QSV27-36 Troubleshooting and Repair - 4021310

Troubleshooting and Repair Manual
QSV27 and QSV36 Series Engines
Copyright 2001 Bulletin No. 4021310

Cummins Inc. Printed 10/01
All rights reserved
Foreword
This manual contains information for the correct operation and maintenance of your Cummins engine. It also includes important
safety information, engine and systems specifications, troubleshooting guidelines, and listings of Cummins Authorized Repair
Locations and component manufacturers.
Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i - Introduc-
tion.
Keep this manual with the equipment. If the equipment is traded or sold, give the manual to the new owner.
The information, specifications, and recommended maintenance guidelines in this manual are based on information in effect at
the time of printing. Cummins Inc. reserves the right to make changes at any time without obligation. If you find differences
between your engine and the information in this manual, contact your local 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 were used to produce this engine. 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
Introduction .............................................................................................................................................................. i
Engine Identification ................................................................................................................................................ E
Complete Engine - Group 00 ................................................................................................................................... 0
Cylinder Block - Group 01 ....................................................................................................................................... 1
Cylinder Head - Group 02 ........................................................................................................................................ 2
Rocker Levers - Group 03........................................................................................................................................ 3
Cam Followers/Tappets - Group 04 ........................................................................................................................ 4
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
Engine Testing - Group 14....................................................................................................................................... 14
Mounting Adaptations - Group 16 .......................................................................................................................... 16
Electronic Engine Controls - Group 19 .................................................................................................................. 19
Troubleshooting Symptoms.................................................................................................................................... TS
Service Literature ..................................................................................................................................................... L
Specifications ........................................................................................................................................................... V
Index .......................................................................................................................................................................... X
Important Reference Numbers
Fill in the part name and number in the blank spaces provided below. This will give you a reference whenever service or mainte-
nance is required.
Engine Model
Engine Serial Number (ESN)
Control Parts List (CPL)
Fuel Pump Part Number
Filter Part Numbers:
• Air Cleaner Element
• Lubricating Oil Filter
- Bypass
- Full-flow
- Combination
Fuel Filter
Fuel-Water Separator
Belt Part Numbers
QSV27 and QSV36
Section i - Introduction Page i-1
Section i - Introduction
Section Contents
Page
About the Manual ...................................................................................................................................................................... i-3
General Cleaning Instructions ................................................................................................................................................. i-8
Glass or Plastic Bead Cleaning ............................................................................................................................................. i-8
Solvent and Acid Cleaning..................................................................................................................................................... i-8
Steam Cleaning ..................................................................................................................................................................... i-8
General Repair Instructions ..................................................................................................................................................... i-7
General Safety Instructions...................................................................................................................................................... i-6
Important Safety Notice ......................................................................................................................................................... i-6
How to Use the Manual ............................................................................................................................................................. i-3
Illustrations ................................................................................................................................................................................ i-5
Symbols ..................................................................................................................................................................................... i-4
To the Owner and Operator ...................................................................................................................................................... i-3
QSV27 and QSV36
Page i-2 Section i - Introduction
THIS PAGE LEFT INTENTIONALLY BLANK.

QSV27 and QSV36 To the Owner and Operator
To the Owner and Operator

Planned maintenance is the easiest and least expensive type of maintenance. Follow the maintenance schedule recommenda-
tions outlined in the Maintenance Guidelines.
Keep records of regularly scheduled maintenance.
Use the correct fuel, oil and coolant in your engine as specified in the Specifications and Torque Values section.
Cummins uses the latest technology and the highest quality components to produce its engines. Cummins recommends using
only genuine Cummins parts and ReCon® exchange parts.
Personnel at Cummins authorized repair locations have been trained to provide expert service and parts support. If you have a
problem that can not be resolved by a Cummins authorized repair location, follow the steps outlined in Service Assistance.
About the Manual

This manual contains information needed to correctly operate and maintain your Cummins engine as recommended by Cum-
mins Inc. Additional service literature (Shop Manual, Troubleshooting and Repair, etc.) can be ordered by filling out and mailing
the Literature Order Form.
Both metric and U.S. customary values are listed in this manual. The metric value is listed first, followed by the U.S. customary
in brackets.
Each section is preceded by a Section Contents page to aid in locating information more quickly.
How to Use the Manual

The manual is organized according to the maintenance intervals that are to be performed. A table that states the required inter-
vals and checks to be made is located in the Maintenance Guidelines section. Locate the maintenance interval that you are per-
forming and follow all the procedure steps given in that section. In addition, all the previous maintenance interval procedures
must also be performed.
Keep a record of all the checks and inspections made. A record form for recording the date and hours on the engine and what
maintenance checks were performed is located in the Maintenance Guidelines section.
Refer to Section TS for a troubleshooting guide to your engine. Follow the Troubleshooting Section Contents for location and
correcting engine problems.
Refer to the Specifications and Torque Values section for engine system specifications.
Symbols QSV27 and QSV36
Symbols
The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the sym-
bols appears, it conveys the meaning defined below:
WARNING - Serious personal injury or extensive property damage can result if the warning instructions ar not fol-
lowed.
CAUTION - Minor personal injury can result or a part, an assembly, or the engine can be damaged if the caution
instructions are not followed.
Indicates a REMOVAL or DISASSEMBLY step.
Indicates an INSTALLATION or ASSEMBLY step.
INSPECTION is required.
CLEAN the part or assembly.
PERFORM a mechanical or time MEASUREMENT.
LUBRICATE the part or assembly.
Indicates that a WRENCH or TOOL SIZE will be given.
TIGHTEN to a specific torque.
PERFORM an electrical MEASUREMENT.
Refer to another location in this manual or another publication for additional information.
The component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assis-
tance to lift the component.
QSV27 and QSV36 Illustrations
Illustrations
Some of the illustrations throughout this manual are generic
and will not look exactly like the engine or parts used in your
application. The illustrations can contain symbols to indicate an
action required and an acceptable or not acceptable condition
The illustrations are intended to show repair or replacement

