.No./
Steps
.
Dipstick Plastic Tube 27 N•m [ 20 ft-lb ]
Dipstick Tube Bracket 7 N•m [ 80 in-lb ]
Lubricating Oil Filter (Spin-On) (007-013)

Oil Pan Drain Plug 47 N•m [ 35 ft-lb ]
Hex Plug 27 N•m [ 20 ft-lb ]
Hex Plug 27 N•m [ 20 ft-lb ]
10 N•m [ 84 in-lb ]

Filter Head Adapter Capscrews 23 N•m [ 17 ft-lb ]
QSK45 and QSK60 Lubricating Oil System — Group 07
Ref.No./
Steps
.
Oil Filter Head Bypass Valve Cover Plate 45 N•m [ 33 ft-lb ]

Capscrews
Filter Head Mounting Capscrews 45 N•m [ 33 ft-lb ]
Filter Head Mounting Capscrews 45 N•m [ 33 ft-lb ]
Lubricating Oil Filter Head Adapter (007-018)

Adapter Capscrews 23 N•m [ 17 ft-lb ]
Lubricating Oil High Pressure Relief Valve (007-021)

Oil Pump Gear Cover Capscrews M8 23 N•m [ 17 ft-lb ]
Capscrews 80 N•m [ 60 ft-lb ]
Oil Pump Gear Cover Capscrews M12
Capscrews
Lubricating Oil Pan (007-025)

Oil Pan Capscrews 45 N•m [ 33 ft-lb ]
47 N•m [ 35 ft-lb ]
Ref.No./
Steps
.
Lubricating Oil Pan Adapter Cover Plate (007-026)

Oil Pan Adapter Cover Capscrews 45 N•m [ 33 ft-lb ]
47 N•m [ 35 ft-lb ]
Lubricating Oil Pan Adapter (007-027)

Oil Pan Capscrews 45 N•m [ 33 ft-lb ]
45 N•m [ 33 ft-lb ]
Lubricating Oil Pressure Regulator (Main Rifle) (007-029)

Lubricating Oil Pressure Regulator Plug 60 N•m [ 44 ft-lb ]
Lubricating Oil Pressure Regulator (Piston Cooling) (007-030)

Lubricating Oil Pressure Regulator (Piston 45 N•m [ 33 ft-lb ]
Cooling) Plug

Lubricating Oil Pump Pressure Regulator 136 N•m [ 100 ft-lb ]
Straight Thread O-Ring Plug
Lubricating Oil Pump Idler Gear Retainer 55 N•m [ 40 ft-lb ]

Capscrews
Ref.No./
Steps
.
Lubricating Oil Pump Gear Cover 23 N•m [ 17 ft-lb ]

Capscrews M8 80 N•m [ 60 ft-lb ]
Lubricating Oil Pump Gear Cover
Capscrews M12
Lubricating Oil Pump Suction Head 47 N•m [ 35 ft-lb ]

Capscrews
Oil Pump Capscrews M12 80 N•m [ 59 ft-lb ]

Oil Pump Capscrews M10 45 N•m [ 33 ft-lb ]
Oil Pump Mounting Capscrews M12 80 N•m [ 59 ft-lb ]

Oil Pump Mounting Capscrews M10 45 N•m [ 33 ft-lb ]
Lubricating Oil Suction Tube (Block-Mounted) (007-035)

Lubricating Oil Suction Tube Mounting 45 N•m [ 33 ft-lb ]
45 N•m [ 33 ft-lb ]
Lubricating Oil Temperature Gauge (007-038)

47 N•m [ 35 ft-lb ]
Lubricating Oil Transfer Tube (007-040)

Oil Transfer Tube M10 Capscrews 45 N•m [ 33 ft-lb ]
45 N•m [ 33 ft-lb ]
Ref.No./
Steps
.


Lubricating Oil Cooler Cover (007-045)

Lubricating Oil Cooler Cover Capscrews 45 N•m [ 33 ft-lb ]
95 N•m [ 70 ft-lb ]
Pre-Lubricating Oil Pump (007-063)

Prelub High-Volume Pump Bracket 80 N•m [ 50 ft-lb ]
Capscrews M12 78 N•m [ 58 ft-lb ]
Prelub High-Volume Pump Bracket
Capscrews M10
Prelub High-Volume Pump U-Shaped 30 N•m [ 22 ft-lb ]

Bracket Capscrews
74 N•m [ 55 ft-lb ]
163 N•m [ 120 ft-lb ]

45 N•m [ 33 ft-lb ]
Ref.No./
Steps
.
190 N•m [ 140 ft-lb ]

45 N•m [ 33 ft-lb ]
Lubricating Oil Fill Tube (007-065)

Crankcase Breather Integral Hose Clamps 6 N•m [ 53 in-lb ]
Eliminator Filter (007-067)

Eliminator Filtering Unit Distributor Cover 35 N•m [ 26 ft-lb ]
Capscrews
25 N•m [ 18 ft-lb ]
Eliminator Filter Head Capscrews 35 N•m [ 26 ft-lb ]
Eliminator Internal And External Flange 20 N•m [ 177 in-lb ]

Assembly Plugs
Ref.No./
Steps
.
25 N•m [ 18 ft-lb ]
5 N•m [ 44 in-lb ]
Hydraulic Motor Capscrews 25 N•m [ 18 ft-lb ]
Hydraulic Motor Return Pipe Banjo Screw 40 N•m [ 30 ft-lb ]
Eliminator Cover Capscrews 25 N•m [ 18 ft-lb ]
Eliminator Filter Bracket Capscrews 67 N•m [ 50 ft-lb ]
Eliminator Hand Hole Cover Capscrews 40 N•m [ 30 ft-lb ]
Eliminator Mounting Capscrews 40 N•m [ 30 ft-lb ]

40 N•m [ 30 ft-lb ]
Ref.No./
Steps
.
Eliminator Pipe Plugs 10 N•m [ 96 in-lb ]

Cooling System — Group 08 - Specifications QSK45 and QSK60
Ref.No./
Steps
.
Cooling System — Group 08 - Specifications

Thermostat Initial Opening Temperature 74.4 °C MIN 166 °F
48.3 °C MAX 173 °F
Minimum Open Distance at Full Open 10.0 mm MIN 0.40 in

Temperature
Full-Open Temperature 90 °C MIN 194 °F
Cooling System Diagnostics (008-020)

Coolant Pressure Cap Removed: 241 kPa MAX 35 psi
Coolant Pressure Cap Removed: 241 kPa MAX 35 psi
Fan Drive Idler Arm Assembly (008-029)

Fan Drive Idler Arm Assembly Outside 38.087 mm MIN 1.500 in
Diameter
38.113 mm MAX 1.501 in
Fan Drive Idler Pulley Assembly (008-030)

Fan Drive Idler Pulley Assembly End 0.08 mm MIN 0.003 in
Clearance
0.25 mm MAX 0.010 in
Shaft Outside Diameter 59.97 mm MIN 2.3610 in

59.98 mm MAX 2.3614 in
QSK45 and QSK60 Cooling System — Group 08
Ref.No./
Steps
.

Bearing End Clearance 0.03 mm MIN 0.001 in
0.25 mm MAX 0.010 in

Water Pump Shaft Diameter (bearing area) 30.010 mm MIN 1.181 in
30.020 mm MAX 1.812 in
Water Pump Shaft Diameter (impeller end) 24.999 mm MIN 0.984 in

25.009 mm MAX 0.985 in
Water Pump Impeller Inside Diameter, Part 24.919 mm MIN 0.981 in

Numbers 3050453, 3050454 and 3050455
25.945 mm MAX 0.982 in
Water Pump Impeller Inside Diameter, Part 24.932 mm MIN 0.982 in
Numbers 3001711, 3002106, and 3175069
25.958 mm MAX 0.983 in
Water Pump Housing Mechanical Water 53.60 mm MIN 2.110 in

Seal Bore
54.10 mm MAX 2.130 in
Water Pump Housing Oil Seal Bore 38.05 mm MIN 1.498 in
38.10 mm MAX 1.500 in
Water Pump Housing Rear Bearing Bore 61.997 mm MIN 2.440 in
62.009 mm MAX 2.441 in
Water Pump Housing Front Bearing Bore 71.996 mm MIN 2.834 in
72.012 mm MAX 2.835 in
Cooling System — Group 08 - Torque Values QSK45 and QSK60
Ref.No./
Steps
.
Cooling System — Group 08 - Torque Values

Drive Belt, Cooling Fan (008-002)
Belt Tensioner Adjusting Capscrews 200 N•m [ 148 ft-lb ]
Coolant Filter Head (008-007)

Coolant Filter Head Mounting Capscrews 45 N•m [ 33 ft-lb ]

45 N•m [ 33 ft-lb ]
45 N•m [ 33 ft-lb ]
Lta Housing Cover Capscrews 45 N•m [ 33 ft-lb ]
Clamp Plate Capscrews 45 N•m [ 33 ft-lb ]
Thermostat Housing Cover Capscrews 45 N•m [ 33 ft-lb ]

Ref.No./
Steps
.
Coolant Thermostat Housing Support (008-015)

Thermostat Housing Support Top 80 N•m [ 59 ft-lb ]
Capscrews
Thermostat Housing Support Mounting 1 195 N•m [ 144 ft-lb ]

Capscrews 2 550 N•m [ 406 ft-lb ]
Aftercooler Supply And Return Tube 20 N•m [ 15 ft-lb ]

Mounting Capscrews
Bypass Tube Mounting Capscrews 45 N•m [ 33 ft-lb ]
Cooling System Hose Clamp 6 N•m [ 53 in-lb ]
80 N•m [ 59 ft-lb ]
1 195 N•m [ 144 ft-lb ]

2 550 N•m [ 406 ft-lb ]
Cooling System — Group 08 QSK45 and QSK60
Ref.No./
Steps
.
Aftercooler Supply And Return Line 20 N•m [ 15 ft-lb ]

Mounting Capscrews
Low Temperature Aftercooler Coolant 45 N•m [ 33 ft-lb ]

Pump Pipe Mounting Capscrews
45 N•m [ 33 ft-lb ]
45 N•m [ 33 ft-lb ]
45 N•m [ 33 ft-lb ]
45 N•m [ 33 ft-lb ]
45 N•m [ 33 ft-lb ]
Bypass Tube Mounting Capscrews 45 N•m [ 33 ft-lb ]

6 N•m [ 53 in-lb ]
Ref.No./
Steps
.
Cooling System (008-018)

27 N•m [ 20 ft-lb ]
5 N•m [ 44 in-lb ]
Fan Drive Idler Arm Assembly (008-029)

Fan Drive Idler Arm Assembly Capscrew 203 N•m [ 150 ft-lb ]
Pulley Arm Assembly To Pivot Arm 47 N•m [ 35 ft-lb ]

Assembly Capscrews
Idler Pulley Support Bracket Mounting 115 N•m [ 85 ft-lb ]

Actuator Bracket Mounting Capscrews 115 N•m [ 85 ft-lb ]
Idler Arm Assembly Mounting Capscrews 45 N•m [ 33 ft-lb ]

Ref.No./
Steps
.
Fan Drive Idler Pulley Assembly (008-030)

Idler Lever Shaft Retaining Plate 20 N•m [ 177 in-lb ]
Capscrews

Fan Hub Pipe Plugs 15 N•m [ 133 in-lb ]
Fan Hub Mounting Capscrews 280 N•m [ 207 ft-lb ]
Rockford Fan Clutch Speed Sensor 280 N•m [ 207 ft-lb ]

30 N•m [ 22 ft-lb ]
Rockford Fan Clutch Solenoid Mounting 45 N•m [ 33 ft-lb ]

47 N•m [ 35 ft-lb ]
11 N•m [ 97 in-lb ]
Ref.No./
Steps
.
48 N•m [ 35 ft-lb ]
80 N•m [ 59 ft-lb ]
48 N•m [ 35 ft-lb ]
6 N•m [ 142 in-lb ]
6 N•m [ 142 in-lb ]

6 N•m [ 142 in-lb ]
6 N•m [ 142 in-lb ]
95 N•m [ 70 ft-lb ]
Ref.No./
Steps
.
Marine Gear Oil Cooler (008-041)

Marine Oil Cooler Bracket Capscrews 45 N•m [ 33 ft-lb ]
Marine Gear Oil Cooler Coolant And Oil 74 N•m [ 55 ft-lb ]

Lines
Radiator Hoses (008-045)





Ref.No./
Steps
.

8 N•m [ 71 in-lb ]
T-Bolt Clamp
Expansion Tank (008-052)

Expansion Tank Support Bracket 45 N•m [ 33 ft-lb ]
Capscrews
Expansion Tank Mounting Capscrews 40 N•m [ 30 ft-lb ]
Expansion Tank Hose Fittings 74 N•m [ 55 ft-lb ]

Heat Exchanger Cover Capscrews 15 N•m [ 120 in-lb ]
135 N•m [ 100 ft-lb ]
Heat Exchanger Side Alignment Capscrews 88 N•m [ 65 ft-lb ]
Heat Exchanger Shroud Capscrews 9 N•m [ 80 in-lb ]

Ref.No./
Steps
.
Heat Exchanger Bracket Capscrews 45 N•m [ 33 ft-lb ]
Heat Exchanger Plumbing Capscrews 45 N•m [ 33 ft-lb ]
Sea Water Pump (008-057)

Sea Water Pump To Front Accessory Drive 80 N•m [ 60 ft-lb ]
Adaptor Capscrews
45 N•m [ 33 ft-lb ]
Water Manifold (008-061)

47 N•m [ 35 ft-lb ]
47 N•m [ 35 ft-lb ]
47 N•m [ 35 ft-lb ]
Ref.No./
Steps
.
550 N•m [ 406 ft-lb ]

Water Pump Impeller Drive Key Capscrews 20 N•m [ 177 in-lb ]
Water Pump Inlet Housing Capscrews 45 N•m [ 33 ft-lb ]
Water Pump Inlet Connection Capscrews 40 N•m [ 30 ft-lb ]

Water Pump Draincock 15 N•m [ 133 in-lb ]
Water Pump Mounting Capscrews 80 N•m [ 59 ft-lb ]

Water Pump Adapter Mounting Capscrews 45 N•m [ 33 ft-lb ]
Water Pump Support Bracket Capscrews 45 N•m [ 33 ft-lb ]
Water Pump Inlet Mounting Capscrews 45 N•m [ 33 ft-lb ]

Water Pump Bypass Tube Mounting 45 N•m [ 33 ft-lb ]
Water Pump Bypass Tube Hose Clamp
Ref.No./
Steps
.
Water Pump Mounting Capscrews 80 N•m [ 59 ft-lb ]
Support Bracket Capscrews 45 N•m [ 33 ft-lb ]
Jacket Water Inlet Capscrews 45 N•m [ 33 ft-lb ]
Jacket Water Radiator Inlet Capscrews 45 N•m [ 33 ft-lb ]
Low Temperature Aftercooler Bypass Pipe 45 N•m [ 33 ft-lb ]

Clamp Capscrews
Bypass Pipe Capscrews 45 N•m [ 33 ft-lb ]
U Clamps Nuts 45 N•m [ 33 ft-lb ]

Ref.No./
Steps
.
Low-Temperature Aftercooler (LTA) Water Pump (008-109)

Bearing Housing Capscrews 33 N•m [ 24 ft-lb ]
Drive End Housing Capscrews 33 N•m [ 24 ft-lb ]
Low Temperature Aftercooled Water Pump 80 N•m [ 59 ft-lb ]

Capscrews
Low Temperature Aftercooled Water Pump 20 N•m [ 15 ft-lb ]

Nuts
Right Bank Number 8 Coolant Loop (008-116)

45 N•m [ 33 ft-lb ]
5 N•m [ 44 in-lb ]
45 N•m [ 33 ft-lb ]
Ref.No./
Steps
.
45 N•m [ 33 ft-lb ]
ECM Cooling Plate (008-128)

Coolant Return Tee 25 N•m [ 18 ft-lb ]
Coolant Supply Elbow 25 N•m [ 18 ft-lb ]
Ecm Mounting Studs 80 N•m [ 60 ft-lb ]
Ecm Cooling Plate Nuts 23 N•m [ 17 ft-lb ]
Coolant Lines 15 N•m [ 89 in-lb ]
P-Clamps 45 N•m [ 35 ft-lb ]

Ref.No./
Steps
.
ECM Cooling Plate Lines (008-130)

Coolant Adapters 15 N•m [ 133 in-lb ]
Male Connectors 15 N•m [ 133 in-lb ]
Supply And Return Colant Line Nuts 15 N•m [ 133 in-lb ]
Coolant Line Brackets 45 N•m [ 33 ft-lb ]
Bracket Capacrews 45 N•m [ 33 ft-lb ]

Drive Units — Group 09 - Specifications QSK45 and QSK60
Ref.No./
Steps
.
Drive Units — Group 09 - Specifications

Accessory Shaft End Clearance 0.05 mm MIN 0.002 in
0.30 mm MAX 0.012 in
Accessory Drive Bushing Inside Diameter 49.95 mm MIN 1.967 in

