40 Pages

Cylinder Head Changes Page 1 of 40
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Topic Number Revision Level Group Number
Date
02T2-1 MARCH 2002 02
Expiration Date (U.S. and Canada) Expiration Date (International)
Engine Family Fuel System

QSK45 QSK
QSK60 QSK
Design Application Market Application

Industrial All
Engine Serial Number Range
CPL
From To
Service/Parts Topics
Cylinder Head Changes

Publications Affected by This
Service/Parts Topic
Operation
Troubleshooting
Engine and Shop Other
and Repair
Maintenance
QSK45
4056471
QSK60 2
NOTE: Publications identified as Other

include the following:
1Master Repair Manual, 2Parts Catalog,
3Specifications Manual, 4Alternative
Repair Manual, 5Wiring Diagram,

6Features Manual
Warranty Impact
None The information in this document has no effect on current warranty coverages or
repair practices, nor does it authorize TRP or Campaign actions.
This service/parts topic provides a history of the changes made to the QSK45/60 cylinder
head. Also provided is updated parts information, which will be required during in-shop
rebuilds of QSK45/60 cylinder heads.
file:///C:/Users/Engine/FTSEARCH/tmp00000001.html 10/30/2018
The Tribaloy intake valve, Part Number 4016438, is faced with a durable, wear-resistant
material: Tribaloy. This valve is used on all QSK45/60 applications, including haul-truck
applications, and on applications with valve beat-in problems. When the intake valve is
used with rotators, it reduces the rate of intake valve beat-in. These high-load, constant-
speed applications include prime-power and base-load generator sets, marine applications,
some drilling machines, and hydraulic excavators.
CAUTION
Do not use the Tribaloy intake valve, Part Number 4016438, without the
Tribaloy intake valve insert, Part Number 4080326, and valve rotator,
Part Number 3085961. Do not use the Tribaloy intake valve in the
exhaust valve position. Incorrect use of this valve can cause engine
damage.
The valve head thickness of the Tribaloy intake valve, Part Number 4016438, must be
measured with the valve head thickness tool, Part Number 3823800. The intake valve head
thickness tool, Part Number 3375940, must not be used on the Tribaloy intake valve. If it is
used on the valve, the Tribaloy facing could be ground too thin.
The material of the intake valve, Part Number 4016438, is Tribaloy 400, which is denoted
with a "K."
Intake valve stem seal, Part Number 3170134, changed to Part Number 3408282. This
prevents excessive carbon build-up.
Pyromet with Stellite Face Exhaust Valve
Because of exhaust valve failures, early valves, Part Number 3090469, were changed to
Pyromet, Part Number 4065481, with a Stellite face on all QSKV engines. This valve has
greater high-temperature fatigue strength with resistance to face pitting and valve beat-in
and will provide improved durability. The engine serial number first is 33146911, July 2000.
Valve Identification
There are two methods to identify intake and exhaust valves; always use the part number
for identification when possible. Part numbers are stamped on the valve stem just above
the collet groove. A letter code, cast onto a recess on the combustion face of the valve
head, often can be used when the part number is illegible.
The material of the exhaust valve, Part Number 4065481, is Pyromet with a Stellite facing,
which is denoted with an "L." Before engine serial number 33146911, valve identification
was with an "S," which stood for Stellite 6 facing.
Valve Leakage Testing
Vacuum leakage-testing cup, Part Number 3823852, and seal, Part Number 3823853, were
released primarily for K Series engine cylinder heads. The vacuum leakage-testing cup and
seal will not determine if there is a leak between the valve insert and cylinder head.
Valve Spring Identification
The present valve spring used on the QSK45/60 cylinder head is a chromium silicon valve
spring, Part Number 3085962. This valve spring is identified by a blue-painted mark and is
classified as a beehive style of spring. Following are additional valve spring reuse
specifications: A bent, broken, or nicked valve spring mustnot be reused.
If a valve spring with a notch worn in the first active coil is reused, the ends of the valve
spring will wear into the first coil, creating a worn notch in the material. If a worn notch can
be seen or felt, the valve spring mustnot be reused. Often a valve spring that has these will
make a clicking noise. To check for the noise, compress the valve spring by hand until the
end of the first coil is completely collapsed. A large notch will cause a clicking noise. Listen
for the noise at both ends of the valve spring. Refer to Table 1 below for valve spring load
reuse guidelines.
Table 1, Spring Load/Height Verification Values