procedures. The procedure will be the same for all applications,
although the illustration can differ.
General Safety Instructions QSV27 and QSV36
General Safety Instructions
Important Safety Notice
WARNING
Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation, asphyxiation or other
bodily injury or death.
Read and understand all of the safety precautions and warnings before performing any repair. This list contains the general
safety precautions that must be followed to provide personal safety. Special safety precautions are included in the procedures
when they apply.
• Work in an area surrounding the product that is dry, well lit, ventilated, free from clutter, loose tools, parts, ignition sources
and hazardous substances. Be aware of hazardous conditions that can exist.
• Always wear protective glasses and protective shoes when working.
• Rotating parts can cause cuts, mutilation or strangulation.
• Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
• Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work. Discon-
nect the air starting motor if equipped to prevent accidental engine starting. Put a "Do Not Operate" tag in the operator's
compartment or on the controls.
• Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the crankshaft
by pulling or prying on the fan. This practice can cause serious personal injury, property damage, or damage to the fan
blade(s) causing premature fan failure.
• If an engine has been operating and the coolant is hot, allow the engine to cool before slowly loosening the filler cap to
relieve the pressure from the cooling system.
• Always use blocks or proper stands to support the product before performing any service work. Do not work on anything
that is supported ONLY by lifting jacks or a hoist.
• Relieve all pressure in the air, oil, fuel and the cooling systems before any lines, fittings, or related items are removed or
disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not
check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.
• To prevent suffocation and frostbite, wear protective clothing and ONLY disconnect fuel and liquid refrigerant (Freon) lines
in a well ventilated area. To protect the environment, liquid refrigerant systems must be properly emptied and filled using
equipment that prevents the release of refrigerant gas (fluorocarbons) into the atmosphere. Federal law requires captur-
ing and recycling refrigerant.
• To reduce the possibility of personal injury, use a hoist or get assistance when lifting components that weigh 23 kg [50 lb]
or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and are of the correct capac-
ity. Make sure hooks are positioned correctly. Always use a spreader bar when necessary. The lifting hooks must not be
side-loaded.
• Corrosion inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the substance in eyes. Avoid pro-
longed or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash skin with soap and
water. In case of contact, immediately flood eyes with large amounts of water for a minimum of 15 minutes. IMMEDI-
ATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
• Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the manufac-
turer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF CHILDREN.
• To reduce the possibility of burns, be alert for hot parts on products that have just been turned off, and hot fluids in lines,
tubes, and compartments.
• Always use tools that are in good condition. Make sure you understand how to use the tools before performing any ser-
vice work. Use ONLY genuine Cummins or Cummins ReCon® replacement parts.
• Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of lesser
quality if replacements are necessary.
• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.
• Some state and federal agencies in the United States of America have determined that used engine oil can be carcino-
genic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine
oil.
• Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations.
QSV27 and QSV36 General Repair Instructions
General Repair Instructions

This engine incorporates the latest technology at the time it was manufactured; yet, it is designed to be repaired using normal
repair practices performed to quality standards.
• Cummins Inc. does not recommend or authorize any modifications or repairs to engines or components except
for those detailed in Cummins Service Information. In particular, unauthorized repair to safety-related compo-
nents can cause personal injury or death. Below is a partial listing of components classified as safety-related:
Air Compressor Flywheel Mounting Capscrews

Air Controls Fuel Shutoff Assemblies
Air Shutoff Assemblies Fuel Supply Tubes
Balance Weights Lifting Brackets
Cooling Fan Throttle Controls
Fan Hub Assembly Turbocharger Compressor Casing
Fan Mounting Bracket(s) Turbocharger Oil Drain Line(s)
Fan Mounting Capscrews Turbocharger Oil Supply Line(s)
Fan Hub Spindle Turbocharger Turbine Casing
Flywheel Vibration Damper Mounting Capscrews
Flywheel Crankshaft Adapter
• Follow all safety instructions noted in the procedures

— Follow the manufacturer's recommendations for cleaning solvents and other substances used during the repair of the
engine. Some solvents and used engine oil have been identified by government agencies as toxic or carcinogenic.
Avoid excessive breathing, ingestion and contact with such substances. Always use good safety practices with tools
and equipment.
• Provide a clean environment and follow the cleaning instructions specified in the procedures
— The engine and its components must be kept clean during any repair. Contamination of the engine or components
will cause premature wear.
• Perform the inspections specified in the procedures
• Replace all components or assemblies which are damaged or worn beyond the specifications
• Use genuine Cummins new or ReCon®; service parts and assemblies
— The assembly instructions have been written to use again as many components and assemblies as possible. When it
is necessary to replace a component or assembly, the procedure is based on the use of new Cummins or Cummins
ReCon® components. All of the repair services described in this manual are available from all Cummins Distributors
and most Dealer locations.
• Follow the specified disassembly and assembly procedures to reduce the possibility of damage to the compo-
nents
Complete rebuild instructions are available in the shop manual which can be ordered or purchased from a Cummins Authorized
Repair Location. Refer to Section L — Service Literature for ordering instructions.
General Cleaning Instructions QSV27 and QSV36
General Cleaning Instructions

Solvent and Acid Cleaning
Several solvent and acid-type cleaners can be used to clean the engine parts. Experience has shown that the best results can
be obtained using a cleaner that can be heated to 90 to 95 degrees Celsius [180 to 200 degrees Fahrenheit]. A cleaning tank
that provides a constant mixing and filtering of the cleaning solution will give the best results. Cummins Inc. does not recom-
mend any specific cleaners. Always follow the cleaner manufacturer's instructions.
Remove all the gasket material, o-rings, and the deposits of sludge, carbon, etc., with a wire brush or scraper before putting the
parts in a cleaning tank. Be careful not to damage any gasket surfaces. When possible, steam clean the parts before putting
them in the cleaning tank.
Acid is extremely dangerous and can cause personal injury and damage the machinery. Always provide a tank of
strong soda water as a neutralizing agent. Wear goggles and protective clothing to reduce the possibility of serious
personal injury.
Rinse all of the parts in hot water after cleaning. Dry completely with compressed air. Blow the rinse water from all of the cap-
screw holes and the oil drillings.
If the parts are not to be used immediately after cleaning, dip them in a suitable rustproofing compound. The rustproofing com-
pound must be removed from the parts before installation on the engine.
Steam Cleaning
Steam cleaning can be used to remove all types of dirt that can contaminate the cleaning tank. It is a good way to clean the oil
drillings.
When using a steam cleaner, wear safety glasses or a face shield, as well as protective clothing. Hot steam can cause
serious personal injury.
Do not steam clean the following parts:
1. Electrical Components 4. Fuel Pump
2. Wiring 5. Belts and Hoses
3. Injectors 6. Bearings
Glass or Plastic Bead Cleaning