50.03 mm MAX 1.970 in
Accessory Drive Busing Thrust Face 45.370 mm MIN 1.786 in

Distance
45.450 mm MAX 1.789 in
Accessory Drive Lovejoy Coupling Inside 25.377 mm MIN 0.999 in

Diameter
25.407 mm MAX 1.000 in
Accessory Drive Spline Coupling Inside 25.255 mm MIN 0.994 in
Diameter
25.278 mm MAX 0.996 in
Accessory Drive Bushing Bore Inside 60.00 mm MIN 2.362 in
Diameter
60.05 mm MAX 2.364 in
Accessory Drive Shaft Outside Diameter

Measurements
(1) 34.964 MIN 1.376
34.976 MAX 1.377
(2) 43.928 MIN 1.729
43.940 MAX 1.730
(3) 44.370 MIN 1.747
44.630 MAX 1.757
(4) 45.070 MIN 1.774
45.082 MAX 1.775
(5) 49.820 MIN 1.961
49.832 MAX 1.962
(6) 25.424 MIN 1.001
25.436 MAX 1.001
QSK45 and QSK60 Drive Units — Group 09
Ref.No./
Steps
.
Accessory Drive Gear Inside Diameter 44.98 mm MIN 1.771 in

45.02 mm MAX 1.772 in
Accessory Drive Gear to Shaft Distance 0.05 mm MAX 0.002 in
Accessory Drive Shaft End Clearance 0.05 mm MIN 0.002 in

0.30 mm MAX 0.012 in
Accessory Drive End Clearance 0.13 mm MIN 0.005 in

0.29 mm MAX 0.011 in
Accessory Drive Pulley (009-004)

Accessory Drive Pulley Inside Diameter 34.912 mm MIN 1.375 in
34.938 mm MAX 1.376 in

Fuel Pump Shaft End Clearance 0.05 mm MIN 0.002 in
0.30 mm MAX 0.012 in
Fuel Pump Drive Bushing Inside Diameter 49.95 mm MIN 1.967 in

50.03 mm MAX 1.970 in
Drive Units — Group 09 QSK45 and QSK60
Ref.No./
Steps
.
Fuel Pump Drive Busing Thrust Face 45.370 mm MIN 1.786 in

Distance
45.450 mm MAX 1.789 in
Fuel Pump Drive Lovejoy Coupling Inside 25.377 mm MIN 0.999 in

Diameter
25.407 mm MAX 1.000 in
Fuel Pump Drive Spline Coupling Inside 25.255 mm MIN 0.994 in
Diameter
25.278 mm MAX 0.996 in
Fuel Pump Drive Bushing Bore Inside 60.00 mm MIN 2.362 in
Diameter
60.05 mm MAX 2.364 in
Fuel Pump Drive Shaft Outside Diameter

Measurements
(1) 34.964 MIN 1.376
34.976 MAX 1.377
(2) 43.928 MIN 1.729
43.940 MAX 1.730
(3) 44.370 MIN 1.747
44.630 MAX 1.757
(4) 45.070 MIN 1.774
45.082 MAX 1.775
(5) 49.820 MIN 1.961
49.832 MAX 1.962
(6) 25.424 MIN 1.001
25.436 MAX 1.001
Fuel Pump Drive Gear Inside Diameter 44.98 mm MIN 1.771 in
45.02 mm MAX 1.772 in
Fuel Pump Drive Gear to Shaft Distance 0.05 mm MAX 0.002 in
Fuel Pump Drive Shaft End Clearance 0.05 mm MIN 0.002 in

0.30 mm MAX 0.012 in
QSK45 and QSK60 Drive Units — Group 09
Ref.No./
Steps
.

Hydraulic Pump Drive End Clearance 0.125 mm MIN 0.005 in
0.285 mm MAX 0.011 in
Hydraulic Pump Drive End Clearance - 0.125 mm MIN 0.005 in

Installed
0.285 mm MAX 0.011 in

Water Pump Drive End Clearance - Installed 0.05 mm MIN 0.002 in
0.21 mm MAX 0.008 in
Water Pump Drive Bushing Diameter

Flanged Bushings 49.95 MIN 1.967
50.03 MAX 1.970
Standard Bushings 44.48 MIN 1.751
44.58 MAX 1.755
Water Pump Drive Thrust Bearing Face 45.370 mm MIN 1.786 in

Distance
45.450 mm MAX 1.789 in
Water Pump Drive Housing Bushing Bore 60.000 mm MIN 2.362 in

60.050 mm MAX 2.364 in
Ref.No./
Steps
.
Water Pump Drive Shaft Outside Diameter

(1) 35.084 MIN 1.381
35.096 MAX 1.382
(2) 43.928 MIN 1.729
43.940 MAX 1.730
(3) 44.370 MIN 1.747
44.630 MAX 1.757
(4) 45.070 MIN 1.774
45.082 MAX 1.775
(5) 49.820 MIN 1.961
49.832 MAX 1.962
(6) 39.994 MIN 1.574
40.006 MAX 1.575
Water Pump Drive Gear Inside Diameter 44.98 mm MIN 1.771 in
45.02 mm MAX 1.772 in
Water Pump Drive End Clearance - Installed 0.05 mm MIN 0.002 in

0.21 mm MAX 0.008 in
QSK45 and QSK60 Drive Units — Group 09 - Torque Values
Ref.No./
Steps
.
Drive Units — Group 09 - Torque Values

Accessory Drive Housing Pipe Plug 8 N•m [ 75 in-lb ]
Accessory Drive Coupling Capscrew 9.525 45 N•m [ 35 ft-lb ]

Mm [0.375 In] Capscrew Length 100 N•m [ 75 ft-lb ]
Accessory Drive Coupling Capscrew 12.7
Mm [0.50 In] Capscrew Length
Accessory Drive Mounting Capscrews 45 N•m [ 33 ft-lb ]

Fuel Pump Drive Housing Pipe Plug 8 N•m [ 75 in-lb ]
Fuel Pump Drive Coupling Capscrew 9.525 45 N•m [ 35 ft-lb ]

Mm [0.375 In] Capscrew Length 100 N•m [ 75 ft-lb ]
Fuel Pump Drive Coupling Capscrew 12.7
Mm [0.50 In] Capscrew Length


Water Pump Drive Mounting Capscrews 45 N•m [ 33 ft-lb ]
Ref.No./
Steps
.
Engine Barring Device (009-035)

Engine Barring Device Mounting Capscrew 9 N•m [ 80 in-lb ]
60 N•m [ 45 ft-lb ]
185 N•m [ 135 ft-lb ]
QSK45 and QSK60 Air Intake System - Group 10 - Specifications
Ref.No./
Steps
.
Air Intake System - Group 10 - Specifications

Air Intake Restriction (010-031)
Maximum Operating Air Restriction - Dirty Air 635 mm MAX 25 in H2O
Filter H2O
Turbocharger Shaft End Clearance
0.152 MAX 0.006
HX82 and HX83 Turbochargers 0.051 MIN 0.002
0.125 MAX 0.005
HX60 and HX82 Turbocharger Radial

Bearing Clearance
0.45 MAX 0.018
0.55 MAX 0.022
HX83 Turbocharger Radial Bearing
Clearance
0.70 MAX 0.028
0.77 MAX 0.031
Turbocharger Compressor Impeller Radial
Movement
0.584 MAX 0.023
HX82 and HX83 Turbochargers 0.485 MIN 0.019
0.786 MAX 0.031
Turbocharger Shaft Bend 0.025 mm MAX 0.001 in
Turbocharger Turbine Shaft Journals

Air Intake System - Group 10 QSK45 and QSK60
Ref.No./
Steps
.
Turbocharger Turbine Shaft Sealing Ring

Groove Width
Turbocharger Turbine Housing Flange 0.010 mm MIN 0.004 in

Flatness
HX60 Turbocharger Center Housing Journal 22.27 mm MAX 0.877 in

Bearing Bore
HX60 Turbocharger Center Housing Journal 1.25 mm MAX 0.049 in
Bearing Snap Ring Groove Width
Turbocharger Oil Seal Plate Retaining Ring 2.0 mm MAX 0.079 in

Groove Width
Turbocharger Oil Slinger Sealing Ring 1.70 mm MAX 0.067 in

Groove Width
QSK45 and QSK60 Air Intake System - Group 10 - Torque Values
Ref.No./
Steps
.
Air Intake System - Group 10 - Torque Values

Aftercooler Assembly (010-002)
Aftercooler Element Capscrews 45 N•m [ 33 ft-lb ]
Qsk45 Aftercooler Cover Capscrews 45 N•m [ 33 ft-lb ]
Aluminum Aftercooler Assembly Element 45 N•m [ 33 ft-lb ]

Cast Iron Aftercooler Assembly Element
Capscrews
Aluminum Aftercooler Assembly 45 N•m [ 33 ft-lb ]

Cast Iron Aftercooler Assembly 65 N•m [ 48 ft-lb ]
Qsk45 Aftercooler Mounting Capscrews 45 N•m [ 33 ft-lb ]
Aftercooler Housing Pressure And 15 N•m [ 133 in-lb ]

Temperature Sensors
Aftercooler Connection Tee Mounting 45 N•m [ 33 ft-lb ]

Intake Air Systems Hose Clamps
Ref.No./
Steps
.
10 N•m [ 89 in-lb ]
9 N•m [ 80 in-lb ]

Cast Iron Aftercooler Assembly 65 N•m [ 48 ft-lb ]
65 N•m [ 48 ft-lb ]
Cast Iron Aftercooler Assembly
Intake Manifold Temperature And Pressure 15 N•m [ 133 in-lb ]

Sensors
Air Crossover Mounting Capscrews 45 N•m [ 33 ft-lb ]
10 N•m [ 89 in-lb ]
9 N•m [ 80 in-lb ]
QSK45 and QSK60 Air Intake System - Group 10
Ref.No./
Steps
.
Aftercooler Element (010-008)

Aftercooler Cover Capscrews 45 N•m [ 33 ft-lb ]
10 N•m [ 89 in-lb ]
Aftercooler Tee Connection Capscrews 45 N•m [ 33 ft-lb ]
45 N•m [ 33 ft-lb ]
10 N•m [ 89 in-lb ]
10 N•m [ 89 in-lb ]
Air Cleaner Assembly (Engine-Mounted) (010-013)

Fuel Line Bracket Capscrews 44 N•m [ 33 ft-lb ]
Ref.No./
Steps
.
Cross Beam Capscrews 81 N•m [ 60 ft-lb ]
Support Frame Capscrews 190 N•m [ 140 ft-lb ]
Air Filter Box Support Runners Capscrews 44 N•m [ 33 ft-lb ]

102 N•m [ 75 ft-lb ]
Air Leaks, Air Intake and Exhaust Systems (010-024)

Intake Air System Capscrews 20 N•m [ 15 ft-lb ]
Turbocharger V-Band Clamps 8 N•m [ 71 in-lb ]

Ref.No./
Steps
.
Bellows Clamps 17 N•m [ 150 in-lb ]
Install Exhaust Manifold Leak Test Kit 20 N•m [ 15 ft-lb ]
Hx60 Turbocharger Compressor Impeller 41 N•m [ 30 ft-lb ]
Locknut
Hx60 Turbocharger Center Housing 9 N•m [ 80 in-lb ]

Rotating Assembly To Turbine Housing V-
Band Clamp
Hx60 Turbocharger Center Housing 9 N•m [ 80 in-lb ]

Rotating Assembly To Compressor Housing
V-Band Clamp
Hx82 Turbocharger Diffuser Plate 22 N•m [ 16 ft-lb ]

Capscrews
Ref.No./
Steps
.
Hx82 Turbocharger Compressor Impeller 38 N•m [ 28 ft-lb ]

Locknut
Hx82 Turbine Housing Capscrews 22 N•m [ 16 ft-lb ]
Hx82 Turbocharger Compressor V-Band 27 N•m [ 20 ft-lb ]

Clamp
Hx83 Turbocharger Turbine Capscrews 20 N•m [ 177 in-lb ]
Hx83 Turbocharger Compressor Housing 12 N•m [ 106 in-lb ]

V-Band Clamp
Turbocharger, High Pressure (010-034)

Turbocharger Mounting Capscrews 45 N•m [ 33 ft-lb ]
Turbocharger Bearing Housing Capscrews 21 N•m [ 186 in-lb ]

Ref.No./
Steps
.
Turbocharger Oil Drain Line Mounting 45 N•m [ 33 ft-lb ]

Capscrews
Turbocharger Oil Supply Line Connection 54 N•m [ 40 ft-lb ]
Coolant Supply And Return Line Fittings 54 N•m [ 40 ft-lb ]
V-Band Clamp 9 N•m [ 80 in-lb ]
Turbocharger Mounting Capscrews 45 N•m [ 33 ft-lb ]

Ref.No./
Steps
.
Bearing Housing Capscrews 21 N•m [ 186 in-lb ]

Capscrews
Turbocharger Oil Supply Line Fitting 54 N•m [ 40 ft-lb ]
Turbocharger Coolant Supply And Return 54 N•m [ 40 ft-lb ]

Line Fittings
Intercooler Air Crossover Mounting 45 N•m [ 33 ft-lb ]

Capscrews
Exhaust Outlet Mounting Base Capscrews 45 N•m [ 33 ft-lb ]

Ref.No./
Steps
.
Exhaust Outlet Support Brace Capscrews 80 N•m [ 59 ft-lb ]
Top Cross Support Brace Mounting 80 N•m [ 59 ft-lb ]

Intercooler Air Crossover Mounting 45 N•m [ 33 ft-lb ]

Capscrews
Turbocharger, Low Pressure (010-035)

Low Pressure Turbocharger Mounting 45 N•m [ 33 ft-lb ]
Capscrew
Low Pressure Turbocharger Exhuast 9 N•m [ 80 in-lb ]

Bellows V-Band Clamp
Ref.No./
Steps
.
Low Pressure Turbocharger Inlet Piping 8 N•m [ 71 in-lb ]

Clamp
Low Pressure Turbocharger Oil Drain Line 45 N•m [ 33 ft-lb ]

Mounting Capscrew
Low Pressure Turbocharger Oil Supply Line 54 N•m [ 40 ft-lb ]
Low Pressure Turbocharger Outlet Clamp 8 N•m [ 71 in-lb ]
Turbocharger Coolant Hoses (010-041)

Turbocharger Fittings 72 N•m [ 52 ft-lb ]
Water Manifold Elbow 72 N•m [ 52 ft-lb ]
Coolant Supply Hose 45 N•m [ 33 ft-lb ]
Male Unions 72 N•m [ 52 ft-lb ]

Coolant Supply Hose 45 N•m [ 33 ft-lb ]

Ref.No./
Steps
.
Water Transfer Connection Unions 100 N•m [ 74 ft-lb ]
Thermostat Housing Elbow And Union 100 N•m [ 74 ft-lb ]

Coolant Return Line 65 N•m [ 48 ft-lb ]
Water Transfer Union 72 N•m [ 52 ft-lb ]

Coolant Return Hose 45 N•m [ 33 ft-lb ]
Manifold Capscrews. 45 N•m [ 33 ft-lb ]
Thermostat Housing Elbow 100 N•m [ 74 ft-lb ]

T-Fitting 100 N•m [ 74 ft-lb ]
Large Unions 100 N•m [ 74 ft-lb ]
72 N•m [ 52 ft-lb ]
Drain Cock Union 45 N•m [ 33 ft-lb ]
Drain Cock Nut

Coolant Return Line Right Bank 65 N•m [ 48 ft-lb ]
Coolant Return Line Left Bank 65 N•m [ 48 ft-lb ]
45 N•m [ 33 ft-lb ]
Line Clips
Reducers 80 N•m [ 60 ft-lb ]

Turbocharger Drain Port Unions 72 N•m [ 52 ft-lb ]
45 N•m [ 33 ft-lb ]
P-Clip Capscrews 72 N•m [ 52 ft-lb ]
Supply Line Unions
Water Manifold Elbows 72 N•m [ 52 ft-lb ]

Coolant Supply Lines 45 N•m [ 33 ft-lb ]
Ref.No./
Steps
.
Turbocharger Oil Drain Line (010-045)

Mounting Capscrew

Capscrew

Mounting Capscrew

Capscrew
P-Clip Nut And Bolt 43 N•m [ 31 ft-lb ]
Turbocharger Oil Supply Line (010-046)

Brace Capscrews 80 N•m [ 60 ft-lb ]
Line Clamp Capscrews 45 N•m [ 33 ft-lb ]

Ref.No./
Steps
.
Turbocharger Male Unions 60 N•m [ 44 ft-lb ]

90 N•m [ 66 ft-lb ]
T-Fitting 45 N•m [ 33 ft-lb ]
Oil Supply Line Clip Capscrews 45 N•m [ 33 ft-lb ]
Oil Supply Tube Nut 45 N•m [ 33 ft-lb ]

45 N•m [ 33 ft-lb ]
Turbocharger Oil Supply Hose 45 N•m [ 33 ft-lb ]

45 N•m [ 33 ft-lb ]
Oil Supply Manifold 45 N•m [ 33 ft-lb ]
Oil Supply Manifold Unions 55 N•m [ 41 ft-lb ]
Elbow Union 80 N•m [ 60 ft-lb ]