Load at 71.882 mm [2.83 in] = 77.111 kg ±4.083 kg [170 lb ±9 lb]
Load at 57.226 mm [2.253 in] = 158.757 kg ±8.165 kg [350 lb ±18 lb]
(-8% relaxation) = 138.346-kg [305-lb] minimum load
Valve Spring Rotator
The valve spring rotator is designed to decrease valve guide wear. It lets the valve spring
rotate the valve naturally as the valve opens and prevents the valve from rotating back into
the original position. The valve spring rotator fits between the cylinder head and the valve
spring and adds approximately 10.3 mm [0.406 in] to the valve spring assembly height.
When installing a QSKV valve spring rotator, Part Number 3085961, a rotation check of the
valve spring rotator in the free state can not be done.
When turning the valve spring rotator by hand, it can be difficult to turn or can not turn at
all. Even if a valve spring rotator is difficult to turn by hand, it is not "seized"; such difficulty
is common. Slight dimensional variations of components can make some valve spring
rotators seem tight; but when the valve spring load is applied, the valve spring rotator
compresses, which provides more clearance between the collar and the body of the valve
spring rotator, allowing it to rotate freely.
Fig. 1, Rotator Installed over the Valve Guide with the Spring-Pilot Flange Face-up
Valve Crossheads and Guides
Cummins has released a stemless valve crosshead, Part Number 3085964, for use on all
QSKV 45/60 engines. No adjustment is required, and it can be installed with the small
pocket on either valve. Adjustment of the rocker lever to crosshead lash remains
unchanged.
Intake valve seat, Part Number 4080223, changed to Part Number 4080326 to correct
valve-to-insert overhang issues. Exhaust valve seat, Part Numbers 3171702 to 4080333,
introduced to correct valve-to-insert overhang issues, is engine serial number first
33149408. The intake seat is made of Tribaloy 400, and the exhaust seat is made of Stellite
3.
Table 2, QSK45 and QSK60 Cylinder Head Part Numbers

Item Present Part Number Old Part Number
Head assembly 4080358 4080224
Head casting 4080225 N/A
Dowel pin 3900257 N/A
Exhaust seat 4080333 3171702
Exhaust valve 4065481 (4025070*) N/A
Exhaust valve stem seal 4080343 N/A
Expansion plug 3007635 N/A
Expansion plug (1/4-in) 203933 N/A
Expansion plug (7/8-in) 205401 N/A
Intake seat 4080326 4080223
Intake valve 4016438 (3800955*) N/A
Intake valve stem seal 3408282 3170134
Valve collet 3081534 N/A
Valve guide 3170135 N/A
Valve spring 3085962 N/A
Valve spring retainer 3331752 N/A
Valve spring rotator 3085961 N/A
Pipe plug 3278039 N/A
*With collets
N/A = Not applicable
Service Tools
(022-001)
Cylinder Head
Cylinder Head Capscrew Length

Tool Number Gauge
3163328 Used to check the length of the cylinder

head capscrews.
Valve Spring Compressor Kit

Tool Number
Compress the valve spring to allow the
valve to be removed or installed. Use
3163606
with valve spring compressor plate, Part
Number 3163177.
Valve Spring Compressor

Tool Number
Compress the valve spring to allow the
3375960 valve to be removed or installed. This tool
is air-operated.
Hydrostatic Tester
Tool Number
Check for coolant leaks in the cylinder
head. Requires shop air, a lifting hoist, a
ST-1012
water tank, and the appropriate test
adapter plate and o-ring.
Water Test Plates

Tool Number
Check for coolant leaks in the cylinder
head. Use with Part Number ST-1012,
3375070
hydrostatic tester. Use with Part Number
3375071, water test plate o-rings.
Depth Gauge Assembly

Tool Number
Measure cylinder liner counterbore ledge
3823495
angle and injector protrusion.
Tool Number Valve Seat Grinding Machine
ST-685 Used to grind the valve seats.
Valve Vacuum Tester

Tool Number
Used to test the valve to valve seat
ST-1257
connection.
Tool Number Exhaust Valve Seat Extractor
ST-1323-1 Used to remove the valve seats.
Tool Number Intake Valve Seat Extractor
3376799 Used to remove the valve seats.
Tool Number Valve Spring Tester
3375182 Used to test the valve springs.
Valve Lapping Compound

Tool Number
An abrasive compound used to lap the
3375805
valves.
Valve Head Thickness Gauge

Tool Number
Used to check the intake and exhaust
3824861
valve head thickness after reconditioning.
Water Tube Driver

Tool Number
Used to push the tubes toward the front
and rear of the engine and to push the
ST-1319
tube until it clears the rocker lever
housing.
Cylinder Head - Overview

(002-999)
Table of Contents
General Information
General Information TOC
The QSK45 and QSK60 engines use a

torque-turn method for tightening all
cylinder head capscrews. This method
provides better control of the load on the
capscrews. Next Summary 1
The QSK45 and QSK60 utilize a stemless

crosshead design. This design does not
require adjustment.
The QSK45 and QSK60 cylinder head Previous Summary 2

gasket has been altered because of
changes to the shape of the push tube hole
Next Summary 3
and a seven-bolt-per-head block design.
The grommets have been built into the
gasket.
1. Capscrew, 12-point
2. Gasket, cylinder head
3. Seal, valve stem
4. Collet, valve
5. Valve, exhaust
6. Valve, intake
7. Rotator, valve
8. Spring, valve
9. Pin, groove
10. Inserve, valve, exhaust
11. Inserve, valve, intake
12. Plug, expansion
13. Plug, expansion
14. Plug, expansion
15. Plug, threaded
16. Plug, threaded
17. Head, cylinder
18. Guide, valve stem
19. Retainer, valve spring
20. Plug, pipe.
Cylinder Head
(002-004)
Table of Contents
Summary
Remove
Disassemble
Clean
Inspect for Reuse
Magnetic Crack Inspect
Grind
Valves
Valve Seat
Lap
Pressure Test
Vacuum Test
Assemble
Install
Summary
Measure the inside diameter