Glass or plastic bead cleaning can be used on many engine components to remove carbon deposits. The cleaning process is
controlled by the size of the glass or plastic beads, the operating pressure, and the cleaning time.
Do not use glass or plastic bead cleaning on aluminum piston skirts. Do not use glass bead cleaning on aluminum ring
grooves. Small particles of glass or plastic will embed in the aluminum and result in premature wear. Valves, turbo-
charger shafts, etc., can also be damaged. Follow the cleaning directions listed in the procedures.
NOTE: Plastic bead blasting media, Part Number 3822735, can be used to clean aluminum ring grooves. Do not use any bead
blasting media on pin bores or aluminum skirts.
Follow the equipment manufacturer's cleaning instructions. The following guidelines can be used to adapt to manufacturer's
instructions:
1. Bead size: - Use U.S. size No. 16-20 for piston cleaning with plastic bead media, Part Number 3822735.
- Use U.S. size No. 70 for piston domes with glass media.
- Use U.S. size No. 60 for general purpose cleaning with glass media.
2. Operating Pressure: - Glass: Use 620 kPa [90 psi] for general purpose cleaning.
- Plastic: Use 270 kPa [40 psi] for piston cleaning.
3. Steam clean or wash the parts with solvent to remove all of the foreign material and glass or plastic beads after cleaning.
Rinse with hot water. Dry with compressed air.
4. Do not contaminate the wash tanks with glass or plastic beads.
QSV27 and QSV36
Section E - Engine Identification E-1
Section E - Engine Identification

Section Contents
Page
Engine Diagrams ......................................................................................................................................................................E-4
Engine Views ........................................................................................................................................................................E-4
Engine Identification ................................................................................................................................................................E-3
Engine Dataplate ..................................................................................................................................................................E-3
Fuel Pump Dataplate ............................................................................................................................................................E-3
General Information ..............................................................................................................................................................E-3
QSV27 and QSV36
E-2 Section E - Engine Identification

QSV27 and QSV36 Engine Identification
Engine Identification
General Information
The engine model names QSV27 and QSV36, supply the fol-
lowing data:
QSV27 and QSV36
• Q = Quantum family
• S = System
• V = Engine series
• 27, 36 = Displacement in liters
Engine Dataplate
The engine dataplate shows specific information about your
engine. The engine serial number (ESN) and model provide
information for ordering parts and service needs.
The engine dataplate is located on the rear, left side of the
engine.
NOTE: The engine dataplate must not be changed unless
approved by Cummins Inc.
Fuel Pump Dataplate

The fuel pump dataplates are located on the front of the pump
housings. They provide information for fuel pump calibration.
Engine Diagrams QSV27 and QSV36
Engine Diagrams
Engine Views
1. Rocker Lever Cover 12. Flywheel Housing

2. Camshaft Access Cover 13. Cylinder Block
3. Hot Box Cover 14. Oil Sump
4. Engine Stop Lever 15. Engine Mount
5. Fuel Pump Control Rack 16. Fuel Filter
6. Turbocharger 17. Crankshaft Access Cover
7. Air Shutdown Reservoir 18. Centrifugal Filter Oil Supply
8. Camshaft Gear Cover 19. Oil Fill Cap
9. Engine Data Tag 20. Centrifugal Oil Bypass Filter
10. Engine Barring Gear
11. Engine Mount
QSV27 and QSV36 Engine Diagrams
1. Oil Filter Selector Lever 9. Oil Drain Plug

2. Oil Cooler 10. Oil Level Dipstick
3. Oil Filter Cartridge Cover 11. Starter
4. Oil Filter Drain Pan 12. Engine Mount
5. Engine Mount 13. Flywheel Housing
6. Cylinder Block 14. Charged Air Duct
7. Crankshaft Access Cover 15. Charge Air Cooler
8. Oil Sump 16. Turbocharger
1. HT LT Thermostat (Coolant) 7. Oil Sump

2. Centrifugal Oil Filter 8. Water Pump
3. Sea Water Pump 9. Oil Thermostats
4. Fuel Filters 10. Heat Exchanger
5. Fuel Transfer Pump 11. Expansion Tank
6. Lubricating Oil Pump
QSV27 and QSV36 Engine Diagrams
1. Turbocharger 6. Oil Drain Plug

2. Charged Air Duct 7. Flywheel Housing
3. Oil Filter Selector Lever 8. Flywheel
4. Oil Filter Drain Pan 9. Turbocharger Oil Drain
5. Oil Sump 10. Fuel Rack Actuator
NOTES
QSV27 and QSV36
Section 0 - Complete Engine - Group 00 Page 0-1
Section 0 - Complete Engine - Group 00

Section Contents
Page
Complete Engine - General Information................................................................................................................................. 0-3
Engine Installation ................................................................................................................................................................... 0-6
General Information .............................................................................................................................................................. 0-6
Engine Removal ....................................................................................................................................................................... 0-3
QSV27 and QSV36
Page 0-2 Section 0 - Complete Engine - Group 00

QSV27 and QSV36 Complete Engine - General Information
Complete Engine - General Informa-

tion
The procedures required to replace an engine will vary with dif-
ferent engine models, the type of equipment, optional equip-
ment, and the shop facilities. Use the following procedures as a
guide.
NOTE: All replacement steps do not apply to all types of equip-
ment. Complete only the steps that apply to the equipment
involved. Use the equipment manufacturer’s recommendations
and precautions for removal of chassis parts to gain access to
the engine
Engine Removal (000-001)