Ref.No./
Steps
.
Oil Manifold Capscrews 45 N•m [ 33 ft-lb ]
Turbocharger Unions 45 N•m [ 33 ft-lb ]
Turbocharger Elbow Union 45 N•m [ 33 ft-lb ]
Flywheel Oil Supply Union 90 N•m [ 66 ft-lb ]

60 N•m [ 44 ft-lb ]
Oil Supply Line To Reducer 45 N•m [ 33 ft-lb ]
Oil Supply Line Clip Capscrews 45 N•m [ 33 ft-lb ]
Oil Supply Union 45 N•m [ 33 ft-lb ]
Oil Supply Hose Nuts 45 N•m [ 33 ft-lb ]

Ref.No./
Steps
.
Turbocharger Oil Supply Line Nuts 25 N•m [ 18 ft-lb ]
Oil Supply Hose P-Clip Capscrew 45 N•m [ 33 ft-lb ]

Ref.No./
Steps
.
Turbocharger Heat Shield (010-076)

Turbocharger Heat Shield Capscrews 23 N•m [ 204 in-lb ]
Rear Heat Shield Capscrews 44 N•m [ 33 ft-lb ]

Ref.No./
Steps
.
Front Heat Shield Capscrews 44 N•m [ 33 ft-lb ]
Turbocharger Heat Shield Capscrews 23 N•m [ 204 in-lb ]
Rear Heat Shield Bracket Capscrews 44 N•m [ 33 ft-lb ]
Front Heat Shield Bracket Capscrews 44 N•m [ 33 ft-lb ]
Frame, Two-Stage Turbocharger (010-082)

Two-Stage Frame Assembly Mounting 80 N•m [ 59 ft-lb ]
Capscrews
Two-Stage Frame Lifting Eye Capscrew 195 N•m [ 144 ft-lb ]
280 N•m [ 207 ft-lb ]

Ref.No./
Steps
.
45 N•m [ 33 ft-lb ]
54 N•m [ 40 ft-lb ]
45 N•m [ 33 ft-lb ]
9 N•m [ 80 in-lb ]
54 N•m [ 40 ft-lb ]
Turbocharger Oil Drain Line Capscrew 45 N•m [ 33 ft-lb ]
54 N•m [ 40 ft-lb ]
Turbocharger Oil Supply Line To Flywheel 54 N•m [ 40 ft-lb ]

Housing Fitting
Ref.No./
Steps
.
9 N•m [ 80 in-lb ]
Two-Stage Frame Assembly Support 45 N•m [ 33 ft-lb ]

Capscrews
9 N•m [ 80 in-lb ]
Two-Stage Frame Assembly Mounting 80 N•m [ 59 ft-lb ]

Capscrews
Intercooler Assembly (010-083)

Intercooler Element Capscrews 45 N•m [ 33 ft-lb ]
Intercooler Bracket Capscrews 45 N•m [ 33 ft-lb ]
Intercooler Cover Capscrews 45 N•m [ 33 ft-lb ]

Ref.No./
Steps
.
Intercooler Fitting Capscrews 45 N•m [ 33 ft-lb ]
Intercooler Petcock 8 N•m [ 71 in-lb ]
High Pressure Turbo V-Band Clamps 9 N•m [ 80 in-lb ]
Intercooler And Lifting Eye Mounting 280 N•m [ 207 ft-lb ]

Capscrews
Intercooler Mounting Capscrews 280 N•m [ 207 ft-lb ]
Intercooler Flange Capscrews 45 N•m [ 33 ft-lb ]
Lta Thermostat Housing Fitting 54 N•m [ 40 ft-lb ]
Intercooler Intake Crossover Mounting 45 N•m [ 33 ft-lb ]

Capscrews
Ref.No./
Steps
.
High Pressure Turbo V-Band Clamps 9 N•m [ 80 in-lb ]
Intercooler Element (010-084)

Intecooler Element Mounting Capscrews 45 N•m [ 33 ft-lb ]
Intercooler Cover Capscrews 45 N•m [ 33 ft-lb ]
Intercooler Fitting Mounting Capscrews 45 N•m [ 33 ft-lb ]
Intercooler Bracket Mounting Capscrews 45 N•m [ 33 ft-lb ]
Intercooler Petcock Vent 8 N•m [ 71 in-lb ]
Intercooler Air Connection Hose Clamps 9 N•m [ 80 in-lb ]

Ref.No./
Steps
.
Intercooler Inlet Mounting Capscrews 45 N•m [ 33 ft-lb ]
Turbocharger Inlet Connections (010-130)

Right Front Turbocharger Inlet Connection 23 N•m [ 204 in-lb ]

QSK45 and QSK60 Exhaust System — Group 11 - Specifications
Ref.No./
Steps
.
Exhaust System — Group 11 - Specifications

Exhaust Restriction (011-009)
Exhaust Restriction - QSK45 and QSK60 75 mm Hg MAX 3.0 in Hg
Single Stage and QSK60 Marine
Exhaust Restriction - QSK60 Two Stage 50 mm Hg MAX 2.0 in Hg
Exhaust System — Group 11 - Torque Values QSK45 and QSK60
Ref.No./
Steps
.
Exhaust System — Group 11 - Torque Values

Exhaust Connection Pipe (011-001)
Exhaust Connection To Rocker Lever 45 N•m [ 33 ft-lb ]
Housing 80 N•m [ 60 ft-lb ]
Exhaust Connection To Rocker Lever
Housing
Exhaust Connection To Bellows 195 N•m [ 140 ft-lb ]
Exhaust Connection To Frame 45 N•m [ 33 ft-lb ]
Exhaust Connection To Bellows 195 N•m [ 140 ft-lb ]
Exhaust Connection Pipe (Turbocharger to Turbocharger) (011-002)

Exhaust Connection Pipe To Frame 80 N•m [ 60 ft-lb ]
Exhaust Connection Pipe To Bellows 195 N•m [ 140 ft-lb ]
Exhaust Manifold, Dry (011-007)

Exhaust Manifold Capscrews 47 N•m [ 35 ft-lb ]
QSK45 and QSK60 Exhaust System — Group 11
Ref.No./
Steps
.
Exhaust Bellows Clamp 6 N•m [ 53 in-lb ]
Marine Application Bellows Clamp 17 N•m [ 150 in-lb ]

Exhaust System — Group 11 QSK45 and QSK60
Ref.No./
Steps
.
Marine Application Bellows Clamps 17 N•m [ 150 in-lb ]
Exhaust Manifold Heat Shield (011-015)

Number Four And Five Rocker Lever 45 N•m [ 33 ft-lb ]
Housing Exhaust Manifold Heat Shield
Capscrews
Exhaust Manifold S-Tube Capscrews 25 N•m [ 18 ft-lb ]
Rear Exhaust Manifold Heat Shield 45 N•m [ 33 ft-lb ]

Capscrews
Exhaust Manifold Heat Shield Front 45 N•m [ 33 ft-lb ]

Support Bracket Capscrews 45 N•m [ 33 ft-lb ]
QSK45 and QSK60 Exhaust System — Group 11
Ref.No./
Steps
.
45 N•m [ 33 ft-lb ]
Left And Right Rear Corner Plate 10 N•m [ 89 in-lb ]

Capscrews
Right And Left Bank Side Exhaust Manifold 45 N•m [ 33 ft-lb ]

Heat Shield Capscrews
Right And Left Bank Front Exhaust Manifold 45 N•m [ 33 ft-lb ]

Heat Shield Capscrews
Front Exhaust Manifold Heat Shield 23 N•m [ 17 ft-lb ]

Capscrews And Right Cornor Plate
Capscerews
Junction Blocking And Mounting Bracket 47 N•m [ 35 ft-lb ]

16 N•m [ 143 in-lb ]
16 N•m [ 143 in-lb ]
16 N•m [ 143 in-lb ]
Aftercooler Water Tube Capscrews 10 N•m [ 89 in-lb ]

Compressed Air System - Group 12 - Specifications QSK45 and QSK60
Ref.No./
Steps
.
Compressed Air System - Group 12 - Specifications

Single Cylinder Crankshaft End Clearance 0.05 mm MIN 0.002 in
0.69 mm MAX 0.027 in
Twin Cylinder Crankshaft End Clearance 0.038 mm MIN 0.001 in

0.200 mm MAX 0.008 in
QSK45 and QSK60 Compressed Air System - Group 12 - Torque Values
Ref.No./
Steps
.
Compressed Air System - Group 12 - Torque Values

Air Compressor Unloader and Valve Assembly (012-013)
Holset Ss, E-Type, And St Unloader 14 N•m [ 120 in-lb ]
Capscrews
Holset Qe Unloader Capscrew 27 N•m [ 20 ft-lb ]

Air Compressor To Accessory Drive 60 N•m [ 44 ft-lb ]
45 N•m [ 33 ft-lb ]
6 N•m [ 53 in-lb ]
60 N•m [ 44 ft-lb ]
45 N•m [ 33 ft-lb ]
Twin Cylinder Air Compressor Support To 45 N•m [ 33 ft-lb ]

Air Compressor Capscrews

Compressed Air System - Group 12 QSK45 and QSK60
Ref.No./
Steps
.
Air Compressor Inlet And Outlet Hose 6 N•m [ 53 in-lb ]

Clamps
QSK45 and QSK60 Electrical Equipment — Group 13 - Specifications
Ref.No./
Steps
.
Electrical Equipment — Group 13 - Specifications

Belt Tensioner, Automatic (Alternator) (013-021)
Spring Tensioner Clearance 3 mm MAX 0.12 in
Electrical Equipment — Group 13 - Torque Values QSK45 and QSK60
Ref.No./
Steps
.
Electrical Equipment — Group 13 - Torque Values

Alternator (013-001)
Alternator Pulley Nut 95 N•m [ 70 ft-lb ]
Jam Nut 80 N•m [ 59 ft-lb ]

115 N•m [ 85 ft-lb ]
Drive Belt, Alternator (013-005)

Belt Tensioner Jam Nut And Alternator 80 N•m [ 59 ft-lb ]
Mounting Capscrews Jam Nuts 115 N•m [ 85 ft-lb ]
Belt Tensioner Jam Nut And Alternator
Mounting Capscrews Alternator Mounting
Capscrews
Belt Tensioning Jam Nuts And Alternator 80 N•m [ 59 ft-lb ]

Mounting Capscrews Jam Nuts 115 N•m [ 85 ft-lb ]
Belt Tensioning Jam Nuts And Alternator
Mounting Capscrews Alternator Mounting
Capscrews
Starting Motor (013-020)

Starting Motor Mounting Capscrews With 215 N•m [ 159 ft-lb ]
Cast-Iron Flywheel Housing
Belt Tensioner, Automatic (Alternator) (013-021)

Alternator Automatic Belt Tensioner 9.8 45 N•m [ 33 ft-lb ]
Capscrew 65 N•m [ 48 ft-lb ]
Alternator Automatic Belt Tensioner 10.9
Capscrew
65 N•m [ 48 ft-lb ]
QSK45 and QSK60 Engine Testing — Group 14 - Specifications
Ref.No./
Steps
.
Engine Testing — Group 14 - Specifications

Engine Testing (Chassis Dynamometer) (014-002)
Engine Blowby 10-mm [0.406-in] Orifice
rpm = All ratings
New/Rebuilt Engine 127 MAX 5
Used Engine 330 MAX 13

Low Idle (Minimum Allowable) 138 MAX 20
At 1200 rpm (Minimum Allowable) 207 MAX 30
Engine Testing (Engine Dynamometer) (014-005)

QSK45 and QSK60 Blowby Limits for All
HP and RPM Rating
New and Rebuilt Engines 127 MAX 5
Used Engines 330 MAX 13

Low Idle 138 MIN 20
Rated rpm 413 MIN 60
Coolant Pressure 241 kPa MAX 35 psi
Engine Run-in (Engine Dynamometer) (014-006)

Main Oil Rifle Pressure (at Low Idle) 138483 MAX 2070
kPa kPa psipsi
Engine Testing — Group 14 - Torque Values QSK45 and QSK60
Ref.No./
Steps
.
Engine Testing — Group 14 - Torque Values

Engine Run-in (Without Dynamometer) (014-004)
60 N•m [ 44 ft-lb ]
48 N•m [ 35 ft-lb ]
Engine Testing (Engine Dynamometer) (014-005)

60 N•m [ 44 ft-lb ]
48 N•m [ 35 ft-lb ]
Engine Compression (014-012)

Injector Hold Down 54 N•m [ 40 ft-lb ]
QSK45 and QSK60 Mounting Adaptations — Group 16 - Specifications
Ref.No./
Steps
.
Mounting Adaptations — Group 16 - Specifications

Engine Support Bracket, Front (016-002)
Front Support Bore
Previous Engine Support Bracket 279.45 MIN 11.00
279.95 MAX 11.02
New Engine Support Bracket 294.00 MIN 11.57
294.07 MAX 11.58
Flywheel (016-005)
Flywheel Housing Number 0 648 mm 25.5 in
Flywheel Face Total Indicator Runout

Number 0 (with a 254-mm [10-in] center 0.254 MAX 0.010
distance)
Number 00 (with a 305-mm [12-in] center 0.305 MAX 0.012
distance)

Number 0 0.25 MAX 0.010
Number 00 0.30 MAX 0.012

Number 0 0.25 MAX 0.010
Number 00 0.30 MAX 0.012

Number 0 0.25 MAX 0.010
Number 00 0.30 MAX 0.012

Number 0 0.25 MAX 0.010
Number 00 0.30 MAX 0.012
Mounting Adaptations — Group 16 - Torque Values QSK45 and QSK60
Ref.No./
Steps
.
Mounting Adaptations — Group 16 - Torque Values

Engine Support Bracket, Front (016-002)
Front Engine Support Bracket Mounting 205 N•m [ 151 ft-lb ]
Capscrews
Flywheel (016-005)
Flywheel Mounting Capscrews 1 200 N•m [ 148 ft-lb ]
2 380 N•m [ 280 ft-lb ]
3 685 N•m [ 505 ft-lb ]

Flywheel Housing Capscrews 1 95 N•m [ 70 ft-lb ]
2 195 N•m [ 144 ft-lb ]
Oil Pressure Regulator Plug 60 N•m [ 44 ft-lb ]
Flywheel Gasket Capscrews 9 N•m [ 80 in-lb ]
Flywheel Housing Mounting Capscrews 1 95 N•m [ 70 ft-lb ]

2 195 N•m [ 144 ft-lb ]
QSK45 and QSK60 General Engine
General Engine
General Specifications
Listed below are general specifications for the engine. See each system section for additional specifications.
No injector adjustments are required for engines with electronic injectors.
QSK45 Engines
Horsepower........................................................................................................................See the engine dataplate
Engine Speed...........................................................................See the fuel system calibration data for speed rating
Aspiration..................................................................................................................Turbocharged and Aftercooled
Bore and Stroke................................................................................................159 mm [6.25 in] x 190 mm [7.48 in]
Compression Ratio:
Industrial..............................................................................................................................Application-Dependent
Two-Pump and Two-Loop Cooling System:
at 1800 rpm...................................................................................................................................................14.5:1
at 1900 rpm...................................................................................................................................................16.5:1
Power-Generation.................................................................................................................Application-dependent
Jacket Water Aftercooled, Two-Pump and Two-Loop Cooling System, TA Luft:
at 1800 rpm/60 Hz.........................................................................................................................................14.5:1
at 1900 rpm/50 Hz.........................................................................................................................................16.2:1
Displacement...........................................................................................................................45 liters [2746 C.I.D.]
Firing Order..................................................................................................1R-6L-5R-2L-3R-4L-6R-1L-2R-5L-4R-3L
Type....................................................................................................................4 cycle, 60-degree vee, 12 cylinder
Engine Weight (estimates only):
Wet...........................................................................................................................................6123 kg [13.499 lb]
Dry............................................................................................................................................5813 kg [12,815 lb]
Crankshaft Rotation (viewed from the front of the engine)........................................................................ Clockwise
Valve and Injector Settings:
Intake Valve Adjustment.............................................................................................................0.36 mm [0.014 in]
Intake Valve Limits............................................................................................0.28 to 0.43 mm [0.011 to 0.017 in]
Exhaust Valve Adjustment..........................................................................................................0.81 mm [0.032 in]
Exhaust Valve Limits.........................................................................................0.74 to 0.89 mm [0.029 to 0.035 in]
Injector Outer Base Circle Method Adjustment (in engine)...........................................................19 N•m [168 in-lb]
Cylinder Numbering Sequence: RB = Right-bank of cylinders and LB = Left-bank of cylinders.
The intake and exhaust valve locations as shown in the illustration.