Stepblock and depth of insert bore in See detail.
head.
If the inside diameter is not

Stepblock within specification, use an
oversize seat.
Stepblock
Machine valve seat insert 0.064 mm to 0.114 mm
bore. [0.0025 in to 0.0045 in].
Remove TOC
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment Previous Summary 1
before servicing the batteries. To
reduce the possibility of arcing, remove Next

the negative (-) battery cable first and
attach the negative (-) battery cable
last.
Disconnect the batteries or air supply to

the air starter to prevent accidental
engine starting.
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.
Previous Summary 2
WARNING Next Summary 3
Coolant is toxic. Keep away from

children and pets. If not reused,
dispose of in accordance with local
environmental regulations.
NOTE: On two-loop cooling systems,

drain both of the cooling systems.
Drain the cooling system. Refer to

Procedure 008-018.
Remove the crankcase breathers. Refer to

Procedure 003-001.
Previous
Next
Remove the lock plates from the heads of the

exhaust manifold hex head bolts.
Remove the exhaust manifold bolts from the
cylinder head being removed. Loosen the Previous

exhaust manifold bolts from the other heads on
the same manifold section. Refer to Procedure Next
011-007.
Disconnect the wiring harness in the areas that

restrict access to the cylinder head.
Previous
Next
Remove the air crossover. Refer to Procedure

010-002.
Previous
Next
WARNING
This assembly weighs 23 kg [50 lb] or more.
To reduce the possibility of personal injury, Previous
use a hoist or get assistance to lift this
assembly.
Next
Remove aftercooler assembly. Refer to

Procedure 010-002.
Remove the fuel manifold. Refer to Procedure

006-022. Inspect the gaskets; discard any that
are not reusable.
Previous
NOTE: The QSK45 contains six gaskets per
bank, and the QSK60 contains eight gaskets Next
per bank.
Remove the rocker lever cover. Refer to

Procedure 003-011.
Previous
Next
NOTE: Mark each rocker lever assembly to

designate the cylinder head from which the
rocker lever assembly was removed.
Previous
Remove the rocker levers. Refer to Procedure
003-009. Next
Remove the push rods and the crossheads.
NOTE: It is a good service practice to mark

the push rods so they can be installed in Previous
their original positions.
Next
Remove the clips holding the water tubes in

position.
Use the water tube driver, Part Number ST-

Previous
1319. Push the tubes on the right bank toward
the rear of the engine. Push the tubes on the
left bank toward the front of the engine. Push Next
the tube until it clears the rocker lever housing.
Remove the rocker lever housing. Refer to

Procedure 003-013.
Remove and discard the gasket. Previous
Next
Remove the injector. Refer to Procedure 006-

026.
Previous
Next
WARNING
This component weighs 23 kg [50 lb] or more. Previous

To reduce the possibility of personal injury,
use a hoist or get assistance to lift this Next
component.
Remove the seven cylinder head mounting

capscrews.
Remove the cylinder head.
Remove and discard the cylinder head gasket.
Disassemble TOC
CAUTION
The valve springs are under compression. Be
cautious when using the valve spring
compressor. Personal injury can result if the
tool slips from your hands.
Use a valve spring compressor, Part Number

3163606 or Part Number 3375960, or the
equivalent. Valve spring stand, Part Number
ST-1022, and the compressor plate, Part Previous
Number 3375043, can be used to compress all
four springs at the same time.
Next
Mark the valves for location prior to removal.

The intake and exhaust valves are different.
This practice will aid the assembly procedure.
Remove the parts.
1. Collet, valve
2. Retainer, valve spring
3. Spring, valve
4. Guide valve spring/rotator valve
5. Valve.
Discard the valve springs, collets, and valve
rotators.
Use a drill, a sheet metal screw, and the

following parts from the light-duty puller kit, Part
Number 3375784, to remove the cup plugs.
Previous
Slide hammer
Hook. Next
Remove and discard the 10 cup plugs.
Cup plugs must be removed from the head

casting for cleaning purposes. Previous
Next
CAUTION
If a valve guide is replaced, the valve seat
insert for the valve guide must be ground; or
severe engine damage can result. Previous
Only replace the valve guide if it is not within Next

specifications.
Use an arbor press and a suitable mandrel (1)

to remove the worn valve guide (2).
Use a valve seat grooving kit, Part Number

3376405, or equivalent.
Machine a groove in the seat as close to the Previous

bottom of the bore as possible. This will allow
the valve seat extractor to be used. Next
Use the specified valve seat extractor. Use an

extractor knocker assembly, Part Number
3376617.
Exhaust seat - Part Number ST-1323-1

extractor
Previous
Intake seat - Part Number 3376799 Next

extractor.
NOTE: Only the intake ports contain

antiswirl plates.
Discard the antiswirl plates.
Clean TOC
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for use. Previous
Wear goggles and protective clothing to
reduce the possibility of personal injury. Next
Clean the cylinder heads, capscrews, valve