General Information
NOTE: Place a tag on all hoses, lines, linkages, and electrical
connections as they are removed to identify their locations on
the engine.
WARNING
Batteries can emit explosive gases. To reduce the possibil-
ity of personal injury, always ventilate the compartment
before servicing the batteries. To reduce the possibility of
arcing, remove the negative (-) cable first and attach the
negative (-) battery cable last.
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.
Disconnect the battery cables.
Drain the engine coolant. Refer to Procedure 008-018.
NOTE: If the coolant is not going to be reused, dispose of used
coolant or antifreeze in accordance with federal, state, and local
laws and regulation.
Engine Removal (000-001) QSV27 and QSV36
WARNING
To reduce the possibility of personal injury, avoid direct
contact of hot oil with your skin.
WARNING
Some state and federal agencies have determined that
used engine oil can be carcinogenic and cause reproduc-
tive toxicity. Avoid inhalation of vapors, ingestion, and pro-
longed contact with used engine oil.
Drain the lubricating oil. Refer to Procedure 007-025.
Disconnect the starting motor cable, the engine ground straps,
the tubing, the electrical wires, and the hydraulic lines, if
installed.
NOTE: Dispose of used oil in accordance with federal, state,
and local laws and regulations.
Disconnect the exhaust pipe.

Disconnect all mounted, engine-driven accessories.
NOTE: If the rear engine mounts are attached to the transmis-

sion, it will probably be necessary to remove the engine and the
transmission as an assembly.
CAUTION
Engine lifting brackets are designed to lift the engine only.
Additional brackets are required for driven units.
QSV27 and QSV36 Engine Removal (000-001)
Disconnect the drive units from the flywheel.
WARNING
The engine lifting equipment must be designed to safely lift
the engine. The wet weight of the standard engine with
accessories is 6,500 kg [14,300 lb]. Lifting eyes are
designed to lift the engine only, not driven units.
Use a correctly rated hoist, and attach the engine lifting fixture
to the engine-mounted lifting brackets to remove the engine.
NOTE: If the transmission is not removed from the frame, place
a support under the transmission to prevent it from falling.
Remove the engine.
WARNING
The oil sump or cover plate will not support the weight of
the engine. The engine will fall and personal injury can
result.
WARNING
Use a stand or skid that contacts the engine mounts. The
stand must hold the weight of the engine and provide per-
manent support to prevent the engine from falling.
Put the engine on the stand.
Cover all engine openings to prevent dirt and debris from enter-
ing the engine.
Remove and use all remaining accessories and brackets with

the replacement engine.
Engine Installation (000-002) QSV27 and QSV36
Engine Installation (000-002)

General Information
Install all accessories and brackets that were removed from the
previous engine.
NOTE: If the rear engine mounts are attached to the transmis-

sion, it probably will be necessary to install the engine and the
transmission as an assembly. Use additional lifting brackets to
lift driven units.
WARNING
The engine lifting equipment must be designed to safely lift
the engine only. The wet weight of the standard engine
with accessories is 6,500 kg [14,300 lb]. Lifting eyes are
designed to lift the engine only, not driven units.
Use a correctly rated hoist, and attach engine lifting fixture to
the engine-mounted lifting brackets to install the engine.
Align the engine on frame rails and tighten the engine mounting
capscrews. Refer to the equipment manufacturer’s torque spec-
ifications.
Connect all engine and chassis-mounted accessories that were
removed.
NOTE: Make sure all lines, hoses, and tubes are correctly
routed and fastened to prevent damage.
QSV27 and QSV36 Engine Installation (000-002)
Fill the engine with clean 15W-40 lubricating oil. Refer to Proce-
dure 007-025.
NOTE: The engine lubricating oil system must be primed.
Refer to Procedure 007-037.
Total Oil Capacity

QSV27 230 liters [61 gal]
Fill the cooling system with 50-percent water, 50-percent ethyl-

ene glycol-based antifreeze, and DCA corrosion protection.
Total Coolant Capacity (engine only)

NOTE: Refer to the equipment manufacturer’s specifications for

radiator and system capacity.
Make a final inspection to make sure all hoses, wires, linkages,

and components have been correctly installed and tightened.
WARNING
Do not remove the radiator cap from a hot engine. Hot
steam can cause serious personal injury. The engine cool-
ant temperature must be below 70°C [160°F].
Operate the engine at low idle for 2 to 3 minutes.
Stop the engine and check the oil and the coolant levels again.
Engine Installation (000-002) QSV27 and QSV36
Fill the engine to the correct oil and coolant levels, if necessary.
Refer to the following: Procedure 008-018 and Procedure 007-
025.
Operate the engine for 8 to 10 minutes to check for correct

engine operation, unusual noises, and coolant, fuel, or lubricat-
ing oil leaks.
Repair all leaks and component problems. Refer to the appro-
priate sections.
QSV27 and QSV36
Section 1 - Cylinder Block - Group 01 Page 1-1
Section 1 - Cylinder Block - Group 01