General Engine QSK45 and QSK60
QSK60 Engines
Horsepower........................................................................................................................See the engine dataplate
Engine Speed...........................................................................See the fuel system calibration data for speed rating
Aspiration:
Single-Stage.............................................................................................................Turbocharged and aftercooled
Two-Stage............................................................................................Turbocharged, aftercooled, and intercooled
Bore and Stroke................................................................................................159 mm [6.25 in] x 190 mm [7.48 in]
Compression Ratio with mechanically actuated injectors:
Marine...........................................................................................................................................................14.5:1
Industrial..............................................................................................................................Application-Dependent
Two-Pump and Two-Loop Cooling System:
at 1800 rpm...................................................................................................................................................14.5:1
at 1900 rpm...................................................................................................................................................16.5:1
Power-Generation.................................................................................................................Application-dependent
Jacket Water Aftercooled, Two-Pump and Two-Loop Cooling System, TA Luft:
at 1800 rpm/60 Hz.........................................................................................................................................14.5:1
at 1900 rpm/50 Hz.........................................................................................................................................16.2:1
Compression Ratio with electronically actuated injectors:
All Applications..............................................................................................................................................14.5:1
Displacement...........................................................................................................................60 liters [3660 C.I.D.]
Firing Order..............................................................................1R-1L-3R-3L-2R-2L-5R-4L-8R-8L-6R-6L-7R-7L-4R-5L
Type....................................................................................................................4 cycle, 60-degree vee, 16 cylinder
Industrial and Power-Generation Single-Stage Engine Weight with mechanically actuated injectors (estimates only):
Wet...........................................................................................................................................7956 kg [17,540 lb]
Dry............................................................................................................................................7535 kg [16,612 lb]
Industrial and Power-Generation Single-Stage Engine Weight with electronically actuated injectors (estimates only):
Wet...........................................................................................................................................8570 kg [18,893 lb]
Dry............................................................................................................................................6759 kg [14,900 lb]
Industrial and Power-Generation Two-Stage Engine Weight with mechanically actuated injectors (estimates only):
Wet...........................................................................................................................................9305 kg [20,514 lb]
Dry............................................................................................................................................8852 kg [15,515 lb]
Industrial and Power-Generation Two-Stage Engine Weight with electronically actuated injectors (estimates only):
Wet...........................................................................................................................................9616 kg [21,207 lb]
Dry............................................................................................................................................7790 kg [17,175 lb]
Marine Engine Weight with mechanically actuated injectors (estimates only):
Engine only (estimate)*
Wet...........................................................................................................................................8671 kg [19,117 lb]
Dry............................................................................................................................................8448 kg [18,625 lb]
Marine Engine with heat exchanger and expansion tank with mechanically actuated injectors (estimate)*
Wet...........................................................................................................................................8980 kg [19,797 lb]
Dry............................................................................................................................................8675 kg [19,125 lb]
Marine Engine Dimensions *
Height
Engine only ...............................................................................................................................2420 mm [95.3 in]
Engine with heat exchanger and expansion tank.........................................................................2420 mm [95.3 in]
Width
Engine only ...............................................................................................................................1730 mm [68.1 in]
Engine with heat exchanger and expansion tank.........................................................................1730 mm [68.1 in]
Length
Engine only .............................................................................................................................3357 mm [132.2 in]
Engine with heat exchanger and expansion tank.......................................................................3602 mm [141.8 in]
Marine Ratings
Continuous
2000 hp....................................................................................................................................................1800 rpm
2200 hp....................................................................................................................................................1800 rpm
Heavy Duty
2300 hp....................................................................................................................................................1900 rpm
2500 hp....................................................................................................................................................1900 rpm
Prime power
At 50 Hz.................................................................................................................................1563 kW at 1500 rpm
At 60 Hz.................................................................................................................................1900 kW at 1800 rpm
Crankshaft Rotation (viewed from the front of the engine)........................................................................ Clockwise
Valve and Injector Settings:
QSK45 and QSK60 General Engine
Intake Valve Adjustment.............................................................................................................0.36 mm [0.014 in]

Intake Valve Limits............................................................................................0.28 to 0.43 mm [0.011 to 0.017 in]
Exhaust Valve Adjustment..........................................................................................................0.81 mm [0.032 in]
Exhaust Valve Limits.........................................................................................0.74 to 0.89 mm [0.029 to 0.035 in]
Injector Outer Base Circle Method Adjustment (in engine)(No adjustment required for engines with electronically
actuated injectors)........................................................................................................................19 N•m [168 in-lb]
* QSK60M-specific
Cylinder Numbering Sequence: RB = Right-bank of cylinders and LB = Left-bank of cylinders.
The intake and exhaust valve locations as shown in the illustration.

Fuel System QSK45 and QSK60
Fuel System
Specifications
For performance and fuel rate values, refer to the engine data sheet or the fuel pump code for the specific rating
involved.
Engine Idle Speed................................................................................................................See Engine Data Sheet
Fuel Inlet Maximum Restriction:
Clean Fuel Filter..................................................................................................................102 mm Hg [4.0 in Hg]
Dirty Fuel Filter....................................................................................................................229 mm Hg [9.0 in Hg]
Fuel Drain Line Restriction:
With Check Valves...............................................................................................................127 mm Hg [5.0 in Hg]
With Check Valves Removed.............................................................................................254 mm Hg [10.0 in Hg]
Water Removal:
Free.......................................................................................................................................................95 percent
Emulsified..............................................................................................................................................95 percent
Engine Minimum Cranking Speed................................................................................................................150 rpm
For performance and fuel rate values, refer to the engine data sheet or the fuel pump code for the specific rating
involved.
Engine Idle Speed...............................................................................................................................700 ± 25 rpm
Maximum Fuel Inlet Restriction (at rated power):
Clean Fuel Filter..................................................................................................................100 mm Hg [4.0 in Hg]
Dirty Fuel Filter....................................................................................................................203 mm Hg [8.0 in Hg]
Maximum Fuel Drain Line Restriction (Industrial and Power-Generation only):
Before Check Valves.............................................................................................................254 mm Hg [10 in Hg]
After Check Valves...............................................................................................................228 mm Hg [9.0 in Hg]
Maximum Fuel Drain Line Restriction (Marine only):
Before Check Valves.............................................................................................................304 mm Hg [12 in Hg]
After Check Valves and Before Fuel Cooler...........................................................................279 mm Hg [11 in Hg]
Fuel Check Valve Between Fuel Pump and Electronic Fuel Control Valve Assembly (integral to fuel pump):
Opening Pressure...............................................................................................................14 to 21 kPa [2 to 3 psi]
Engine Minimum Cranking Speed................................................................................................................175 rpm
Fuel Check Valve in Fuel Drain Line:
Opening Pressure........................................................................................13 to 25 mm Hg [0.512 to 0.984 in Hg]
Derate Engine Fuel Rate for High Altitude..........................Refer to the engine performance curves and data sheets
Shutoff Valve Solenoid Coil Resistance in Ohms at 24VDC.................................................................28 to 32 ohms
Fuel Pump Cranking Pressure........................................................................................241 kPa [35 psi] at 175 rpm
Fuel Pump Pressure:
1500 rpm (50 Hz)........................................................................................................................1572 kPa [228 psi]
1800 rpm (60 Hz)........................................................................................................................1820 kPa [264 psi]
1900 rpm....................................................................................................................................1896 kPa [275 psi]
2070 rpm....................................................................................................................................1896 kPa [275 psi]
2470 rpm....................................................................................................................................1896 kPa [275 psi]
Fuel Filter Specifications:
Efficiency:
at 10 microns.......................................................................................................................................98.7 percent
at 8 microns...........................................................................................................................................96 percent
at 5 microns...........................................................................................................................................86 percent
Water Removal:
Free.......................................................................................................................................................95 percent
Emulsified..............................................................................................................................................95 percent
QSK45 and QSK60 Lubricating Oil System
Lubricating Oil System

Specifications
Lubricating Oil Pressure, Main Oil Rifle (15W-40 oil at 107°C [225°F]):
Minimum at rated rpm....................................................................................................................310 kPa [45 psi]
Maximum at rated rpm...................................................................................................................483 kPa [70 psi]
Minimum at idle rpm......................................................................................................................138 kPa [20 psi]
Lubricating Oil Pressure Spike on Cold Engine.............................................................................1724 kPa [250 psi]
Lubricating Oil Temperature - Maximum.............................................................................................120°C [248°F]
Lubricating Oil Pan Sump Capacity...........................................................................................................See below
Eliminator Oil Capacity - Engine Operation:
QSK45..........................................................................................................................................18 liters [4.8 gal]
QSK60..........................................................................................................................................20 liters [5.2 gal]
Fleetguard® Centrifuge - Engine Operation:
Centrifuge capacity.........................................................................................................................1 liter [0.26 gal]
Lubricating Oil Filter Capacity (each filter)(model LF9024):
Combination Filter (three required on QSK45, four required on QSK60)....................................2.65 liters [0.70 gal]
Sump Configuration System Capacity

QSK45 Engine
No Sump 132.5 liters [35 gal]
Middle Sump 174.1 liters [46 gal]
Rear Sump 174.1 liters [46 gal]
Front and Middle Sump 215.7 liters [57 gal]
Middle and Rear Sump 215.7 liters [57 gal]
Full Length Sump 284 liters [75 gal]
QSK60 Engine
No Sump 176 liters [46.5 gal]
Middle Front Sump 174.1 liters [46 gal]
Middle Rear Sump 174.1 liters [46 gal]
Front and Middle Front Sump 261.18 liters [69 gal]
Middle Front and Middle Rear Sump 261.18 liters [69 gal]
Middle Rear and Rear Sump 261.18 liters [69 gal]
Full Length Sump 378.5 liters [100 gal]
Cooling System
Specifications
QSK45 Engines
Coolant Capacity (engine only).......................................................................................................105 liters [28 gal]
Standard Modulating Thermostat Range...........................................................................85 to 97°C [185 to 207°F]
Standard LTA Thermostat Range......................................................................................46 to 57°C [115 to 135°F]
Maximum Allowable Top Tank Temperature (Industrial and Non-Prime Power-Generation only).........100°C [212°F]
Maximum Allowable Top Tank Temperature (Prime Power-Generation only)......................................104°C [220°F]
Minimum Recommended Top Tank Temperature.................................................................................71°C [160°F]
Maximum Allowable Deaeration Time.......................................................................................................25 minutes
Minimum Allowable Drawdown or 20 Percent of System Capacity (whichever is greater).....................26 liters [7 gal]
Minimum Allowable Pressure Cap......................................................................................................76 kPa [11 psi]
QSK60 Engines
Coolant Capacity (Industrial and Power-Generation only):
Single-Stage.................................................................................................................................140 liters [37 gal]
Two-Stage....................................................................................................................................170 liters [45 gal]
Coolant Capacity (Marine only):
Engine only .................................................................................................................................233 liters [62 gal]
Engine with heat exchanger and expansion tank..........................................................................318 liters [84 gal]
Standard Modulating Thermostat Range (with Mechanically Actuated Injectors)................85 to 97°C [185 to 207°F]
Standard Modulating Thermostat Range (with Electronically Actuated Injectors)................82 to 94°C [180 to 202°F]
Standard LTA Thermostat Range......................................................................................46 to 57°C [115 to 135°F]
Maximum Allowable Top Tank Temperature (Industrial, Marine, and Non-Prime Power-Generation only)....100°C
[212°F]
Maximum Allowable Top Tank Temperature (Prime Power-Generation only)......................................104°C [220°F]
Minimum Recommended Top Tank Temperature.................................................................................71°C [160°F]
Maximum Allowable Deaeration Time.......................................................................................................25 minutes
Minimum Allowable Drawdown or 20 Percent of System Capacity (whichever is greater)..................28 liters [7.4 gal]
Allowable Pressure Cap Relief Range at Sea Level.........................................................76 to 103 kPa [11 to 15 psi]
Maximum Seawater Pump Outlet Pressure......................................................................................206 kPa [30 psi]
Maximum Seawater Pressure Drop Across Heat Exchanger.............................................................138 kPa [20 psi]
Maximum Seawater Pump Inlet Restriction...............................................................................255 mm Hg [8 in Hg]
Maximum Seawater Outlet Temperature...............................................................................................54°C [130°F]
Maximum Seawater Temperature Rise Across Heat Exchanger..............................................................22°C [40°F]
Minimum Seawater Temperature Rise Across Heat Exchanger..................................................................3°C [5°F]
QSK45 and QSK60 Air Intake System
Air Intake System

Specifications
Maximum Allowable Intake Restriction:
With Clean Filter Element...................................................................................................380 mm H20 [15 in H20]
With Dirty Filter Element....................................................................................................635 mm H20 [25 in H20]
Exhaust System QSK45 and QSK60
Exhaust System
Specifications
Maximum Back Pressure (at rated speed and load):
QSK45 (1500 hp and less)........................................................................................................75 mm Hg [3 in Hg]
QSK45 (greater than 1500 hp)...................................................................................................51 mm Hg [2 in Hg]
QSK60 Single-Stage (up to an including 2000 hp).....................................................................75 mm Hg [3 in Hg]
QSK60 Single-Stage (greater than 2000 hp)..............................................................................50 mm Hg [2 in Hg]
QSK Two-Stage (greater than 2000 hp).....................................................................................50 mm Hg [2 in Hg]
Exhaust Pipe Size (normally acceptable inside diameter):
QSK45.........................................................................................................................................139.5 mm [5.5 in]
QSK60, Single-Stage.........................................................................................................................230 mm [9 in]
QSK60, Two-Stage...........................................................................................................................254 mm [10 in]
QSK45 and QSK60 Electrical System
Electrical System
Specifications
Minimum recommended battery capacity:
Maximum
Temperature Cold Cranking Reserve Allowable
Engine Model System Voltage
Range Amperes Capacity Starting Circuit
Resistance
QSK45 24 -18 to 0°C [0 to 1800 640 A 0.0020 ohms
32°F]
QSK60 24 Above 0°C [32°F] 1800 640 A 0.0020 ohms
QSK60 Two- 24 All 1800 640 A 0.0020 ohms
Stage
Battery Cable Sizes - American Wire Gauge (maximum length in cranking motor circuit):
24 to 32 VDC
Number 00...........................................................................................................................................6.1 m [20 ft]
Number 000.........................................................................................................................................8.2 m [27 ft]
Number 0000 or two Number 0 (see note).............................................................................................6.1 m [20 ft]
Two Number 00..................................................................................................................................13.7 m [45 ft]
NOTE: Two strands of number 0 cable can be used instead of on number 0000 cable, provided all connections are
carefully made to maintain equal current flow in each parallel cable.
Minimum Cranking Speed Without Starting Aid............................................................................................150 rpm
Starting aids, such as block heaters, lubricating oil pan heaters, and so forth, are available to aid in cold weather
starting.
The number of plates within a given battery size determines reserve capacity. Reserve capacity is the length of time
sustained cranking can occur.
CCA ratings are based on two 12 VDC batteries in series.
Batteries (Specific Gravity)
Battery State of Charge Specific Gravity (at 27°C [80°F])
100 % 1.260 to 1.280
75% 1.230 to 1.250
50% 1.200 to 1.220
25% 1.170 to 1.190
DISCHARGED 1.110 to 1.130
Compressed Air System QSK45 and QSK60
Compressed Air System

Specifications
The following specifications are for a upright two-cylinder air compressor (Holset® ST676 Air Compressor Model)
Cylinders................................................................................................................................................................2
Compressor Capacity (at 1250 rpm).........................................................................14.2 liter [30.00 cfm] per second
Piston Displacement...................................................................................................................676 cc [41.3 C.I.D.]
Bore...........................................................................................................................................92.08 mm [3.625 in]
Stroke.................................................................................................................................................50.8 mm [2 in]
Speed..................................................................................................................................................Engine speed
Cooling..............................................................................................................................................Engine coolant
Lubrication...............................................................................................................................Engine lubricating oil
Plumbing Line Sizes:
Coolant Inlet and Outlet (pipe fitting).........................................................................12.7 mm NPTF [0.50 in NPTF]
Air Inlet (inside diameter)..........................................................................................................22.22 mm [0.875 in]
Air Outlet (minimum inside diameter)........................................................................................15.88 mm [0.625 in]
Height, Overall (approximate)..........................................................................................................34.3 cm [13.5 in]
Width, Overall (approximate)................................................................................................................17.8 cm [7 in]
Length, Overall (approximate).......................................................................................................28.7 cm [11.30 in]
Weight (approximate).......................................................................................................................33.5 kg [74.5 lb]
NOTE: In applications where duty cycles average 10 percent or more or air pressures are above 862 kPa [125 psi],
use a discharge line with a minimum inside diameter of 15.9 mm [0.625 in] for single-cylinder compressors and 25.4
mm [1 in] for twin-cylinder compressors to prevent carbon buildup. Examples of these applications are as follows:
• Refuse trucks
• Pickup and delivery trucks
• Transit buses
• Equipment with high accessory air usage.
The following specifications are for a upright single-cylinder air compressor (Holset® HD850 Air Compressor Models)
Cylinders................................................................................................................................................................1
Compressor Capacity (at 1250 rpm)..........................................................................7.1 liter [15.00 cfm] per second
Piston Displacement..................................................................................................................338 cc [20.63 C.I.D.]
Bore.............................................................................................................................................98.4 mm [3.875 in]
Stroke............................................................................................................................................44.5 mm [1.75 in]
Speed..................................................................................................................................................Engine speed
Cooling..............................................................................................................................................Engine coolant
Lubrication...............................................................................................................................Engine lubricating oil
Plumbing Line Sizes:
Coolant Inlet and Outlet (pipe fitting).......................................................................9.53 mm NPTF [0.375 in NPTF]
Air Inlet (inside diameter)..........................................................................................................22.22 mm [0.875 in]
Air Outlet (minimum inside diameter)........................................................................................15.88 mm [0.625 in]
Height, Overall (approximate)........................................................................................................31.1 cm [12.25 in]
Width, Overall (approximate)...........................................................................................................14.6 cm [5.75 in]
Length, Overall (approximate)..............................................................................................................22.9 cm [9 in]
Weight (approximate).............................................................................................................................18 kg [40 lb]
QSK45 and QSK60 Drive Belt Tension
Drive Belt Tension

Tension Chart
SAE Belt Size Belt Tension Gauge Part No. Belt Tension New Belt Tension Range Used*
Click-type Burroughs N lbf N lbf
0.380 in 3822524 620 140 270 to 490 60 to 110
0.440 in 3822524 620 140 270 to 490 60 to 110
1/2 in 3822524 ST-1138 620 140 270 to 490 60 to 110
11/16 in 3822524 ST-1138 620 140 270 to 490 60 to 110
3/4 in 3822524 ST-1138 620 140 270 to 490 60 to 110
7/8 in 3822524 ST-1138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 110
5 rib 3822524 ST-1138 670 150 270 to 530 60 to 120
6 rib 3822525 ST-1293 710 160 290 to 580 65 to 130
8 rib 3822525 ST-1293 890 200 360 to 710 80 to 160
10 rib 3822525 3823138 1110 250 440 to 890 100 to 200
12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240
12 rib K section 3822525 3823138 1330 300 890 to 1070 200 to 240
NOTE: This chart does not apply to automatic belt tensioners.