spring retainers, and valves with solvent.
Inspect for Reuse TOC
Check for cracks on the combustion surface.
NOTE: If a crack around the injector bore

exceeds the maximum length, the cylinder
head must be replaced.
Injector Bore Allowable Crack Length

mm in Previous
6.4 MAX 0.252
Next
NOTE: Both ends of a crack between the
valve must be visible. If one end of a crack

extends into the valve seat bore (behind the
valve seat), the condition of the cylinder
head is questionable. To be sure that the
cylinder head is reusable, remove the valve
and valve seat.
Use a straightedge to measure the flatness of

the head gasket surface.
The head must be resurfaced if a feeler gauge Previous

larger than 0.08 mm [0.003 in] will fit between
the straightedge and the cylinder head. Next
The head can be resurfaced as long as the

head thickness (1) measurement is within
specifications.
Minimum Head Thickness (1)

Previous
mm in
152.4 MIN 6
Next
If the head is resurfaced, make certain that the

injector protrusion and the valve depth in the
head are adjusted properly.
Clean the valve seat insert bore.
Check the length of any cracks extending into

the valve seat insert bore.
NOTE: The cylinder head must be replaced if Previous

a crack extends into the bottom of the bore.
Next
NOTE: At times it is possible to remove the
crack by machining the head to use an
oversize valve seat insert.
Using the torque plus angle method of

installation places the cylinder head capscrew
beyond the yield point and permanently
stretches the capscrew. These capscrews can
be reused throughout the life of the engine
unless the capscrew exceeds the specified free
length. Previous
The free length must be checked to avoid Next

bottoming in the block during installation and to
make sure the capscrew still has the proper
strength.
A cylinder head capscrew length gauge has

been developed to check the capscrew free
length.
To check the capscrew free length, place the

head of the capscrew in the slot with the flange
against the base of the slot.
Previous
Next
If the end of the capscrew touches the foot of

the gauge, the capscrew is too long and must
be discarded.
Previous
Next
If there is clearance between the end of the

capscrew and the bottom base of the tool, the
capscrew is acceptable for reuse.
Previous
Next
The capscrew can also be checked using a set

of calipers. The maximum allowable free length
is measured from the bottom of the flange to the
end of the capscrew (dimension X).
Previous
Cylinder Head Capscrew Free Length
mm in Next
207.3 MAX 8.161
Inspect the injector bore for cracks or other
damage.
Previous
Next
Apply a thin coating of Prussian blue on the

sealing ring.
Previous
Next
CAUTION
Support the cylinder head to reduce the risk of
damage to the injector tip that protrudes from
the combustion face.
Previous
Install the injector and injector hold-down clamp.

Next
Tighten the hold-down capscrew.
Torque 16 [142 in-

Value: n.m lb ]
Use a gauge block, Part Number 3164438, or

equivalent to measure the injector protrusion.
Measure as shown in the illustration.

Previous
Injector Protrusion
mm in Next
2.42 MIN 0.095
2.92 MAX 0.115
If the protrusion is not within specifications, use

an oversize sealing ring. Sealing rings are
available in various sizes.
Injector Sealing Rings Previous
mm in
Next
Wall Thickness 0.343 MIN 0.0135
0.419 MAX 0.0165
Protrusion Change 0.00 NOM 0.000
0.546 MAX 0.0215
0.673 MAX 0.0265
0.800 MAX 0.0315
NOTE: The 0.343/0.419 mm [0.0135/0.0165 in]

is the standard sealing ring.
Remove the injector hold-down clamp

capscrew.
Remove the injector and injector hold-down Previous

clamp.
Next
Inspect the contact pattern in the injector bore.

A blue band 1.52 mm [0.060 in] wide and 360
degrees' full circumference minimum must be
visible.
Previous
NOTE: If the pattern does not meet the
specification, clean the injector bore with a
Next
tapered brush. Inspect the seating pattern
again. The cylinder head must be replaced
or repaired if it is not within specfications.
With the valve seats removed, measure the

inside diameter and the depth of the insert bore
in the head.
Valve Seat Bore Measurements

mm in
Previous
Intake Diameter 60.37 MIN 2.377
60.40 MAX 2.378
Next
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
If the inside diameter is not within

specifications, use an oversize seat.
NOTE: Oversize valve seat inserts are

available in the following sizes. Machine the
valve seat insert bore in the head. A press fit
within 0.064 to 0.114 mm [0.0025 to 0.0045
in] between the valve seat insert and the
valve seat insert bore must be maintained. Previous
Next
Outside Diameter Depth (thickness)
Oversize Oversize
0.25 mm [0.010 in] Standard
0.51 mm [0.020 in] 0.13 mm [0.005 in]
0.76 mm [0.030 in] 0.25 mm [0.010 in]
1.02 mm [0.040 in] 0.38 mm [0.015 in]
Inspect the collet grooves for wear.
Measure the outside diameter of the valve stem.
Valve Stem Outside Diameter Previous
mm in
Next
10.490 MIN 0.4130
10.510 MAX 0.4138
Use a valve head checking tool, Part Number