Section Contents
Page
Bearings, Connecting Rod ...................................................................................................................................................... 1-8
Clean .................................................................................................................................................................................... 1-9
Inspect for Reuse.................................................................................................................................................................. 1-9
Install .................................................................................................................................................................................... 1-9
Remove ................................................................................................................................................................................ 1-8
Bearings, Thrust..................................................................................................................................................................... 1-18
Clean and Inspect ............................................................................................................................................................... 1-19
Initial Check ........................................................................................................................................................................ 1-18
Install .................................................................................................................................................................................. 1-20
Measure .............................................................................................................................................................................. 1-20
Remove .............................................................................................................................................................................. 1-18
Camshaft ................................................................................................................................................................................. 1-21
Clean .................................................................................................................................................................................. 1-24
Inspect for Reuse................................................................................................................................................................ 1-25
Install .................................................................................................................................................................................. 1-26
Preparatory ......................................................................................................................................................................... 1-21
Remove .............................................................................................................................................................................. 1-23
Camshaft Bushings................................................................................................................................................................ 1-29
Inspect ................................................................................................................................................................................ 1-30
Install .................................................................................................................................................................................. 1-30
Remove .............................................................................................................................................................................. 1-29
Camshaft Cover Plate ............................................................................................................................................................ 1-31
Clean .................................................................................................................................................................................. 1-31
Install .................................................................................................................................................................................. 1-32
Remove .............................................................................................................................................................................. 1-31
Camshaft Gear........................................................................................................................................................................ 1-32
Clean .................................................................................................................................................................................. 1-34
Install .................................................................................................................................................................................. 1-35
Remove .............................................................................................................................................................................. 1-32
Camshaft Gear Bushings ...................................................................................................................................................... 1-76
Clean .................................................................................................................................................................................. 1-76
Install .................................................................................................................................................................................. 1-77
Remove .............................................................................................................................................................................. 1-77
Camshaft Intermediate Gear ................................................................................................................................................. 1-77
Clean .................................................................................................................................................................................. 1-80
Remove .............................................................................................................................................................................. 1-77
Connecting Rod...................................................................................................................................................................... 1-37
Assemble ............................................................................................................................................................................ 1-41
Clean .................................................................................................................................................................................. 1-39
Disassemble ....................................................................................................................................................................... 1-38
General Information ............................................................................................................................................................ 1-37
Install .................................................................................................................................................................................. 1-42
Measure .............................................................................................................................................................................. 1-40
Remove .............................................................................................................................................................................. 1-38
QSV27 and QSV36
Page 1-2 Section 1 - Cylinder Block - Group 01
Crankshaft Gear, Front (Crankshaft Installed)..................................................................................................................... 1-43

Clean .................................................................................................................................................................................. 1-43
Install .................................................................................................................................................................................. 1-44
Remove .............................................................................................................................................................................. 1-43
Crankshaft Seal, Rear ............................................................................................................................................................ 1-45
Finishing ............................................................................................................................................................................. 1-47
Install .................................................................................................................................................................................. 1-46
Preparatory ......................................................................................................................................................................... 1-45
Remove .............................................................................................................................................................................. 1-45
Cylinder Block ........................................................................................................................................................................ 1-47
Cylinder Block and Liner Seats ............................................................................................................................................ 1-48
Leak Test ............................................................................................................................................................................ 1-48
Cylinder Liner ......................................................................................................................................................................... 1-49
Clean .................................................................................................................................................................................. 1-53
Disassemble ....................................................................................................................................................................... 1-52
Finishing ............................................................................................................................................................................. 1-60
Install .................................................................................................................................................................................. 1-56
Preparatory ......................................................................................................................................................................... 1-49
Remove .............................................................................................................................................................................. 1-49
Gear Housing, Front............................................................................................................................................................... 1-61
Clean .................................................................................................................................................................................. 1-62
Finishing ............................................................................................................................................................................. 1-65
Install .................................................................................................................................................................................. 1-63
Preparatory ......................................................................................................................................................................... 1-61
Remove .............................................................................................................................................................................. 1-61
Gear Train Backlash............................................................................................................................................................... 1-76
Measure .............................................................................................................................................................................. 1-76
Main Bearings......................................................................................................................................................................... 1-10
Clean .................................................................................................................................................................................. 1-13
Install .................................................................................................................................................................................. 1-14
Preparatory ......................................................................................................................................................................... 1-10
Remove ...............................................................................................................................................................................1-11
Piston ...................................................................................................................................................................................... 1-66
Clean .................................................................................................................................................................................. 1-66
Install .................................................................................................................................................................................. 1-70
Preparatory ......................................................................................................................................................................... 1-66
Piston Cooling Nozzle............................................................................................................................................................ 1-70
Clean .................................................................................................................................................................................. 1-71
Install .................................................................................................................................................................................. 1-72
Remove .............................................................................................................................................................................. 1-70
Service Tools ............................................................................................................................................................................ 1-5
Cylinder Block ....................................................................................................................................................................... 1-5
QSV27 and QSV36
Vibration Damper ................................................................................................................................................................... 1-73

Clean .................................................................................................................................................................................. 1-73
Eccentricity ......................................................................................................................................................................... 1-75
Install .................................................................................................................................................................................. 1-75
Preparatory ......................................................................................................................................................................... 1-73
Remove .............................................................................................................................................................................. 1-73
Wobble Check..................................................................................................................................................................... 1-76
QSV27 and QSV36

QSV27 and QSV36 Service Tools
Service Tools
Cylinder Block
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
Hydraulic Set Tightening Tool
3164395
Main Bearing Roll-out Tool
3164620
Cylinder Liner and Piston Lifting Assembly
3164397
Liner Driver
3164572
Camshaft Bushing Extractor
3164407
Camshaft Bushing Positioning Rod
3164404
Service Tools QSV27 and QSV36
Dial Bore Gauge
3375072
Piston Ring Expander
3164401
Piston Ring Compressor
3164399
Crack Detection Kit
3375432
Dial Indicator
3376050
Indicator Base
3377399
Camshaft Bushing Installation Tool
3164640
Bearings, Connecting Rod (001-005) QSV27 and QSV36
Bearings, Connecting Rod (001-005)

Remove
Remove the inspection covers from both sides of the engine.
Bar crankshaft to position the rod cap for removal.

Remove rod cap.
Install a 11x175x140 mm capscrew into service tool 3162284.

Install tool in hand hole cover mounting hole to support the rod
and piston assembly.
Bar the crankshaft away from the connecting rod.

QSV27 and QSV36 Bearings, Connecting Rod (001-005)
Roll out the upper bearing.
Clean
WARNING
When using solvents, acids, or alkaline materials for clean-
ing, follow the manufacturer’s recommendations for use.
Wear goggles and protective clothing to reduce the possi-
bility of personal injury.
Clean the bearings and rod caps.
Do not damage or scratch parts during cleaning and inspection.
Inspect for Reuse

Inspect the bearings for wear/scoring.
Do not reuse bearing if copper is exposed on the upper shell.
Do not reuse if scoring or pitting exists on bearing shells.
Install
Install the upper bearing shell, lubricate bearing with clean
engine oil.
NOTE: Check tang alignment.
Bar the crankshaft up until the rod bearing contacts the crank-
shaft journal.
Main Bearings (001-006) QSV27 and QSV36
Remove the holding tool.
Lubricate the lower shell with clean engine oil.