* A belt is considered used if it has been in service for ten minutes or longer.
* If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
Capscrew Markings and Torque Values QSK45 and QSK60
Capscrew Markings and Torque Values

General Information
CAUTION
When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew
being replaced. Using the wrong capscrews can result in engine damage.
Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface
of the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew.
The following examples indicate how capscrews are identified:
NOTES:
1. Always use the torque values listed in the following tables when specific torque values are not available.
2. Do not use the torque values in place of those specified in other sections of this manual.
3. The torque values in the table are based on the use of lubricated threads.
4. When the ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torque
wrench. Example: 6 ft-lb equals 72 in-lb.
Capscrew Markings and Torque Values - Metric
Body Size Torque Torque Torque

Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
mm N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb
6 9 5 7 4 13 10 7 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
8 23 17 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 65 50 30 25 70 50 30 25
12 80 60 55 40 115 85 55 40 125 95 55 40
14 125 90 90 65 180 133 90 65 195 145 90 65
16 195 140 140 100 280 200 140 100 290 210 140 100
18 280 200 180 135 390 285 180 135 400 290 180 135
20 400 290 — — 550 400 — — — — — —
Capscrew Markings and Torque Values - U.S. Customary

QSK45 and QSK60 Capscrew Markings and Torque Values
Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum

N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb
1/4 - 20 9 7 8 6 15 11 8 6
1/4 - 28 12 9 9 7 18 13 9 7
5/16 - 18 20 15 16 12 30 22 16 12
5/16 - 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
3/8 - 24 40 30 35 25 60 45 35 25
7/16 - 14 60 45 45 35 90 65 45 35
7/16 - 20 65 50 55 40 95 70 55 40
1/2 - 13 95 70 75 55 130 95 75 55
1/2 - 20 100 75 80 60 150 110 80 60
9/16 - 12 135 100 110 80 190 140 110 80
9/16 - 18 150 110 115 85 210 155 115 85
5/8 - 11 180 135 150 110 255 190 150 110
5/8 - 18 210 155 160 120 290 215 160 120
3/4 - 10 325 240 255 190 460 340 255 190
3/4 - 16 365 270 285 210 515 380 285 210
7/8 - 9 490 360 380 280 745 550 380 280
7/8 - 14 530 390 420 310 825 610 420 310
1-8 720 530 570 420 1100 820 570 420
1 - 14 800 590 650 480 1200 890 650 480
Fraction, Decimal, Millimeter Conversions QSK45 and QSK60
Fraction, Decimal, Millimeter Conversions

Conversion Chart
Fraction inch mm Fraction inch mm
1/64 0.0156 0.397 33/64 0.5156 13.097
1/32 0.0313 0.794 17/32 0.5313 13.494
3/64 0.0469 1.191 35/64 0.5469 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.0781 1.984 37/64 0.5781 14.684
3/32 0.0938 2.381 19/32 0.5938 15.081
7/64 0.1094 2.778 39/64 0.6094 15.478
1/8 0.1250 3.175 5/8 0.6250 15.875
9/64 0.1406 3.572 41/64 0.6406 16.272
5/32 0.1563 3.969 21/32 0.6563 16.669
11/64 0.1719 4.366 43/64 0.6719 17.066
3/16 0.1875 4.763 11/16 0.6875 17.463
13/64 0.2031 5.159 45/64 0.7031 17.859
7/32 0.2188 5.556 23/32 0.7188 18.256
15/64 0.2344 5.953 47/64 0.7344 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17/64 0.2656 6.747 49/64 0.7656 19.447
9/32 0.2813 7.144 25/32 0.7813 19.844
19/64 0.2969 7.541 51/64 0.7969 20.241
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.3281 8.334 53/64 0.8281 21.034
11/32 0.3438 8.731 27/32 0.8438 21.431
23/64 0.3594 9.128 55/64 0.8594 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.3906 9.922 57/64 0.8906 22.622
13/32 0.4063 10.319 29/32 0.9063 23.019
27/64 0.4219 10.716 59/64 0.9219 23.416
7/16 0.4375 11.113 15/16 0.9375 23.813
29/64 0.4531 11.509 61/64 0.9531 24.209
15/32 0.4688 11.906 31/32 0.9688 24.606
31/64 0.4844 12.303 63/64 0.9844 25.003
1/2 0.5000 12.700 1 1.0000 25.400
Conversion Factor: 1 inch = 25.4 mm

QSK45 and QSK60 Newton-Meter to Foot-Pound Conversions
Newton-Meter to Foot-Pound Conversions

Conversion Chart
N•m ft-lb N•m ft-lb N•m ft-lb
1 9 in-lb 55 41 155 114
5 44 in-lb 60 44 160 118
6 53 in-lb 65 48 165 122
7 62 in-lb 70 52 170 125
8 71 in-lb 75 55 175 129
9 80 in-lb 80 59 180 133
10 89 in-lb 85 63 185 136
11 97 in-lb 90 66 190 140
12 106 in-lb 95 70 195 144
14 124 in-lb 100 74 200 148
15 133 in-lb 105 77 205 151
16 142 in-lb 110 81 210 155
18 159 in-lb 115 85 215 159
20 15 ft-lb 120 89 220 162
25 18 125 92 225 165
30 22 130 96 230 170
35 26 135 100 235 173
40 30 140 103 240 177
45 33 145 107 245 180
50 37 150 111 250 184
NOTE: To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803.
Pipe Plug Torque Values QSK45 and QSK60
Pipe Plug Torque Values

Torque Table
Size Torque Torque
Thread Actual Thread O.D. In Aluminum Components In Cast Iron or
Steel Components
in in N•m ft-lb N•m ft-lb
1/16 0.32 5 45 in-lb 15 10
1/8 0.41 15 10 20 15
1/4 0.54 20 15 25 20
3/8 0.68 25 20 35 25
1/2 0.85 35 25 55 40
3/4 1.05 45 35 75 55
1 1.32 60 45 95 70
1-1/4 1.66 75 55 115 85
1-1/2 1.90 85 65 135 100
QSK45 and QSK60 Tap-Drill Chart - U.S. Customary and Metric
Tap-Drill Chart - U.S. Customary and Metric

General Information
NOTE ON SELECTING TAP-DRILL SIZES: The tap drill sizes shown on this card give the theoretical tap drill size for
approximately 60% and 75% of full thread depth. Generally, it is recommended that drill sizes be selected in the 60%
range as these sizes will provide about 90% of the potential holding power. Drill sizes in the 75% range are
recommended for shallow hole tapping (less than 1 1/2 times the hole diameter) in soft metals and mild steel.
Weights and Measures - Conversion Factors QSK45 and QSK60
Weights and Measures - Conversion Factors

Conversion Chart
From U.S. From Metric
Customary To U.S.
Quantity U.S. Customary Metric
To Metric Customary
Multiply By Multiply By
Unit Name Abbreviation Unit Name Abbreviation
sq. inch in2 sq. millimeters mm2 645.16 0.001550
Area sq. centimeters cm2 6.452 0.155
sq. foot ft2 sq. meter m2 0.0929 10.764
Fuel pounds per lb/hp-hr grams per kilowatt g/kW-hr 608.277 0.001645
Consumption horsepower hour hour
Fuel miles per gallon mpg kilometers per liter km/l 0.4251 2.352
Performance gallons per mile gpm liters per kilometer l/km 2.352 0.4251
Force pounds force lbf Newton N 4.4482 0.224809
inch in millimeters mm 25.40 0.039370
Length
foot ft millimeters mm 304.801 0.00328
Power horsepower hp kilowatt kW 0.746 1.341
pounds force per psi kilopascal kPa 6.8948 0.145037
sq. inch
inches of mercury in Hg kilopascal kPa 3.3769 0.29613
inches of water in H2O kilopascal kPa 0.2488 4.019299
inches of mercury in Hg millimeters of mm Hg 25.40 0.039370
Pressure mercury
inches of water in H2O millimeters of mm H2O 25.40 0.039370
water
bars bars kilopascals kPa 100.001 0.00999
bars bars millimeters of mm Hg 750.06 0.001333
mercury
Temperature fahrenheit °F centigrade °C (°F-32) ÷1.8 (1.8 x °C) +32
pound force per ft-lb Newton-meter N•m 1.35582 0.737562
foot
Torque
pound force per in-lb Newton-meter N•m 0.113 8.850756
inch
Velocity miles/hour mph kilometers/hour kph 1.6093 0.6214
gallon (U.S.) gal. liter l 3.7853 0.264179
Volume: gallon (Imp*) gal. liter l 4.546 0.219976
liquid
displacement
cubic inch in3 liter l 0.01639 61.02545
cubic inch in3 cubic centimeter cm3 16.387 0.06102
Weight (mass) pounds (avoir.) lb kilograms kg 0.4536 2.204623
British Thermal BTU joules J 1054.5 0.000948
Unit
Work British Thermal BTU kilowatt-hour kW-hr 0.000293 3414
Unit
horsepower hours hp-hr kilowatt-hour kW-hr 0.746 1.341
Index
Page X-1
Accessory Drive ...........................................................................................9-3 Twin Cylinder......................................................................................12-13

Assemble....................................................................................................9-8 Air Compressor (Oil Carryover) ...............................................................12-22
with Mechanically Actuated Injector........................................................9-8 Inspect for Reuse....................................................................................12-22
Disassemble...............................................................................................9-4 Air Compressor Carbon Buildup ................................................................12-2
with Mechanically Actuated Injector........................................................9-4 Initial Check..............................................................................................12-2
Finishing Steps.........................................................................................9-11 Air Compressor Pin Bore Wear ..................................................................12-4
with Mechanically Actuated Injector......................................................9-11 Initial Check..............................................................................................12-4
Initial Check................................................................................................9-3 Air Compressor Unloader and Valve Assembly ........................................12-7
with Mechanically Actuated Injector........................................................9-3 Assemble..................................................................................................12-9
Inspect for Reuse........................................................................................9-6 Holset® QE230, QE296, and QE338 A/C Model.....................................12-9
with Mechanically Actuated Injector........................................................9-6 Clean and Inspect for Reuse.....................................................................12-8
Install........................................................................................................9-10 Disassemble.............................................................................................12-8
with Mechanically Actuated Injector......................................................9-10 Holset® QE230, QE296, and QE338 A/C Model.....................................12-8
Preparatory Steps.......................................................................................9-3 Finishing Steps.......................................................................................12-11
with Mechanically Actuated Injector........................................................9-3 Initial Check..............................................................................................12-7
Remove......................................................................................................9-3 Air Governor (Air Compressor Pumps Continuously) .............................12-19
with Mechanically Actuated Injector........................................................9-3 Initial Check............................................................................................12-19
Accessory Drive Cover ...............................................................................9-29 Air Governor (Air Compressor Will Not Pump) ........................................12-18
Clean and Inspect for Reuse.....................................................................9-30 Initial Check............................................................................................12-18
Install........................................................................................................9-30 Air in Fuel .....................................................................................................6-4
Remove....................................................................................................9-29 General Information....................................................................................6-4
Accessory Drive Pulley ..............................................................................9-11 Test............................................................................................................6-4
Clean and Inspect for Reuse.....................................................................9-12 Sight Glass Method................................................................................6-4
Install........................................................................................................9-13 Gear Pump Drain Method.......................................................................6-5
Remove....................................................................................................9-11 Air Intake Restriction ...............................................................................10-44
Additional Service Literature .......................................................................L-1 Measure..................................................................................................10-44
General Information....................................................................................L-1 Air Intake System .....................................................................................V-121
Aftercooler Assembly .................................................................................10-3 Specifications.........................................................................................V-121
Assemble................................................................................................10-11 Air Leaks, Air Intake and Exhaust Systems ............................................10-38
QSK45 Engines..................................................................................10-11 Inspect for Reuse....................................................................................10-38
QSK60 Engines..................................................................................10-12 Pressure Test..........................................................................................10-40
Disassemble.............................................................................................10-6 On-Engine Repair...............................................................................10-40
Finishing Steps.......................................................................................10-18 Pressure Test..........................................................................................10-42
Industrial and Power Generation.........................................................10-18 Off-Engine Repair...............................................................................10-42
QSK60 Marine Applications.................................................................10-18 Air Leaks, Compressed Air System .........................................................12-21
Inspect for Reuse......................................................................................10-7 Initial Check............................................................................................12-21
Install......................................................................................................10-14 Air Starting Motor .....................................................................................12-23
QSK45 Engines..................................................................................10-14 General Information................................................................................12-23
QSK60 Engines..................................................................................10-16 Alternator ....................................................................................................13-2
Machine....................................................................................................10-7 Clean and Inspect for Reuse.....................................................................13-4
QSK60 Engines....................................................................................10-7 Install........................................................................................................13-5
Preparatory Steps.....................................................................................10-3 Remove....................................................................................................13-3
Industrial and Power Generation...........................................................10-3 Test..........................................................................................................13-2
QSK60 Marine Applications...................................................................10-3 Alternator Drive Pulley ...............................................................................9-13
Pressure Test...........................................................................................10-7 Finishing Steps.........................................................................................9-14
Remove....................................................................................................10-3 Inspect for Reuse......................................................................................9-14
QSK45 Engines....................................................................................10-3 Install........................................................................................................9-14
QSK60 Engines....................................................................................10-5 Preparatory Steps.....................................................................................9-13
Aftercooler Coolant Tube .........................................................................10-19 Remove....................................................................................................9-13
Clean and Inspect for Reuse...................................................................10-19 Alternator Pulley ........................................................................................13-9
Aftercooler Element .................................................................................10-19 Inspect for Reuse......................................................................................13-9
Finishing Steps.......................................................................................10-32 Alternator Bracket ......................................................................................13-7
QSK45 Engines..................................................................................10-32 Clean and Inspect for Reuse.....................................................................13-7
QSK60 Industrial and Power Generation.............................................10-33 Batteries ...................................................................................................13-10
QSK60 Marine Applications.................................................................10-33 Inspect....................................................................................................13-10
Install......................................................................................................10-29 Battery Cables and Connections .............................................................13-11
QSK60 Engines..................................................................................10-31 Belt Tensioner, Automatic (Alternator) ....................................................13-20
Machine..................................................................................................10-24 Initial Check............................................................................................13-20
Preparatory Steps...................................................................................10-19 Install......................................................................................................13-23
QSK45 Engines..................................................................................10-19 Remove..................................................................................................13-22
QSK60 Industrial and Power Generation.............................................10-20 Capscrew ....................................................................................................17-1
QSK60 Marine Applications.................................................................10-21 Magnetic Crack Inspect.............................................................................17-1
Pressure Test..........................................................................................10-24 Capscrew Markings and Torque Values ..................................................V-126
Remove..................................................................................................10-21 Capscrew Markings and Torque Values - Metric......................................V-126
QSK45 Engines..................................................................................10-21 Capscrew Markings and Torque Values - U.S. Customary.......................V-126
QSK60 Engines..................................................................................10-22 General Information................................................................................V-126
Aftercooler Heat Shield ..........................................................................10-172 Component Manufacturers' Addresses ......................................................M-1
Install....................................................................................................10-172 Air Compressors........................................................................................M-1
Remove................................................................................................10-172 Air Cylinders..............................................................................................M-1
Air Cleaner Assembly (Engine-Mounted) .................................................10-34 Air Heaters................................................................................................M-1
Finishing Steps.......................................................................................10-37 Air Starting Motors.....................................................................................M-1
Install......................................................................................................10-35 Alternators.................................................................................................M-1
Preparatory Steps...................................................................................10-34 Auxiliary Brakes.........................................................................................M-1
Remove..................................................................................................10-34 Belts..........................................................................................................M-1
Air Compressor ........................................................................................12-11 Catalytic Converters...................................................................................M-1
Clean and Inspect for Reuse...................................................................12-13 Coolant Level Switches..............................................................................M-1
Single Cylinder...................................................................................12-14 Clutches....................................................................................................M-1
Twin Cylinder......................................................................................12-14 Coolant Heaters.........................................................................................M-2
Finishing Steps.......................................................................................12-18 Drive Plates...............................................................................................M-2
Install......................................................................................................12-15 Electric Starting Motors..............................................................................M-2
Single Cylinder...................................................................................12-15 Electronic Switches....................................................................................M-2
Twin Cylinder......................................................................................12-16 Engine Protection Controls.........................................................................M-2
Preparatory Steps...................................................................................12-11 Fan Clutches.............................................................................................M-2
Remove..................................................................................................12-12 Fans..........................................................................................................M-2
Single Cylinder...................................................................................12-12 Fault Lamps...............................................................................................M-2
Index
Page X-2
Filters........................................................................................................M-2 Ordering by Telephone...........................................................................L-3