3824861, to measure the head thickness of the
valve.
Previous
Position the tool over the valve, and place on a
flat surface; if the bottom of the tool touches the Next

flat surface, the valve must be replaced.
If a valve head checking tool is not available,

put the valve on a flat surface. Check the height
of the outside diameter.
Valve Head Thickness (at the outside

diameter) Previous
mm in
3.94 MIN 0.155 Next
NOTE: This type of a check is not as

accurate as using the valve head checking
tool.
Measure the inside diameter of the valve guide

bore.
If the bore is not within specifications, ream the

bore for oversize valve guides.
Valve Guide Bore Inside Diameter

mm in Previous
21.438 MIN 0.8440
21.463 MAX 0.8450 Next
Valve guides are available in two oversizes:

0.25 mm [0.10 in] and 0.38 mm [0.015 in].
Ream the valve guide bore to maintain a press
fit with 0.28 and 0.067 mm [0.00111 and 0.0026
in] between the valve guide and the valve guide
bore.
Magnetic Crack Inspect TOC
CAUTION
Always demagnetize and clean the parts Previous

thoroughly after a magnetic particle
inspection. The iron fragments can damage Next
the internal engine components.
Use the magnetic particle residual method.

Check the valves for cracks.
NOTE: Check the intake valves with the coil

and head shot methods (the coil shot first).
Check the exhaust valves with the coil shot
method.
Use a 305-mm [12-in] minimum diameter coil.
Coil Shot Amperage (ampere turns)

MIN 400 D.C. or rectified A.C.
MAX 800 D.C. or rectified A.C.
NOTE: An ampere turn is an electrical Previous

current of 1 ampere flowing through the coil,
multiplied by the number of turns in the coil.
Next
NOTE: A broad, fuzzy pattern will appear at
the welded joint on the exhaust valves. This
is normal. If there is a distinct line in the
broad, fuzzy pattern, the valve must be
replaced.
Head Shot Amperage (ampere)

MIN 500 D.C. or rectified A.C.
Previous
MAX 700 D.C. or rectified A.C.
Next
Acceptance criteria (intake and exhaust valves):
1. Indications less than 38.1 mm [1.5 in] in

length are acceptable. More than five
indications, spaced closer than 3 mm Previous
[0.118 in], are not acceptable.
2. No indications are acceptable.
Next
3. Only longitudinal indications are

acceptable.
4. No indications are acceptable.
Grind TOC
Valves
NOTE: Do not use aluminum oxide cloth or

sandpaper to clean the valves.
Use Scotch-Brite®, Part Number 3823258, to

clean the valve stems. Clean the valve stems.
Clean the carbon deposits from the valve face
and the head. Previous
NOTE: The valves must be clean and free of Next

carbon deposits before they are ground.
Valves can be cleaned by the bead blasting
method in the head area only. If the stems
are bead blasted, the valve should not be
reused because surface finish will be
damaged.
Use a valve facing machine, Part Number

3376256, or equivalent, to grind the face of the
valve.
Previous
NOTE: Follow the instructions supplied with
the valve facing machine for the correct Next
setup before grinding the valves.
Use solvent to clean the metal particles from the

valve.
Dry with compressed air. Previous
Next
Use a valve head checking tool, Part Number

3824861, to measure the head thickness of the
valve.
Previous
Position the tool over the valve, and place on a
flat surface; if the bottom of the tool touches the Next
flat surface, the valve must be replaced.
Use a lead pencil or Prussian blue to mark

across the valve face as shown. Install the valve
in the valve guide.
Hold the valve against the valve seat, and rotate

the valve backward and forward three or four
times.
Previous
Correct contact against the valve seat will break
the marks on the valve face. Next
NOTE: Valves and valve seats that are

correctly machined do not require the use of
lapping compound to make an airtight seal.
If lapping compound is required, inspect the
adjustments of the facing machine and the
condition of the grinding stone.
Valve Seat
Identify the correct valve seat insert.
Top picture: Intake port seat.

Bottom picture: Exhaust port seat.
Both the intake and the exhaust port seats Previous

must be installed with the 30-degree angle
positioned as shown. Next
NOTE: Exhaust seats are color coded blue to

identify the 30-degree angle side of the seat.
Use an arbor press and a mandrel. Install the

insert into the head.
Previous
Next
Use a valve seat grinding machine, Part

Number ST-685, or equivalent. Use a valve
guide arbor set, Part Number 3375946, or
equivalent.
Grind the valve seat insert to the angle shown.
Measure the width. Previous
Valve Seat Width Next

mm in
Intake 3.05 MIN 0.120
3.55 MAX 0.140
Exhaust 1.52 MIN 0.060
2.54 MAX 0.100
If the width of the valve seat is not within

specifications, remove surface material on the
inside diameter and the outside diameter to
decrease the width of the seat.
Previous
NOTE: If the valve seat specifications are not
obtained by grinding, the insert must be Next
replaced.
Lap TOC
Use a fine lapping compound, Part Number

3375805, or equivalent. Apply a thin and even
coating on the valve.
Use a power or a hand suction lapping tool to

provide pressure in the center of the valve. Previous
Turn the valve backward and forward. Next