Do not reuse connecting rod bolts, install new bolts.
Lubricate the connecting rod bolts with 30 weight oil on threads
and 140 weight EP oil under flange.
Install the rod cap.
Torque in cross pattern.
Torque Value: Step 1: 50 N•m [37 ft-lb]
Install covers with a new seal.

Torque Value: 80 N•m [60 ft-lb]
Main Bearings (001-006)

Preparatory
Remove the oil pan. Refer to Procedure 007-025.
Remove the crankshaft hand hole covers. Refer to Procedure
001-035.
QSV27 and QSV36 Main Bearings (001-006)
Remove
CAUTION
Do not loosen all the main bearing capscrews at once.
Remove and replace main bearings one at a time. Begin
with the #1 bearing (second bearing from the flywheel end)
and repeat towards the free end. Replace main bearing #0
last.
Remove the main bearing cap side bolts (1).
Remove the adjacent main bearing cap side bolts.
Install the hydraulic tensioners onto the main bearing studs.
Open the pressure relief valve on the hand pump. Hand tighten
the tensioners until they are fully compressed (excess oil is
expelled). Then loosen 1/4 to 1/2 turn.
Connect the hoses to the tensioners installed on the main bear-

ing studs and the hand pump according to the diagram.
Close the pressure relief valve.
Using the tool, apply pressure to the tensioners equal to 970
bar with Pivicat tools, or 1150 bar with Hydratite tools.
Unscrew the main bearing nuts one turn using the pin supplied
with tool.
Decrease pressure, expel excess oil, and remove hydraulic

tool.
CAUTION
This assembly weighs 23 kg [50 lb] or move. To reduce the
possibility of personal injury, use a hoist or get assistance
to lift this assembly.
Remove the nuts.
Remove the main cap.
Separate the lower bearing from the cap.
Remove the upper bearing (1) by turning the crankshaft. If bear-

ing does not come out, service tool #3164620 (2) can be
inserted into the crankshaft oil drilling to spin the bearing out.
NOTE: Do not use starter to rotate engine.
Clean
WARNING
WARNING
Wear appropriate eye and face protection when using com-
pressed air. Flying debris and dirt can cause bodily injury.
Use solvent to clean the main bearing cap and capscrews.
Dry the parts with compressed air.
Inspect for Reuse

Use a lint free cloth to clean main journal. Inspect for damage or
roughness.
Install
Lubricate face of upper bearing shell with clean engine oil.
Position the upper bearing on the crankshaft journal and rotate

it into position.
NOTE: Do not force the bearing into position as it may become
damaged. Insert service tool #3164620 (1) into the crankshaft
oil drilling and spin the bearing to fully seat it in the block.
Install the lower main bearing shell as follows:

• Align the bearing shell.
• Push the bearing shell into place.
• Lubricate face of bearing with clean engine oil.
Lubricate the mounting nut threads and contact surface with

clean engine oil. Lubricate main bearing studs with clean
engine oil. Allow excess oil to drain from the components before
installing.
Install the main bearing cap and main bearing cap side screws
and hand tighten.
The engine block has locating pins to insure proper cap installa-
tion.
Hand tighten the nuts onto the main bearing studs.
Torque the right side (B side), main bearing side screw only.
Install the hydraulic tensioners onto the main bearing studs.
Open the pressure relief valve on the hand pump. Hand tighten
the tensioners until they are fully compressed.
Connect the hoses to the tensioners installed on the main bear-
ing studs and the hand pump according to the diagram. If
access to the tensioner fittings is difficult, the tensioner may be
adjusted less than one turn.
Close the pressure relief valve on the hand pump. Apply pres-
sure equal to 800 bar.
Tighten the nuts with the pin until the nut contacts the main
bearing cap.
Slowly release pressure.
Reapply pressure to the tensioners. Apply pressure equal to

970 bar with Pivicat tools, or 1150 bar with Hydratite tools.
CAUTION
If nuts do not turn, determine cause before restarting the
procedure.
Tighten the nuts with the pin until the nut contacts the main
bearing cap.
Slowly release the pressure.

Disconnect the hydraulic hoses.
Remove the tensioners.
Check nuts for tightness by tapping nuts lightly in the loosening
direction.
Torque the right side (B side) screw.

Torque the left side (A side) screw.

Bearings, Thrust (001-007) QSV27 and QSV36
Repeat procedure for remaining bearings, working toward the
free end of the engine.
NOTE: Replace #0 bearing and thrust bearing after all other
main bearings have been replaced.
CAUTION
The flywheel must be removed for proper installation of
bearing #0. Forcing the bearing into place could result in
damage to the bearing.
CAUTION
This assembly weighs 23 kg [50 lb] or move. To reduce the
Support the housing with a hoist. Remove one capscrew and
install a guide pin. Remove the remaining capscrews.
Remove the flywheel with the hoist.
Bearings, Thrust (001-007)

Initial Check
Measure the end clearance of the crankshaft. If the clearance is
not within specifications, the thrust bearing must be replaced.
Crankshaft End Clearance

MIN 0.175 mm [0.0069 in]
MAX 0.340 mm [0.0134 in]
Remove
Remove the main bearing cap number zero.
QSV27 and QSV36 Bearings, Thrust (001-007)
Remove the lower thrust bearing halves from the main bearing
cap.
CAUTION
Use care when removing the upper thrust bearings. Dam-
age to the crankshaft journal can result.
Pry the crankshaft away from the thrust bearing being removed.
Push the upper thrust bearings out with a wooded dowel rod.
Clean and Inspect
WARNING
WARNING
Use solvent to clean the main bearing cap, thrust bearings, nuts
and capscrews.
Dry with compressed air.
Check the thrust bearing surface for damage. Make sure the
main cap thrust bearing pins are undamaged and in place.
Bearings, Thrust (001-007) QSV27 and QSV36
Measure
Measure the thrust bearing thickness. Replace the bearing if it
is not within specifications.
Thrust Bearing Thickness