Flexplates..................................................................................................M-2 Ordering On-Line....................................................................................L-3
Fuel Coolers..............................................................................................M-2 Cup Plug .....................................................................................................17-3
Fuel Pumps...............................................................................................M-2 Clean and Inspect for Reuse.....................................................................17-3
Fuel Warmers............................................................................................M-2 Install........................................................................................................17-4
Gauges......................................................................................................M-3 Remove....................................................................................................17-3
Governors..................................................................................................M-3 Cylinder Smokes (Blue Smoke) .................................................................7-86
Heat Sleeves.............................................................................................M-3 Finishing Steps.........................................................................................7-88
Hydraulic and Power Steering Pumps........................................................M-3 Industrial and Power Generation...........................................................7-88
In-Line Connectors.....................................................................................M-3 QSK60 Marine Applications...................................................................7-88
Oil Heaters................................................................................................M-3 Fluorescent Dye Tracer.............................................................................7-86
Prelubrication Systems..............................................................................M-3 Preparatory Steps.....................................................................................7-86
Radiators...................................................................................................M-3 Industrial and Power Generation...........................................................7-86
Throttle Assemblies...................................................................................M-3 QSK60 Marine Applications...................................................................7-86
Torque Converters.....................................................................................M-3 Drive Belt, Cooling Fan ................................................................................8-3
Compressed Air System ..........................................................................V-124 Adjust.........................................................................................................8-4
Specifications.........................................................................................V-124 Finishing Steps...........................................................................................8-5
Coolant Filter ................................................................................................8-5 Inspect for Reuse........................................................................................8-3
Install..........................................................................................................8-6 Install..........................................................................................................8-4
Remove......................................................................................................8-5 Preparatory Steps.......................................................................................8-3
Coolant Filter Head ......................................................................................8-7 Remove......................................................................................................8-3
Finishing Steps...........................................................................................8-7 Drive Belt Tension ...................................................................................V-125
Install..........................................................................................................8-7 Tension Chart.........................................................................................V-125
Preparatory Steps.......................................................................................8-7 Drive Belt, Alternator .................................................................................13-7
Remove......................................................................................................8-7 Adjust.......................................................................................................13-8
Coolant Temperature Gauge ........................................................................8-5 Inspect for Reuse......................................................................................13-7
Inspect for Reuse........................................................................................8-5 Install........................................................................................................13-8
Coolant Thermostat .....................................................................................8-8 Remove....................................................................................................13-7
Finishing Steps.........................................................................................8-16 Dynamometer Worksheet ...........................................................................14-3
QSK45 Engines....................................................................................8-16 Worksheet................................................................................................14-3
with Mechanically Actuated Injector......................................................8-17 ECM Cooling Plate ....................................................................................8-146
with Electronically Actuated Injector......................................................8-17 Assemble................................................................................................8-151
QSK60 Marine Applications...................................................................8-17 Clean and Inspect for Reuse...................................................................8-148
Inspect for Reuse......................................................................................8-11 Disassemble...........................................................................................8-147
Install........................................................................................................8-13 Finishing Steps.......................................................................................8-153
with Mechanically Actuated Injector......................................................8-13 Install......................................................................................................8-152
LTA......................................................................................................8-13 Preparatory Steps...................................................................................8-146
with Electronically Actuated Injector......................................................8-14 Remove..................................................................................................8-146
Leak Test..................................................................................................8-14 ECM Cooling Plate Lines ..........................................................................8-153
Engine Coolant Temperature................................................................8-14 Finishing Steps.......................................................................................8-156
High Coolant Temperature....................................................................8-16 Inspect for Reuse....................................................................................8-154
Preparatory Steps.......................................................................................8-8 Install......................................................................................................8-155
QSK45 Engines......................................................................................8-8 Preparatory Steps...................................................................................8-153
with Mechanically Actuated Injector........................................................8-8 Remove..................................................................................................8-153
with Electronically Actuated Injector........................................................8-9 Electrical System .....................................................................................V-123
QSK60 Marine Applications....................................................................8-9 Batteries (Specific Gravity)......................................................................V-123
Remove....................................................................................................8-10 Specifications.........................................................................................V-123
with Mechanically Actuated Injector......................................................8-10 Eliminator Filter ..........................................................................................7-96
LTA......................................................................................................8-10 Assemble................................................................................................7-122
with Electronically Actuated Injector......................................................8-11 Clean and Inspect for Reuse...................................................................7-119
Test..........................................................................................................8-11 Disassemble...........................................................................................7-111
Coolant Thermostat Seal ...........................................................................8-36 Exploded View..........................................................................................7-98
Install........................................................................................................8-36 Install......................................................................................................7-132
Remove....................................................................................................8-36 Pressure Test..........................................................................................7-133
Coolant Vent Lines .....................................................................................8-37 Remove....................................................................................................7-96
General Information..................................................................................8-37 Engine Barring Device ...............................................................................9-29
Aftercooled Engines..............................................................................8-37 Install........................................................................................................9-29
LTA......................................................................................................8-38 Remove....................................................................................................9-29
QSK60 Marine Applications...................................................................8-38 Engine Compression ................................................................................14-32
Cooling System ........................................................................................V-120 Finishing Steps.......................................................................................14-36
Specifications.........................................................................................V-120 Preparatory Steps...................................................................................14-32
QSK45 Engines..................................................................................V-120 Pressure Differential Test........................................................................14-34
QSK60 Engines..................................................................................V-120 Setup......................................................................................................14-33
Cooling System ..........................................................................................8-39 Engine Lifting Brackets ..............................................................................16-3
Drain.........................................................................................................8-39 Clean and Inspect for Reuse.....................................................................16-3
Aftercooled Engines..............................................................................8-40 Engine Run-in (Engine Dynamometer) .....................................................14-22
LTA......................................................................................................8-40 Install......................................................................................................14-22
Fill............................................................................................................8-49 Test....................................................................................................14-22
Flush........................................................................................................8-40 Engine Throttle Control.......................................................................14-23
Pressure Test...........................................................................................8-43 Run-In Instructions..................................................................................14-24
Internal.................................................................................................8-43 Engine Run-in (Without Dynamometer) ...................................................14-10
External................................................................................................8-48 Finishing Steps.......................................................................................14-13
Cooling System Diagnostics ......................................................................8-55 Preparatory Steps...................................................................................14-10
Pressure Test...........................................................................................8-55 Run-In Instructions..................................................................................14-12
Cooling System Service Requirements .....................................................8-57 Generator Set Applications..................................................................14-12
General Information..................................................................................8-57 Industrial Applications.........................................................................14-13
Water....................................................................................................8-57 Engine Support Bracket, Front ..................................................................16-3
Supplemental Coolant Additive (SCA)...................................................8-58 Finishing Steps.........................................................................................16-6
Cooling System - Air or Combustion Gas Test .........................................8-51 Inspect for Reuse......................................................................................16-5
Test..........................................................................................................8-51 Install........................................................................................................16-5
Overflow Method...................................................................................8-51 Preparatory Steps.....................................................................................16-3
Sight Glass Method...............................................................................8-52 Remove....................................................................................................16-4
Air Compressor.....................................................................................8-53 Engine Testing (Chassis Dynamometer) ...................................................14-4
Cylinder Head and Cylinder Liner..........................................................8-53 Test..........................................................................................................14-4
Cummins Customized Parts Catalog ...........................................................L-3 Engine Speed (rpm)..............................................................................14-4
General Information....................................................................................L-3 Fuel Pressure.......................................................................................14-5
Ordering the Customized Parts Catalog......................................................L-3 Fuel Rate..............................................................................................14-5
Index
Page X-3
Fuel Inlet Restriction.............................................................................14-5 Assemble..................................................................................................8-61

Fuel Drain Line Restriction....................................................................14-5 Clean and Inspect for Reuse.....................................................................8-61
Intake Manifold Pressure......................................................................14-6 Disassemble.............................................................................................8-60
Intake Manifold Air Temperature Control - Chassis Dynamometer test..... Finishing Steps.........................................................................................8-64
14-6 Install........................................................................................................8-63
Intake Air Restriction.............................................................................14-7 Preparatory Steps.....................................................................................8-58
Intake Manifold Air Temperature Control - Chassis Dynamometer test..... Remove....................................................................................................8-58
14-7 Fan Drive Idler Pulley Assembly ................................................................8-64
Engine Blowby......................................................................................14-7 Assemble..................................................................................................8-66
Lubricating Oil Pressure........................................................................14-9 Turnbuckle Idler System.......................................................................8-66
Air Compressor...................................................................................14-10 Clean and Inspect for Reuse.....................................................................8-64
Starting Motor.....................................................................................14-10 Shock Absorber System........................................................................8-64
Engine Testing (Engine Dynamometer) ...................................................14-14 Turnbuckle Idler System.......................................................................8-65
Install......................................................................................................14-14 Disassemble.............................................................................................8-64
Coolant Plumbing...............................................................................14-14 Turnbuckle Idler System.......................................................................8-64
Intake Air Temperature Control...........................................................14-14 Fan Hub Bracket .........................................................................................8-67
LTA.....................................................................................................14-14 Clean and Inspect for Reuse.....................................................................8-67
Test....................................................................................................14-15 Fan Hub, Belt Driven ..................................................................................8-68
Engine Throttle Control.......................................................................14-16 Finishing Steps.........................................................................................8-75
Test........................................................................................................14-17 Inspect for Reuse......................................................................................8-71
Engine Speed (rpm)............................................................................14-17 Standard...............................................................................................8-71
Fuel Drain Line Restriction..................................................................14-17 Install........................................................................................................8-72
Intake Air Restriction...........................................................................14-18 Standard...............................................................................................8-72
Exhaust Air Restriction........................................................................14-18 Rockford...............................................................................................8-72
Engine Blowby....................................................................................14-18 Preparatory Steps.....................................................................................8-68
Lubricating Oil Pressure......................................................................14-20 Remove....................................................................................................8-68
Engine Coolant Pressure.....................................................................14-21 Standard...............................................................................................8-68
Air Compressor...................................................................................14-21 Rockford...............................................................................................8-68
Starting Motor.....................................................................................14-21 Fan Shroud Assembly ................................................................................8-75
Engine Testing (In Chassis) .....................................................................14-26 Inspect for Reuse......................................................................................8-75
Stall Speed Check...................................................................................14-26 Fan, Cooling ...............................................................................................8-75
Stall Speed Checklist..............................................................................14-30 Finishing Steps.........................................................................................8-78
Time Speed Check..................................................................................14-30 Inspect for Reuse......................................................................................8-76
Exhaust Connection Pipe ...........................................................................11-2 Install........................................................................................................8-77
Clean and Inspect for Reuse.....................................................................11-3 Preparatory Steps.....................................................................................8-75
Finishing Steps.........................................................................................11-5 Remove....................................................................................................8-76
Install........................................................................................................11-4 Rotation Check.........................................................................................8-77
Single Stage.........................................................................................11-4 Fleetguard® Centrifuge .............................................................................7-134
Two Stage............................................................................................11-4 Assemble................................................................................................7-135
Preparatory Steps.....................................................................................11-2 Clean and Inspect for Reuse...................................................................7-135
Remove....................................................................................................11-2 Disassemble...........................................................................................7-134
Single Stage.........................................................................................11-2 Flexible Hose ..............................................................................................17-5
Two Stage............................................................................................11-2 Inspect for Reuse......................................................................................17-5
Exhaust Connection Pipe (Turbocharger to Turbocharger) ......................11-5 Flexplate .....................................................................................................16-7
Clean and Inspect for Reuse.....................................................................11-6 Clean and Inspect for Reuse.....................................................................16-7
Finishing Steps.........................................................................................11-7 Flywheel .....................................................................................................16-7
Install........................................................................................................11-6 Clean and Inspect for Reuse.....................................................................16-9
Remove....................................................................................................11-5 Finishing Steps.......................................................................................16-12
Exhaust Manifold Heat Shield ..................................................................11-24 Industrial and Power Generation.........................................................16-12
Finishing Steps.......................................................................................11-32 QSK60 Marine Applications.................................................................16-12
Install......................................................................................................11-27 with Electronically Actuated Injector....................................................16-13
Preparatory Steps...................................................................................11-24 Install......................................................................................................16-10
Remove..................................................................................................11-24 Preparatory Steps.....................................................................................16-7
Exhaust Manifold, Dry ................................................................................11-7 Industrial and Power Generation...........................................................16-7
Clean and Inspect for Reuse...................................................................11-12 QSK60 Marine Applications...................................................................16-8
Finishing Steps.......................................................................................11-20 with Electronically Actuated Injector......................................................16-8
QSK45 Engines..................................................................................11-20 Remove....................................................................................................16-9
QSK60 Single Stage Industrial and Power Generation.........................11-21 Flywheel Housing .....................................................................................16-14
QSK60 Marine Applications.................................................................11-21 Clean and Inspect for Reuse...................................................................16-20
QSK60 Two Stage...............................................................................11-22 Exploded View........................................................................................16-17
General Information..................................................................................11-7 Finishing Steps.......................................................................................16-29
QSK45 Engines....................................................................................11-7 Industrial and Power Generation.........................................................16-29
QSK60 Single Stage Industrial and Power Generation...........................11-7 with Electronically Actuated Injector....................................................16-30
QSK60 Marine Applications...................................................................11-7 QSK60 Marine Applications.................................................................16-31
Install......................................................................................................11-12 Install......................................................................................................16-25
Industrial and Power Generation.........................................................11-12 Preparatory Steps...................................................................................16-14
QSK60 Marine Applications.................................................................11-16 Industrial and Power Generation.........................................................16-14
Preparatory Steps.....................................................................................11-8 with Electronically Actuated Injector....................................................16-15
QSK45 Engines....................................................................................11-8 QSK60 Marine Applications.................................................................16-16
QSK60 Single Stage Industrial and Power Generation...........................11-9 Redowel..................................................................................................16-21
QSK60 Marine Applications...................................................................11-9 Remove..................................................................................................16-17
QSK60 Two Stage...............................................................................11-10 Flywheel Ring Gear ..................................................................................16-31
Remove..................................................................................................11-10 Assemble................................................................................................16-32
Industrial and Power Generation.........................................................11-10 Disassemble...........................................................................................16-31
QSK60 Marine Applications.................................................................11-11 Fraction, Decimal, Millimeter Conversions .............................................V-128
Exhaust Restriction ..................................................................................11-22 Conversion Chart....................................................................................V-128
Measure..................................................................................................11-22 Frame, Two-Stage Turbocharger ...........................................................10-141
Exhaust System .......................................................................................V-122 Clean and Inspect for Reuse.................................................................10-149
Specifications.........................................................................................V-122 Two Stage.........................................................................................10-149
Expansion Tank ..........................................................................................8-90 Finishing Steps.....................................................................................10-157
Clean and Inspect for Reuse.....................................................................8-91 with Mechanically Actuated Injector...................................................10-157
Finishing Steps.........................................................................................8-94 with Electronically Actuated Injector..................................................10-157
Install........................................................................................................8-92 Install....................................................................................................10-150
Preparatory Steps.....................................................................................8-90 with Mechanically Actuated Injector...................................................10-150
.............................................................................................................8-90 with Electronically Actuated Injector..................................................10-155
Remove....................................................................................................8-90 Preparatory Steps.................................................................................10-141
Fan Drive Idler Arm Assembly ...................................................................8-58 with Mechanically Actuated Injector...................................................10-141
Index
Page X-4
with Electronically Actuated Injector..................................................10-141 with Electronically Actuated Injector......................................................6-21