Continue lapping until the compound shows a
continuous contact pattern on both the valve
seat insert and the valve.
CAUTION
Lapping compound is an abrasive material.
Failure will result if the cylinder head, the Previous
valves, and the valve seats are not cleaned
thoroughly. Next
Clean the lapping compound from the parts.
Pressure Test TOC
Remove the valves. Refer to Procedure 002-

020.
Previous
Next
Use a hydrostatic tester, Part Number ST-1012,

with a water test adapter plate, Part Number
3375070, to test the cylinder head.
Previous
Next
Remove one of the two plugs from the pressure

regulator.
Install the pressure gauge in the regulator. Previous
Turn the adjusting knob on the regulator Next

counterclockwise as far as it will turn.
Install the pressure regulator between the air
supply and the quick disconnect fitting.
NOTE: The arrow on the top of the pressure

regulator must point in the direction of the Previous
airflow (toward the quick disconnect fitting).
Next
Use adapter (4), Part Number 3375070, and

plate (5), Part Number 3375071, to test the
head.
Previous
Next
With the head as shown, assemble the adapter

plates. The guide pins on the lower plate must
go in the water passages. The o-ring on the
upper plate creates a seal on the upper water Previous
passage. The other end of the plate goes into
the injector bore. Next
Put the clamping assembly (1) over the head

and adapters. The guide pins on the clamp
must go into the holes in the lower adapter
plate.
Previous
Tighten the clamp on the head.
Next
Connect the wire hose to the upper adapter
fitting.
Attach the lifting arm (2) to the clamp assembly

with the lock pins.
NOTE: One mounting location on each piece Previous

is color-coded red.
Next
Adjust the air pressure.
Cylinder Head Pressure Test: Air

Pressure
kpa psi Previous
552 MAX 80
Next
Lower the head into a tank of water.
Bubbles will indicate an air leak.
If the cylinder head leaks, it must be repaired or

replaced.
Install the cylinder head valves. Refer to

Procedure 002-020.
Previous
Next
Vacuum Test TOC
The valve vacuum tester, Part Number ST-

1257, can be used to test all Cummins engine
models.
NOTE: Before using the tester, test the

leakage shutoff valve. If the valve is dirty or
worn out, it will produce a false leakage
measurement on the gauge.
Previous
Check the valve:
Next
Open the shutoff valve.
Turn on the vacuum pump.
Place the cup against a smooth surface.
Close the shutoff valve.
Turn off the vacuum pump.
Wait approximately 10 seconds.
The gauge must not drop more than 7
kPa [2 in Hg].
The valve and the valve seats must be clean
and dry.
Choose the correct cup for the engine model

that is to be tested. Previous
Next
Choose the correct seal.
1. Intake valve
2. Exhaust valve.
NOTE: A new seal is available that has the Previous

appearance of the seal on the left (1), but it
is manufactured from a softer material. The Next
new seal is to be used on cylinder heads
that are machined with a relief valve between
all four bores.
Install the seal and the cup to the vacuum line

(hose).
Previous
Next
Cover the valve with the cup and the seal. The
seal must have a tight contact on the cylinder
head around the valve.
Previous
To check the exhaust valves, the seal must
completely fill the milled area between the Next
exhaust valves.
Move the toggle switch (3) to the ON position.
Turn the vacuum control valve (4) to the OPEN

position. Previous
Next
When the gauge indicates between 10 in Hg

and 25 in Hg, turn the vacuum control valve (4)
to the CLOSED or OFF position. Previous
Turn the toggle switch (3) to the OFF position. Next
Use a stopwatch. As the vacuum gauge needle

moves counterclockwise, start the timing
when the needle on the gauge points to 18 in
Hg.
Stop the timing when the needle on the gauge

points to 8 in Hg.
The elapsed time for the gauge to move

between the specified readings must be 10
seconds or more.
If the elapsed time is less than 10 seconds,

perform the following checks:
Repeat the test to be certain that the

equipment is functioning properly.
Use a mallet to hit the valve stem lightly to Previous
be certain that the valve is sealing. Repeat
the test.
Next
Apply a thin coating of grease on the
outside diameter of the insert and the
valve head. Repeat the vacuum test. The
grease pattern will show the point of
leakage.
If the leakage is between the insert and
the head, the insert must be replaced.
CAUTION
The cylinder head must be disassembled and
cleaned after any grinding or cutting
procedures to reduce the possibility of
damage.
If the leakage is between the valve and the

insert, one of the following procedures must be
performed:
Lap valve to seat

Grind the valves
Grind the valve seat.
Assemble TOC
Use cup plug Loctite® sealant, Part Number

3375068.
Previous
Next
NOTE: Use the correct expansion plug driver

to make sure the expansion plugs are
installed to the correct depth in the cylinder
head. Drive the plug until the shoulder of the
driver contacts the cylinder head.
Part Number 3376813, expansion plug

driver Previous
Part Number 3376814, expansion plug
driver. Next
NOTE: A cup plug driver handle, Part