MIN 10.86 mm [0.427 in]
MAX 10.88 mm [0.428 in]
Install
Lubricate the upper thrust bearings with clean engine oil.
CAUTION
The grooves in the thrust bearings must be towards the
crankshaft.
CAUTION
The upper and lower thrust bearings must be the same
thickness. Damage to the crankshaft can result.
Pry the crankshaft to the rear and slide in the upper front thrust
bearing.
Pry the crankshaft to the front and slide in the upper rear thrust
bearing.
QSV27 and QSV36 Camshaft (001-008)
Lubricate the lower thrust bearings with clean engine oil. Slide
the lower thrust bearings onto the pins of the main bearing cap.
Install the main bearing cap. Refer to Procedure 001-006.
Measure the crankshaft end clearance.
Crankshaft End Clearance

MIN 0.175 mm [0.0069 in]
MAX 0.340 mm [0.0134 in]
If clearance is not within specifications, check for debris on

thrust bearing or crankshaft.
Camshaft (001-008)
Preparatory
Remove the sea water heat exchanger, support and related
pipes. Refer to Procedure 008-054.
Remove the centrifugal filter. Refer to Procedure 007-002.
Camshaft (001-008) QSV27 and QSV36
Remove the camshaft front end cover (1). Refer to Procedure
001-011.
Remove the camshaft rear end cover. Refer to Procedure 001-

011.
Remove the rocker covers and hot box covers.
Remove the rocker lever assemblies.

Remove the injection pumps.
Remove the nuts from the studs connecting the camshaft to the
camshaft gear stub shaft.
Remove
Fabricate tools from 13 mm [0.5 in] thick material.
Lubricate the flat surface of the camshaft guides and install the
camshaft guides under the camshaft.
Separate the camshaft into sections while the camshaft is still in
the engine.
Using a non-permanent marker, place an alignment mark on
the section for use during assembly.
Remove one section at a time.
Remove the front camshaft end plate.
CAUTION
This assembly weighs 23 kg [50 lb] or more. To reduce the
Slowly push the camshaft assembly toward the free-end. Sup-
port the assembly with a lifting strap as it is removed from the
block.
Clean
WARNING
WARNING
Clean the camshaft with solvent and dry with compressed air.
After cleaning the camshaft, do not touch the machined sur-
faces with bare hands.
Lubricate the camshaft with clean engine oil.
Inspect for Reuse

Check the camshaft for damage. If the camshaft is damaged, it
must be replaced.
Measure the outside diameter. of each of the camshaft journals.

If it is not within specifications, it must be replaced.
Camshaft Journal Outside Diameter

MIN 153.975 mm [6.062 in]
MAX 154.000 mm [6.063 in]
WARNING
Clean the camshaft bushings with a lint-free cloth and solvent
and dry with compressed air.
Inspect the camshaft bushings for scratching, pitting, discolora-
tion, and excessive wear.
If the bushings are damaged, they must be replaced. Refer to
Procedure 001-010.
Measure the installed diameter of the camshaft bushings.

Replace all the bushings if any of the bushing’s diameter is
greater than the wear limit. Refer to Procedure 001-010.
Camshaft Bushing Wear Limit

mm in
154.142 MIN 6.128
154.023 MAX 6.053
Install
Lubricate the camshaft bushings with clean engine oil.
CAUTION
CAUTION
Do not damage the camshaft bushings when installing the
camshaft. This will cause bushing failure.
Lubricate the camshaft support with clean engine oil.
Use a hoist to align the camshaft.
Insert the camshaft into the first two camshaft bushings.
CAUTION
Take care installing the camshafts as to not damage the
camshaft bushings. Damage to the bushings will cause
premature bushing failure.
Carefully rotate the camshaft clockwise and counterclock-
wise during installation. The camshaft sections should slide in
easily if the guide plates are aligned correctly.
Stop after each cam journal has gone in to adjust the lifting
straps for installation.
Connect the section of camshaft in the block to reduce stress-

ing the camshaft studs.
Align the markings that were made prior to removal.
Tighten the nuts in sequence shown to the first torque value.

Repeat the process at the second torque value.
Install the nuts onto the studs connecting the camshaft to the
camshaft gear stub shaft.
Install the front camshaft end plate.
Remove the support tools from the block.
Install the camshaft free-end cover. Refer to Procedure 001-

011.
Install the centrifugal filter. Refer to Procedure 007-002.

Install the sea water heat exchanger, support and related pip-
ing. Refer to Procedure 008-054.
QSV27 and QSV36 Camshaft Bushings (001-010)
Camshaft Bushings (001-010)

Remove
Remove the camshaft.
Use a camshaft bushing puller, Part Number 3164407, to

remove the camshaft bushings.
Place the mandrel in the bushing to be removed.
Position the retainer and threaded rod in the center of an adja-
cent camshaft bore.
Thread the rod into the mandrel.
Turn the threaded rod until the cam bushing is removed from
the bore.
Repeat the process on the remaining bushings.
Wipe the bushing bore with a clean lint free cloth.

Camshaft Bushings (001-010) QSV27 and QSV36
Inspect
Check the bore for scratches or other damage.
Measure the bore I.D.
Camshaft Bushing Bore I.D.