Remove................................................................................................10-142 Remove....................................................................................................6-22
with Mechanically Actuated Injector...................................................10-142 with Mechanically Actuated Injector......................................................6-22
with Electronically Actuated Injector..................................................10-147 with Electronically Actuated Injector......................................................6-22
Fuel Connection Block (Manifold-Mounted) ................................................6-6 Fuel Inlet Restriction ..................................................................................6-31
Assemble....................................................................................................6-9 Measure...................................................................................................6-31
Clean and Inspect for Reuse.......................................................................6-8 with Mechanically Actuated Injector......................................................6-31
Disassemble...............................................................................................6-8 with Electronically Actuated Injector......................................................6-32
Install..........................................................................................................6-9 Fuel Lift Pump ............................................................................................5-44
Remove......................................................................................................6-6 Finishing Steps.........................................................................................5-47
Remove......................................................................................................6-7 with Electronically Actuated Injector......................................................5-47
Fuel Consumption ........................................................................................5-3 Initial Check..............................................................................................5-44
Initial Check................................................................................................5-3 with Electronically Actuated Injector......................................................5-44
Test............................................................................................................5-3 Inspect for Reuse......................................................................................5-46
Off-Highway Applications........................................................................5-3 with Electronically Actuated Injector......................................................5-46
Fuel Control Valve Body Assembly ...........................................................6-76 Install........................................................................................................5-47
Assemble..................................................................................................6-79 with Electronically Actuated Injector......................................................5-47
with Mechanically Actuated Injector......................................................6-79 Preparatory Steps.....................................................................................5-45
Clean and Inspect for Reuse.....................................................................6-78 with Electronically Actuated Injector......................................................5-45
with Mechanically Actuated Injector......................................................6-78 Remove....................................................................................................5-45
Disassemble.............................................................................................6-78 with Electronically Actuated Injector......................................................5-45
with Mechanically Actuated Injector......................................................6-78 Fuel Manifold (Drain) ..................................................................................6-37
Finishing Steps.........................................................................................6-81 Clean and Inspect for Reuse.....................................................................6-38
with Mechanically Actuated Injector......................................................6-81 with Electronically Actuated Injector......................................................6-38
Install........................................................................................................6-80 Finishing Steps.........................................................................................6-41
Preparatory Steps.....................................................................................6-76 Install........................................................................................................6-40
Remove....................................................................................................6-77 Preparatory Steps.....................................................................................6-37
Fuel Cooler .................................................................................................6-90 Remove....................................................................................................6-37
Finishing Steps.........................................................................................6-93 with Electronically Actuated Injector......................................................6-37
with Mechanically Actuated Injector......................................................6-93 Fuel Manifold (Supply) ...............................................................................6-42
Inspect for Reuse......................................................................................6-91 Assemble..................................................................................................6-44
with Mechanically Actuated Injector......................................................6-91 with Mechanically Actuated Injector......................................................6-44
Install........................................................................................................6-93 Clean and Inspect for Reuse.....................................................................6-43
Preparatory Steps.....................................................................................6-90 Disassemble.............................................................................................6-43
Pressure Test...........................................................................................6-91 Finishing Steps.........................................................................................6-45
Remove....................................................................................................6-90 Install........................................................................................................6-44
Fuel Drain Line Restriction ........................................................................6-10 QSK45 Engines....................................................................................6-44
Measure...................................................................................................6-10 QSK60 Engines....................................................................................6-45
Fuel Drain Lines .........................................................................................6-11 Preparatory Steps.....................................................................................6-42
Clean and Inspect for Reuse.....................................................................6-14 with Mechanically Actuated Injector......................................................6-42
with Electronically Actuated Injector......................................................6-15 QSK45 Engines....................................................................................6-42
Finishing Steps.........................................................................................6-18 QSK60 Engines....................................................................................6-43
with Electronically Actuated Injector......................................................6-18 Fuel Pump ....................................................................................................5-4
Install........................................................................................................6-15 Assemble..................................................................................................5-26
with Electronically Actuated Injector......................................................6-16 Fuel Pump Regulator............................................................................5-30
Preparatory Steps.....................................................................................6-11 with Electronically Actuated Injector......................................................5-32
with Electronically Actuated Injector......................................................6-11 Clean and Inspect for Reuse.....................................................................5-21
Remove....................................................................................................6-12 with Mechanically Actuated Injector......................................................5-21
with Mechanically Actuated Injector......................................................6-12 Fuel Pump Regulator............................................................................5-23
with Electronically Actuated Injector......................................................6-12 with Electronically Actuated Injector......................................................5-24
Fuel Filter (Spin-On Type) ..........................................................................6-18 Disassemble.............................................................................................5-15
Clean........................................................................................................6-19 with Mechanically Actuated Injector......................................................5-15
General Information..................................................................................6-18 Fuel Pump Regulator............................................................................5-18
Install........................................................................................................6-19 Exploded View............................................................................................5-6
with Mechanically Actuated Injector......................................................6-19 with Mechanically Actuated Injector........................................................5-6
with Electronically Actuated Injector......................................................6-20 Finishing Steps.........................................................................................5-37
Remove....................................................................................................6-18 with Mechanically Actuated Injector......................................................5-37
with Electronically Actuated Injector......................................................6-19 Install........................................................................................................5-32
Fuel Filter Head ..........................................................................................6-21 with Mechanically Actuated Injector......................................................5-32
Assemble..................................................................................................6-27 with Electronically Actuated Injector......................................................5-33
with Mechanically Actuated Injector......................................................6-27 Preparatory Steps.......................................................................................5-9
with Electronically Actuated Injector......................................................6-27 with Mechanically Actuated Injector........................................................5-9
Clean and Inspect for Reuse.....................................................................6-24 with Electronically Actuated Injector......................................................5-10
with Mechanically Actuated Injector......................................................6-24 Pressure Test.............................................................................................5-4
with Electronically Actuated Injector......................................................6-25 with Mechanically Actuated Injector........................................................5-4
Disassemble.............................................................................................6-22 Engine Cranking.....................................................................................5-4
with Mechanically Actuated Injector......................................................6-22 Engine Operation....................................................................................5-5
with Electronically Actuated Injector......................................................6-23 Remove....................................................................................................5-11
Finishing Steps.........................................................................................6-30 with Mechanically Actuated Injector......................................................5-11
with Electronically Actuated Injector......................................................6-31 Fuel Pump Drive .........................................................................................9-14
with Mechanically Actuated Injector......................................................6-30 Disassemble.............................................................................................9-15
with Electronically Actuated Injector......................................................6-30 Initial Check..............................................................................................9-14
Preparatory Steps.....................................................................................6-21 Inspect for Reuse......................................................................................9-17
with Mechanically Actuated Injector......................................................6-21 Fuel Pump Gear Pump ...............................................................................5-38
Index
Page X-5
Rotation Check.........................................................................................5-38 Assemble..............................................................................................10-162

with Mechanically Actuated Injector......................................................5-38 Disassemble.........................................................................................10-160
Fuel Shutoff Valve ......................................................................................5-39 Finishing Steps.....................................................................................10-166
Assemble..................................................................................................5-42 Inspect for Reuse..................................................................................10-159
with Mechanically Actuated Injector......................................................5-42 Install....................................................................................................10-164
Clean and Inspect for Reuse.....................................................................5-41 Preparatory Steps.................................................................................10-157
with Mechanically Actuated Injector......................................................5-41 Pressure Test........................................................................................10-161
Disassemble.............................................................................................5-40 Remove................................................................................................10-157
with Mechanically Actuated Injector......................................................5-40 Intercooler Element ................................................................................10-166
Install........................................................................................................5-43 Finishing Steps.....................................................................................10-172
with Mechanically Actuated Injector......................................................5-43 Install....................................................................................................10-169
Remove....................................................................................................5-39 .........................................................................................................10-169
with Mechanically Actuated Injector......................................................5-39 Preparatory Steps.................................................................................10-166
Fuel Supply Lines .......................................................................................6-45 Pressure Test........................................................................................10-169
Clean and Inspect for Reuse.....................................................................6-49 Remove................................................................................................10-166
with Mechanically Actuated Injector......................................................6-49 CELECT™ or Centry™........................................................................10-166
with Electronically Actuated Injector......................................................6-49 Low-Temperature Aftercooler (LTA) Water Pump ...................................8-133
Finishing Steps.........................................................................................6-52 Assemble................................................................................................8-139
Install........................................................................................................6-50 with Mechanically Actuated Injector.....................................................8-139
with Mechanically Actuated Injector......................................................6-50 Clean and Inspect for Reuse...................................................................8-138
with Electronically Actuated Injector......................................................6-50 with Mechanically Actuated Injector.....................................................8-138
Preparatory Steps.....................................................................................6-45 Disassemble...........................................................................................8-135
Remove....................................................................................................6-46 with Mechanically Actuated Injector.....................................................8-135
with Mechanically Actuated Injector......................................................6-46 Finishing Steps.......................................................................................8-142
with Electronically Actuated Injector......................................................6-46 with Mechanically Actuated Injector.....................................................8-142
Fuel System .............................................................................................V-118 General Information................................................................................8-133
Specifications.........................................................................................V-118 Install......................................................................................................8-142
with Electronically Actuated Injector....................................................V-118 with Mechanically Actuated Injector.....................................................8-142
with Mechanically Actuated Injector....................................................V-118 Preparatory Steps...................................................................................8-134
General Engine .........................................................................................V-115 with Mechanically Actuated Injector.....................................................8-134
General Specifications............................................................................V-115 Remove..................................................................................................8-134
QSK45 Engines..................................................................................V-115 with Mechanically Actuated Injector.....................................................8-134
QSK60 Engines..................................................................................V-116 Lubricating Oil Contamination ...................................................................7-78
Heat Exchanger ..........................................................................................8-95 Fluorescent Dye Tracer.............................................................................7-78
Assemble................................................................................................8-102 Lubricating Oil Dilution..........................................................................7-78
Clean and Inspect for Reuse...................................................................8-100 QSK60 Marine Applications...................................................................7-80
Disassemble.............................................................................................8-98 General Information..................................................................................7-78
Exploded View..........................................................................................8-95 Pressure Test...........................................................................................7-78
Finishing Steps.......................................................................................8-105 Coolant-Diluted Lubricating Oil..............................................................7-78
Install......................................................................................................8-104 Lubricating Oil Cooler Cover .....................................................................7-83
Preparatory Steps.....................................................................................8-97 Clean and Inspect for Reuse.....................................................................7-84
Remove....................................................................................................8-97 Finishing Steps.........................................................................................7-85
Hydraulic Pump Drive ................................................................................9-21 QSK45 and QSK60 Single Stage...........................................................7-85
Inspect for Reuse......................................................................................9-22 QSK60 Marine Applications...................................................................7-85
Install........................................................................................................9-22 QSK60 Two Stage Insdustrial and Power Gerneration...........................7-86
Remove....................................................................................................9-21 Install........................................................................................................7-85
Injector ........................................................................................................6-63 Preparatory Steps.....................................................................................7-83
Calibrate...................................................................................................6-73 QSK45 and QSK60 Single Stage...........................................................7-83
Clean and Inspect for Reuse.....................................................................6-70 QSK60 Marine Applications...................................................................7-83
with Mechanically Actuated Injector......................................................6-70 QSK60 Two Stage Insdustrial and Power Gerneration...........................7-84
with Electronically Actuated Injector......................................................6-71 Remove....................................................................................................7-84
Finishing Steps.........................................................................................6-76 Lubricating Oil Cooler Element ...................................................................7-3
with Mechanically Actuated Injector......................................................6-76 Clean and Inspect for Reuse.......................................................................7-4
with Electronically Actuated Injector......................................................6-76 Finishing Steps...........................................................................................7-6
General Information..................................................................................6-63 QSK45 and QSK60 Single Stage............................................................7-6
with Electronically Actuated Injector......................................................6-63 QSK60 Two Stage Insdustrial and Power Gerneration.............................7-7
Initial Check..............................................................................................6-63 QSK60 Marine Applications....................................................................7-7
Misfire Using Heat Indicator Marker......................................................6-63 Install..........................................................................................................7-6
Misfire using Infared Thermometer........................................................6-64 Preparatory Steps.......................................................................................7-3
Misfire Using Injector Cutout Tool.........................................................6-64 QSK45 and QSK60 Single Stage............................................................7-3
Install........................................................................................................6-73 QSK60 Two Stage Insdustrial and Power Gerneration.............................7-3
with Mechanically Actuated Injector......................................................6-73 QSK60 Marine Applications....................................................................7-4
with Electronically Actuated Injector......................................................6-74 Pressure Test.............................................................................................7-6
Preparatory Steps.....................................................................................6-68 Remove......................................................................................................7-4
with Mechanically Actuated Injector......................................................6-68 Lubricating Oil Dipstick ...............................................................................7-8
with Electronically Actuated Injector......................................................6-68 Calibrate.....................................................................................................7-9
Remove....................................................................................................6-68 Standard.................................................................................................7-9
with Mechanically Actuated Injector......................................................6-68 Running Level Dipstick.........................................................................7-11
with Electronically Actuated Injector......................................................6-69 Install..........................................................................................................7-8
Injector Supply Lines (High Pressure) .......................................................6-81 Running Level Dipstick...........................................................................7-8
Clean and Inspect for Reuse.....................................................................6-85 Preparatory Steps.......................................................................................7-8
with Electronically Actuated Injector......................................................6-85 Running Level Dipstick...........................................................................7-8
Finishing Steps.........................................................................................6-87 Remove......................................................................................................7-8
with Electronically Actuated Injector......................................................6-87 Running Level Dipstick...........................................................................7-8
General Information..................................................................................6-81 Lubricating Oil Dipstick Tube ....................................................................7-12
with Electronically Actuated Injector......................................................6-81 Clean and Inspect for Reuse.....................................................................7-15
Initial Check..............................................................................................6-82 Standard Tube......................................................................................7-15
Install........................................................................................................6-86 Install........................................................................................................7-16
with Electronically Actuated Injector......................................................6-86 Standard Tube......................................................................................7-16
Leak Test..................................................................................................6-88 Extended Tube.....................................................................................7-17
with Electronically Actuated Injector......................................................6-82 Standard Tube......................................................................................7-12
Remove....................................................................................................6-83 Extended Tube.....................................................................................7-12
Intercooler Assembly .............................................................................10-157 Lubricating Oil Fill Tube ............................................................................7-93
Index
Page X-6
Clean and Inspect for Reuse.....................................................................7-94 Lubricating Oil Pump .................................................................................7-53