Number 3376795, must be used with Part
Number 3376813 and Part Number 3376814,
expansion plug driver.
Install 10 new cup plugs.
Use a hydrostatic tester to check for evidence of

leaks around cup plugs.
Previous
Next
NOTE: When turning the rotator by hand, it

may turn roughly, feel difficult to turn, or not
turn at all. This is normal until the rotator is
installed; after installation it will rotate
freely.
Previous
The rotator must be soaked in clean engine oil
for at least 15 minutes prior to installation. Next
The rotator must be installed over the valve

guide with the spring pilot flange face-up, as
shown in this illustration.
CAUTION
Make certain that the mandrel does not
damage the top of the valve guide. If the guide
is damaged, the valves may stick, causing
severe engine damage.
Use an arbor press and a suitable mandrel (6)

Previous
to install the valve guide.
Next
Install the valve guide (7) to the specified
height.
Valve Guide Height

mm in
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
Inspect the valve guides for chips and cracks.
Use a ball gauge or a dial bore indicator to

measure the inside diameter of the valve
guides.
Previous
Measure the inside diameter.
Next
Valve Guide Inside Diameter (installed)
mm in
10.551 MIN 0.4154
10.589 MAX 0.4169
Measure the valve seat to the valve guide

concentricity.
NOTE: The seat and guide must be

concentric.
Valve Seat to Guide Concentricity Previous
mm in
Next
0.05 MAX 0.002
CAUTION
To avoid the valve seal fitting loosely on the
valve guide, do not lubricate the valve seal.
The seal must be installed dry. Previous
NOTE: If the valve stem seal is installed too Next

far on the guide, the seal will fail
prematurely, causing excessive oil
consumption. The gauge allows correct
positioning of the seal.
Place the valve stem seal depth gauge over the

valve guide and move the smaller slot of the
gauge into the valve guide groove area over the
shoulder.
Previous
Using a 1/2-inch-drive 5/8-inch or 16-mm
socket, drive the valve stem seal over the valve Next
guide until it is positioned against the depth
gauge, Part Number 3164462.
Slide the valve stem seal depth gauge to the

large end of the slot and remove the gauge,
passing over the valve stem seal outside
diameter. Previous
Next
CAUTION
The valve springs are under compression.
Use caution when using the valve spring
compressor. Personal injury can result.
Use a valve spring compressor - Part Number

3163606 or 3375960, or equivalent. Valve
spring stand, Part Number ST-1022, and Previous

compressor plate, Part Number 3163177, can
be used to compress all four springs at the Next
same time.
NOTE: The valve rotator must be soaked in

clean engine oil for at least 15 minutes prior
to installation.
Assemble the parts in the following order:
Valve (5)
Valve rotator (4)
Valve stem seal (6)
Valve spring (3)
Valve spring retainer compressor (2)
Two new valve collets (1).
Compress the valve spring and install the

following parts:
Valve spring retainer (2)

New valve collets (1).
Use a valve vacuum test, Part Number

3824277, or equivalent.
If the valve to the valve seat contact pattern

looks OK and the valve still does not pass the
vacuum test, perform the following check.
Apply a thin coating of grease on the outside Previous

diameter of the insert and the valve head.
Repeat the vacuum test. The grease pattern will Next
show the point of leakage.
If the leakage is between the insert and valve,

refer to Procedure 002-020.
If the leakage is between the insert and the

head, the insert must be replaced.
Install TOC
CAUTION
Using power or pneumatic tools to clean the
head gasket surface on the cylinder block can Previous
damage the cylinder liners.
Next
Clean the top of the cylinder block and the
cylinder liners. Refer to Procedure 001-026.
Measure the liner protrusion. Refer to

Procedure 001-064.
NOTE: If the liner protrusion is not correct, it Previous

must be adjusted before installing the
cylinder head. Refer to Procedure 001-028. Next
Inspect the cylinder block to determine whether

an oversize or a standard-size head gasket is
required.
NOTE: An oversize head gasket is often Previous

required on blocks that have had material
removed from the top surface of the block. Next
Check the block for markings indicating an
oversize gasket is required.
NOTE: The word TOP, stamped on top of the

head gasket, must be visible after the gasket
is installed.
Previous
Next
WARNING
This component weighs 23 kg [50 lb] or more.
component.
Next
Install the cylinder head gasket, using the dowel
pins for alignment.
WARNING
This component weighs 23 kg [50 lb] or more.
To reduce the possibility of personal injury,
component.
Previous
Install the cylinder head. It must slide easily
over the dowel pins.
Next
Lubricate the capscrew head flange with clean
engine oil.
Lubricate the capscrew threads with clean

engine oil. Allow excess oil to drip off the
capscrews before installing in the block.
Install the capscrews.
NOTE: When using torque plus angle, the

tolerance on the 90-degree angle of rotation
is 1½ flats (90 degrees ±5 degrees). If the
capscrew is rotated beyond two flats, do not
loosen the capscrew. The clamp load is still
acceptable; however, rotating the capscrew
beyond two flats causes additional stretch
and reduces the life of the capscrew. With
Previous
proper tightening, the capscrew can
typically be reused for the life of the engine.
Next
After all capscrews on one head have been
tightened to 300 N•m [236 ft-lb], they must be
rotated in the tightening direction an additional
90 degrees. Rotate the capscrew until the mark
on the cylinder head (1) is between the next two
marks joined by an arc ( more than one flat and
less than two flats).
The markings on the head of the flange head