with Electronically Actuated Injector......................................................7-94 Adjust.......................................................................................................7-65
Stand-alone..........................................................................................7-95 Clean and Inspect for Reuse.....................................................................7-56
Integral Crankcase Breather.................................................................7-95 Disassemble.............................................................................................7-54
with Electronically Actuated Injector......................................................7-96 Finishing Steps.........................................................................................7-66
Remove....................................................................................................7-93 Install........................................................................................................7-64
Stand-alone..........................................................................................7-93 Preparatory Steps.....................................................................................7-53
Integral Crankcase Breather.................................................................7-93 Remove....................................................................................................7-53
with Electronically Actuated Injector......................................................7-94 Lubricating Oil Suction Tube (Block-Mounted) .........................................7-66
Lubricating Oil Filter (Spin-On) ..................................................................7-19 Clean and Inspect for Reuse.....................................................................7-67
Inspect......................................................................................................7-19 Install........................................................................................................7-68
Install........................................................................................................7-20 Remove....................................................................................................7-66
Pressure Differential Test..........................................................................7-21 Lubricating Oil System ...............................................................................7-68
Spin-on Type........................................................................................7-21 Drain.........................................................................................................7-68
Eliminator.............................................................................................7-22 Fill............................................................................................................7-69
Remove....................................................................................................7-19 Lubricating Oil System ............................................................................V-119
Lubricating Oil Filter Head .........................................................................7-24 Specifications.........................................................................................V-119
Assemble..................................................................................................7-28 Lubricating Oil Temperature Gauge ..........................................................7-71
Two-Piece Filter Head, Spin-on Filter....................................................7-28 Finishing Steps.........................................................................................7-73
One-Piece Filter Head, Spin-on Filter....................................................7-29 Inspect for Reuse......................................................................................7-71
Clean and Inspect for Reuse.....................................................................7-26 Preparatory Steps.....................................................................................7-71
Two-Piece Filter Head, Spin-on Filter....................................................7-26 Lubricating Oil Transfer Tube ....................................................................7-73
One-Piece Filter Head, Spin-on Filter....................................................7-26 Clean and Inspect for Reuse.....................................................................7-75
Disassemble.............................................................................................7-25 Finishing Steps.........................................................................................7-78
Two-Piece Filter Head, Spin-on Filter....................................................7-25 Install........................................................................................................7-76
One-Piece Filter Head, Spin-on Filter....................................................7-25 S-Shape type........................................................................................7-76
Exploded View..........................................................................................7-24 Elbow type............................................................................................7-77
Finishing Steps.........................................................................................7-30 Straight type.........................................................................................7-77
Install........................................................................................................7-29 Preparatory Steps.....................................................................................7-73
Two-Piece Filter Head, Spin-on Filter....................................................7-29 Remove....................................................................................................7-74
One-Piece Filter Head, Spin-on Filter....................................................7-30 S-Shape type........................................................................................7-74
Preparatory Steps.....................................................................................7-24 Elbow type............................................................................................7-74
Remove....................................................................................................7-25 Straight type.........................................................................................7-74
Two-Piece Filter Head, Spin-on Filter....................................................7-25 Marine Gear Oil Cooler ...............................................................................8-79
One-Piece Filter Head, Spin-on Filter....................................................7-25 Finishing Steps.........................................................................................8-82
Lubricating Oil Filter Head Adapter ...........................................................7-31 Inspect for Reuse......................................................................................8-80
Clean and Inspect for Reuse.....................................................................7-31 Install........................................................................................................8-81
Finishing Steps.........................................................................................7-32 Preparatory Steps.....................................................................................8-79
Install........................................................................................................7-31 Pressure Test...........................................................................................8-80
Remove....................................................................................................7-31 Newton-Meter to Foot-Pound Conversions .............................................V-129
Lubricating Oil High Pressure Relief Valve ...............................................7-32 Conversion Chart....................................................................................V-129
Clean and Inspect for Reuse.....................................................................7-34 Oil Transfer Connection .............................................................................7-88
Finishing Steps.........................................................................................7-35 Clean and Inspect for Reuse.....................................................................7-88
Install........................................................................................................7-34 Pipe Plug ....................................................................................................17-5
Preparatory Steps.....................................................................................7-32 Clean and Inspect for Reuse.....................................................................17-5
Remove....................................................................................................7-32 Install........................................................................................................17-6
Lubricating Oil Leaks .................................................................................7-36 Remove....................................................................................................17-5
Clean and Inspect for Reuse.....................................................................7-37 Pipe Plug Torque Values .........................................................................V-130
Fluorescent Dye Tracer.............................................................................7-36 Torque Table..........................................................................................V-130
Lubricating Oil Pan .....................................................................................7-38 Pre-Lubricating Oil Pump ...........................................................................7-89
Clean and Inspect for Reuse.....................................................................7-39 Finishing Steps.........................................................................................7-93
Finishing Steps.........................................................................................7-40 Install........................................................................................................7-91
Install........................................................................................................7-39 Preparatory Steps.....................................................................................7-89
Remove....................................................................................................7-38 Radiator ......................................................................................................8-82
Lubricating Oil Pan Adapter ......................................................................7-43 Finishing Steps.........................................................................................8-84
Clean and Inspect for Reuse.....................................................................7-45 Test..........................................................................................................8-82
Finishing Steps.........................................................................................7-47 Radiator Hoses ...........................................................................................8-85
with Mechanically Actuated Injector......................................................7-47 Finishing Steps.........................................................................................8-88
with Electronically Actuated Injector......................................................7-47 Inspect for Reuse......................................................................................8-86
Install........................................................................................................7-45 Install........................................................................................................8-87
QSK45 Engines....................................................................................7-45 Aftercooled Engines..............................................................................8-87
QSK60 Engines....................................................................................7-46 LTA......................................................................................................8-87
Preparatory Steps.....................................................................................7-43 Preparatory Steps.....................................................................................8-85
with Electronically Actuated Injector......................................................7-44 Aftercooled Engines..............................................................................8-85
Remove....................................................................................................7-44 LTA......................................................................................................8-86
Lubricating Oil Pan Adapter Cover Plate ..................................................7-40 Radiator Pressure Cap ...............................................................................8-88
Clean and Inspect for Reuse.....................................................................7-41 Inspect for Reuse......................................................................................8-88
Finishing Steps.........................................................................................7-42 Pressure Test...........................................................................................8-89
Install........................................................................................................7-42 Radiator Top Tank ......................................................................................8-89
Preparatory Steps.....................................................................................7-40 Leak Test..................................................................................................8-89
Remove....................................................................................................7-41 Aftercooled Engines..............................................................................8-89
Lubricating Oil Pressure Gauge .................................................................7-48 Right Bank Number 8 Coolant Loop ........................................................8-143
Inspect for Reuse......................................................................................7-48 Clean and Inspect for Reuse...................................................................8-144
Lubricating Oil Pressure Regulator (Main Rifle) ........................................7-49 Finishing Steps.......................................................................................8-146
Clean and Inspect for Reuse.....................................................................7-50 Install......................................................................................................8-145
Finishing Steps.........................................................................................7-51 Preparatory Steps...................................................................................8-143
Install........................................................................................................7-50 QSK60 Two Stage...............................................................................8-143
Preparatory Steps.....................................................................................7-49 Remove..................................................................................................8-143
Remove....................................................................................................7-49 Sea Water Pump .......................................................................................8-105
Lubricating Oil Pressure Regulator (Piston Cooling) ................................7-51 Inspect for Reuse....................................................................................8-106
Clean and Inspect for Reuse.....................................................................7-51 Install......................................................................................................8-107
Install........................................................................................................7-52 Remove..................................................................................................8-105
Remove....................................................................................................7-51 Service Literature Ordering Location ..........................................................L-2
Index
Page X-7
Contact Information....................................................................................L-2 Industrial and Power Generation.........................................................10-46

Service Tools ...............................................................................................5-1 QSK60 Marine Applications.................................................................10-49
Fuel System................................................................................................5-1 Inspect for Reuse....................................................................................10-51
Service Tools ...............................................................................................6-1 Turbocharger Coolant Hoses .................................................................10-109
Injectors and Fuel Lines..............................................................................6-1 Finishing Steps.....................................................................................10-116
Service Tools ...............................................................................................7-1 Inspect for Reuse..................................................................................10-112
Lubricating Oil System................................................................................7-1 Install....................................................................................................10-113
Service Tools ...............................................................................................8-1 Single Stage.....................................................................................10-113
Cooling System...........................................................................................8-1 Two Stage.........................................................................................10-114
Service Tools ...............................................................................................9-1 Preparatory Steps.................................................................................10-109
Drive Units..................................................................................................9-1 Remove................................................................................................10-109
Service Tools ..............................................................................................10-1 Single Stage.....................................................................................10-109
Cylinder Block...........................................................................................10-1 Two Stage.........................................................................................10-111
Service Tools ..............................................................................................11-1 Turbocharger Heat Shield ......................................................................10-137
Exhaust System........................................................................................11-1 Finishing Steps.....................................................................................10-140
Service Tools ..............................................................................................12-1 Install....................................................................................................10-139
Compressed Air System............................................................................12-1 Preparatory Steps.................................................................................10-137
Service Tools ..............................................................................................13-1 Remove................................................................................................10-137
Electrical Equipment.................................................................................13-1 Turbocharger Inlet Connections ............................................................10-173
Service Tools ..............................................................................................14-1 Finishing Steps.....................................................................................10-174
Engine Testing..........................................................................................14-1 Install....................................................................................................10-173
Service Tools ..............................................................................................16-1 Preparatory Steps.................................................................................10-173
Mounting Adaptations...............................................................................16-1 Remove................................................................................................10-173
Starter Magnetic Switch ...........................................................................13-11 Turbocharger Oil Drain Line ..................................................................10-117
Inspect for Reuse....................................................................................13-11 Clean and Inspect for Reuse.................................................................10-118
Starting Motor ...........................................................................................13-17 Install....................................................................................................10-119
Finishing Steps.......................................................................................13-20 QSK45 and QSK60 Single Stage.......................................................10-119
Integral Prelub™ Starter.......................................................................13-20 QSK60 Two Stage.............................................................................10-119
Inspect for Reuse....................................................................................13-18 Remove................................................................................................10-117
Install......................................................................................................13-19 QSK45 and QSK60 Single Stage.......................................................10-117
Integral Prelub™ Starter.......................................................................13-19 QSK60 Two Stage.............................................................................10-117
Preparatory Steps...................................................................................13-17 Turbocharger Oil Supply Line ................................................................10-120
Integral Prelub™ Starter.......................................................................13-17 Clean and Inspect for Reuse.................................................................10-125
Remove..................................................................................................13-18 Install....................................................................................................10-127
Integral Prelub™ Starter.......................................................................13-18 QSK45 and QSK60 Single Stage.......................................................10-127
Starter Solenoid ........................................................................................13-15 QSK60 Two Stage.............................................................................10-129
Voltage Check.........................................................................................13-15 Remove................................................................................................10-120
Starter Switch ...........................................................................................13-13 QSK45 and QSK60 Single Stage.......................................................10-120
Inspect for Reuse....................................................................................13-13 QSK60 Two Stage.............................................................................10-123
Static Injection Timing ...............................................................................6-53 Turbocharger, High Pressure ...................................................................10-88
Finishing Steps.........................................................................................6-63 Finishing Steps.....................................................................................10-104
with Mechanically Actuated Injector......................................................6-63 Industrial and Power Generation.......................................................10-104
General Information..................................................................................6-53 QSK60 Marine Applications...............................................................10-104
with Mechanically Actuated Injector......................................................6-53 Install......................................................................................................10-94
with Electronically Actuated Injector......................................................6-54 Check for Correct Component.............................................................10-94
Measure...................................................................................................6-56 QSK45 and QSK60 Single Stage.........................................................10-95
with Mechanically Actuated Injector......................................................6-56 Bearing Housing Adjustment...............................................................10-95
Preparatory Steps.....................................................................................6-55 QSK60 Two Stage...............................................................................10-98
with Mechanically Actuated Injector......................................................6-55 Bearing Housing Adjustment...............................................................10-99
Setup........................................................................................................6-55 Left-Bank Rear or Right-Bank Front...................................................10-101
with Mechanically Actuated Injector......................................................6-55 Left-Bank Front or Right-Bank Rear...................................................10-102
Straight Thread Plug ..................................................................................17-6 Preparatory Steps...................................................................................10-88
Clean and Inspect for Reuse.....................................................................17-6 Industrial and Power Generation.........................................................10-88
Install........................................................................................................17-7 QSK60 Marine Applications.................................................................10-88
Remove....................................................................................................17-6 Remove..................................................................................................10-88
Supplemental Coolant Additive (SCA) .....................................................8-108 QSK45 and QSK60 Single Stage.........................................................10-88
Maintenance Check................................................................................8-108 QSK60 Two Stage...............................................................................10-89
Tap-Drill Chart - U.S. Customary and Metric ...........................................V-131 Left-Bank Rear or Right-Bank Front.....................................................10-89
General Information................................................................................V-131 QSK45 Single Stage...........................................................................10-91
Coolant Thermostat Housing Support .......................................................8-18 QSK60 Two Stage...............................................................................10-91
Finishing Steps.........................................................................................8-33 Left-Bank Front or Right-Bank Rear.....................................................10-91
Aftercooled Engines..............................................................................8-33 Turbocharger, Low Pressure .................................................................10-104
LTA......................................................................................................8-34 Check for Correct Component...............................................................10-106
QSK60 Marine Applications...................................................................8-35 Finishing Steps.....................................................................................10-109
Install........................................................................................................8-26 Install....................................................................................................10-107
Aftercooled Engines..............................................................................8-26 Preparatory Steps.................................................................................10-104
LTA......................................................................................................8-28 Remove................................................................................................10-105
Preparatory Steps.....................................................................................8-18 Water Pump ..............................................................................................8-113
Aftercooled Engines..............................................................................8-18 Assemble................................................................................................8-124
LTA......................................................................................................8-19 with Mechanically Actuated Injector.....................................................8-124
QSK60 Marine Applications...................................................................8-20 Disassemble...........................................................................................8-118
Remove....................................................................................................8-20 with Mechanically Actuated Injector.....................................................8-118
Aftercooled Engines..............................................................................8-20 New....................................................................................................8-120
LTA......................................................................................................8-21 Finishing Steps.......................................................................................8-133
Turbocharger ............................................................................................10-46 with Mechanically Actuated Injector.....................................................8-133
Assemble................................................................................................10-73 with Electronically Actuated Injector....................................................8-133
HX60 Turbocharger.............................................................................10-73 Inspect for Reuse....................................................................................8-117
HX82 Turbocharger.............................................................................10-80 with Mechanically Actuated Injector.....................................................8-117
HX83 Turbocharger.............................................................................10-86 with Electronically Actuated Injector....................................................8-117
Clean and Inspect for Reuse...................................................................10-66 Install......................................................................................................8-129
HX82 Turbocharger.............................................................................10-72 with Electronically Actuated Injector....................................................8-131
Disassemble...........................................................................................10-56 Machine..................................................................................................8-123
HX60 Turbocharger.............................................................................10-56 Measure..................................................................................................8-121
HX83 Turbocharger.............................................................................10-65 Preparatory Steps...................................................................................8-113
Fluorescent Dye Tracer...........................................................................10-46 with Mechanically Actuated Injector.....................................................8-113
Index
Page X-8
with Electronically Actuated Injector....................................................8-114

Remove..................................................................................................8-114
with Mechanically Actuated Injector.....................................................8-114
with Electronically Actuated Injector....................................................8-115
Water Manifold .........................................................................................8-109
Clean and Inspect for Reuse...................................................................8-111
QSK60 Marine Applications.................................................................8-111
Finishing Steps.......................................................................................8-113
Install......................................................................................................8-111
Preparatory Steps...................................................................................8-109
Remove..................................................................................................8-110
Water Pump Drive ......................................................................................9-23
Assemble..................................................................................................9-27
with Mechanically Actuated Injector......................................................9-27
Clean and Inspect for Reuse.....................................................................9-25
Disassemble.............................................................................................9-24
Finishing Steps.........................................................................................9-28
Initial Check..............................................................................................9-23
Install........................................................................................................9-28
Preparatory Steps.....................................................................................9-23
Remove....................................................................................................9-24
Weights and Measures - Conversion Factors .........................................V-132
Conversion Chart....................................................................................V-132
Service Manual

Service Manual
Cummins Inc.
Box 3005
Columbus, Indiana, U.S.A., 47202 QSK45 and QSK60 Series Engines
Registered Office Volume 2
Cummins Engine Company, Ltd
Unit 1-B Uniongate, Ridgeway Trading Estate,
Iver,
Buckinghamshire SL0 9HX,
England
Registration 573951 England
Copyright© 2006
Cummins Inc.
Volume 2
Bulletin 4021530
Printed in U.S.A. 28-FEBRUARY-2006 p167

Manual de Servicio Vol2 - QSK60

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Service Manual

QSK45 and QSK60 Series Engines

Copyright© 2006 Bulletin 4021530

Fuel System — Group 05 ......................................................................................................................... 5

Injectors and Fuel Lines — Group 06 ...................................................................................................... 6

Lubricating Oil System — Group 07 ........................................................................................................ 7

Cooling System — Group 08 .................................................................................................................... 8

Drive Units — Group 09 ........................................................................................................................... 9

Air Intake System - Group 10 ................................................................................................................... 10

Exhaust System — Group 11 ................................................................................................................... 11

Compressed Air System - Group 12 ........................................................................................................ 12

Electrical Equipment — Group 13 ............................................................................................................ 13

Engine Testing — Group 14 ..................................................................................................................... 14

Mounting Adaptations — Group 16 ......................................................................................................... 16

Miscellaneous - Group 17 ......................................................................................................................... 17

Service Literature ..................................................................................................................................... L

Component Manufacturers ....................................................................................................................... M

Section 5 — Fuel System — Group 05

with Mechanically Actuated Injector..............................................................................................................5-40

Tool No. Tool Description Tool Illustration

Fitting, Quick-Disconnect Male

Tool No. Tool Description Tool Illustration

Remote Starter Switch

AFC Barrel Puller

Injector Orifice Torque Wrench

Fuel Pump Lifting Bracket

Fuel Consumption (005-010)

Install a remote fuel tank (1) with enough capacity to run

After one hour of operation, weigh the remaining fuel, and

Fuel Pump (005-016)

Use a remote starter, Part Number 3376506, to crank the

Install the pressure gauge, hose, and quick fitting

Engine Cranking Fuel Pressure

Fuel Pump Components

Regulator Components - Front Top View

Regulator Components - Rear Bottom View

with Electronically Actuated Injector

Remove the four fuel pump mounting capscrews, two

with Electronically Actuated Injector

Remove the p-clip securing the wiring of the inlet metering

Remove the capscrew securing the upper fuel pump

Remove the two capscrews and spacers securing the

Remove the two capscrews (3) securing part 2 of the upper

Remove the four intake manifold capscrews.

Install the mounting bracket from the fuel pump lifting

Install the winch onto the mounting bracket. Install the

Install the lifting bracket on the fuel pump. Install and

Attach the lifting hook to the lifting bracket.

Attach a 1/2-inch breaker bar in the square notch of the

Lower the fuel pump using the hand winch.

Remove the four capscrews (1) securing the fuel pump

Remove the drive coupling.

Remove the four gear housing mounting capscrews.

Remove the mechanical fuel seal by hand with a twisting,

Use external snap ring pliers to remove the outer retaining

Use external snap ring pliers to remove the inner retaining

Use a screwdriver to remove the check valve locking ring.

Locate a punch in one of the slots of the stationary seal