capscrews serve as an aid during installation.
After tightening the capscrew to 300 N•m [2221
ft-lb], mark the cylinder head (1) adjacent to one Previous
of the two single marks on the capscrew head.
Next
Tighten the cylinder head mounting capscrews

using the following steps and in the sequence
shown.
Torque 70 [52 ft-

Value: n.m lb ]
Previous
Torque 200 [148 ft-
Value: n.m lb ] Next
Torque 300 [221 ft-
Value: n.m lb ]
Turn another 90 degrees
(clockwise)
Install the injectors. Refer to Procedure 006-

026.
Previous
Next
Install the rocker lever housings, push rods, and

crossheads. Refer to Procedure 003-013.
Previous
Next
Using vegetable oil, lubricate the water transfer

tube o-rings (2).
NOTE: Use of other lubricants, such as

engine oil, will cause the o-rings to swell. Previous
Install the water tube o-rings (2). Next
Install the water transfer tube (1).
NOTE: The push rods must be seated
correctly in the cam followers. Previous
NOTE: The injector push rods are thicker in Next

the middle. The valve push rods are the
same for both intake and exhaust.
Using clean engine oil, lubricate the sockets in

the cam followers.
Install the push rods in the same location from

where they were removed.
Lubricate the crosshead pockets with clean

engine oil.
Install the valve crossheads.
Install the rocker levers. Refer to Procedure

003-009.
Previous
Next
Adjust the valves and injectors. Refer to

Procedure 003-006.
Previous
Next
NOTE: Do not use gasket cement. It will

prevent the gasket from sealing properly.
Edge-molded gaskets do not require sealant.
Previous
Install the rocker lever cover. Refer to
Procedure 003-011. Next
Install the fuel manifold. Refer to Procedure

006-022.
Previous
Next
WARNING
This assembly weighs 23 kg [50 lb] or more.
assembly.
Next
Install the aftercooler assembly and the air

crossover. Refer to Procedure 010-002.
NOTE: The embossed bead on the exhaust

manifold gasket must face away from the
cylinder head.
Previous
Install the exhaust manifold. Refer to Procedure
011-007. Next
WARNING
Batteries can emit explosive gases. To reduce
the possibility of personal injury, always
ventilate the compartment before servicing the Previous
batteries. To reduce the possibility of arcing,
remove the negative (-) battery cable first, and Next
attach the negative (-) battery cable last.
Connect the batteries or air starter supply line.
Fill the cooling system(s). Refer to Procedure

008-018.
Operate the engine to 71°C [160°F] minimum

Previous
coolant temperature and check for leaks.
Last Modified: 01-Feb-2002
Copyright© 2002
Cummins, Inc.
All rights reserved

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Cylinder Head Changes Page 1 of 40

Engine Family Fuel System

Design Application Market Application

Cylinder Head Changes

NOTE: Publications identified as Other

Repair Manual, 5Wiring Diagram,

Pyromet with Stellite Face Exhaust Valve

Valve Leakage Testing

Valve Spring Identification

Table 1, Spring Load/Height Verification Values

Valve Spring Rotator

Valve Crossheads and Guides

Table 2, QSK45 and QSK60 Cylinder Head Part Numbers

N/A = Not applicable

Cylinder Head Capscrew Length

3163328 Used to check the length of the cylinder

Valve Spring Compressor Kit

Valve Spring Compressor

Water Test Plates

Depth Gauge Assembly

Tool Number Valve Seat Grinding Machine

ST-685 Used to grind the valve seats.

Valve Vacuum Tester

Tool Number Exhaust Valve Seat Extractor

ST-1323-1 Used to remove the valve seats.

Tool Number Intake Valve Seat Extractor

3376799 Used to remove the valve seats.

Tool Number Valve Spring Tester

3375182 Used to test the valve springs.

Valve Lapping Compound

Valve Head Thickness Gauge

Water Tube Driver

Cylinder Head - Overview

General Information TOC

The QSK45 and QSK60 engines use a

capscrews. Next Summary 1

The QSK45 and QSK60 utilize a stemless

The QSK45 and QSK60 cylinder head Previous Summary 2

Measure the inside diameter

If the inside diameter is not

reduce the possibility of arcing, remove Next

Disconnect the batteries or air supply to

WARNING Next Summary 3

Coolant is toxic. Keep away from

NOTE: On two-loop cooling systems,

Drain the cooling system. Refer to

Remove the crankcase breathers. Refer to

Remove the lock plates from the heads of the

Remove the exhaust manifold bolts from the

cylinder head being removed. Loosen the Previous

Disconnect the wiring harness in the areas that

Remove the air crossover. Refer to Procedure

Remove aftercooler assembly. Refer to

Remove the fuel manifold. Refer to Procedure

Remove the rocker lever cover. Refer to

NOTE: Mark each rocker lever assembly to

Remove the push rods and the crossheads.

NOTE: It is a good service practice to mark