MIN 164.000 mm [6.457 in]
MAX 164.040 mm [6.458 in]
Install
CAUTION
Wear safety glasses or face shield, as well as protective
clothing when handling liquid nitrogen to reduce the possi-
bility of personal injury. Liquid nitrogen can cause freezing
and damage to the skin and eyes.
Cool the camshaft bushings in liquid nitrogen.
Place the cooled bushing on a flat surface. Insert the installation

mandrel, Part Number 3164640, into the bushing and hand
tighten the indexing handle to secure the bushing.
NOTE: The bushing will expand soon after it is placed in the

bore. Make sure the installation and alignment is performed
quickly to prevent improper alignment or damage to the engine.
Using the mandrel and indexing tool, place the bushing into the
bore.
QSV27 and QSV36 Camshaft Cover Plate (001-011)
Insert the bushing locating rod, Part Number 3164404, into the
oil drilling on top of the block, toward the camshaft bushing.
Rotate the mandrel until the locating rod aligns with the bushing
lubrication hole.
Allow the bushing to expand in place before removing the
installation tools.
Repeat the procedure on the remaining bushings.
Lubricate the camshaft bushings.

Install the camshaft.
Camshaft Cover Plate (001-011)

Remove
Remove the three hex socket cap screws and washers.
Remove the cover (1).
Clean
WARNING
Clean the camshaft cover and cap screws.
Make sure the cylinder block mounting surface is clean and free
of debris.
Camshaft Gear (001-012) QSV27 and QSV36
Inspect for Reuse
Inspect the cover, o-ring and capscrews for damage.
Install
Install the o-ring, cover and capscrews. Make sure the drain
grove is lined up with the drain holes. Improper alignment of the
drain grove will cause bearing damage.
Camshaft Gear (001-012)

Remove
Remove the injection pumps and rocker levers.
Refer to Procedures 005-016 and 003-009.
Remove the camshaft gear inspection cover (1).

NOTE: Put an alignment mark on the back of the cam gear and
camshaft to aid in assembly. Mark the cam gear and intermedi-
ate gear teeth for alignment.
QSV27 and QSV36 Camshaft Gear (001-012)
Remove the rear camshaft end cover. Refer to Procedure 001-
011.
Remove the six, 12 point, camshaft gear and pinion capscrews.
Remove the camshaft gear pinion and outer thrust bearing.
CAUTION
Support the cam gear during removal to prevent damage to the
gear or other components.
Carefully slide the camshaft and gear stub shaft toward the
free-end until the gear is free.
Remove the camshaft gear through the inspection port.
NOTE: Use caution when removing the gear. Damage to the
gear or surrounding components may occur.
Remove the camshaft gear inner thrust bearing.
Clean
WARNING
WARNING
Clean the gear, bolts, bushings, and pinion.
Dry parts with compressed air.
Inspect for Reuse

Inspect the camshaft gear for cracks and chipped or broken
teeth.
Inspect the pinion and thrust bearings for damage or wear.
QSV27 and QSV36 Camshaft Gear (001-012)
Use an emery cloth to remove any burrs and sharp edges.
Install
Install the camshaft gear inner thrust bearing.
Support the cam gear during installation to prevent damage to

the gear or other components.
Carefully install the camshaft gear onto the camshaft.
Align the gear with the camshaft and intermediate gear using
the marks applied during disassembly.
Install the camshaft gear outer thrust bearing.

Lubricate the camshaft gear pinion and thrust bearings with
clean engine oil.
Install the camshaft gear pinion.
Install the six, 12 point, camshaft gear and pinion capscrews.
Tighten the capscrews, in the sequence shown, to the first

torque value. Repeat the process at the second torque value.
Use a dial indicator to measure the end clearance of the cam-

shaft. If it is not within specifications, check for debris between
the thrust bearings and camshaft gear.
Camshaft End Clearance

MIN 0.150 mm [0.006 in]
MAX 0.600 mm [0.024 in]
Check the timing. Refer to Procedure 006-025.

QSV27 and QSV36 Connecting Rod (001-014)
Install the rear camshaft end cover.
Ensure the drain grooves in the cover align with the oil pas-
sages in the block.
Install the camshaft gear inspection cover (1).

Install the injection pumps and injection pump covers. Refer to

Procedure 005-016.
Install the rocker levers and rocker lever covers. Refer to Proce-
dure 003-008.
Connecting Rod (001-014)

General Information
The QSV27/36 connecting rod must be removed as an assem-
bly with the piston and cylinder liner.
The lifting tool, service tool #3164397, fastens to the piston and
cylinder liner and extracts them as an assembly. The tool con-
sists of a pilot flange (5), liner carriage (4), locking ring (1), liner
clamping plate halves (2) and lifting eye (3).
Connecting Rod (001-014) QSV27 and QSV36
Remove
Remove the connecting rod, piston and liner from the block.
Disassemble
Remove and mark the connecting rod bearing.
Remove the connecting rod and piston from the bottom end of
the liner.
Remove the piston rings with a ring expander tool.

Remove one wrist pin retaining ring.
CAUTION
Do not use a hammer to remove the pins. Force can distort
the piston, causing it to seize in the liner.
If the pin cannot be easily removed by hand, put the piston and
rod assembly in 30°C [86°F] water for 15 minutes.
Use a blunt tool and push the pin from the piston.
NOTE: Mark the piston and pin with the cylinder number so
they are installed in the same cylinder.
Clean
WARNING
When using a steam cleaner, wear safety glasses or a face
shield, as well as protective clothing. Hot steam can cause
WARNING
WARNING
pressed air. Flying debris and dirt can cause personal
injury.
CAUTION
The number on the connecting rod must be the same as
the number on the rod cap. Never assembly a new cap on
an old rod or an old cap on a new rod.
Remove the capscrews, washers, and the cap from the rod.
Use steam or solvent to clean the parts.
Inspect for Reuse
CAUTION
The connecting rod and connecting cap must be replaced
as an assembly if any fretting damage is visible on either
piece.
Inspect the rod caps, connecting rod bearing saddles for nicks,
cracks, burrs, scratches, or fretting.
CAUTION
Due to the high stress and critical nature of these fasten-
ers, they should not be used more than one time.
Install new connecting rod bolts.
Check the connecting rod capscrew threads for damage.
Check under the capscrew head for fretting.
Measure
Measure the connecting rod wrist pin bushing inside diameter.
Connecting Rod Wrist Pin Bushing

Inside Diameter (Installed)
mm in
75.053 MIN 2.955
75.105 MAX 2.957
CAUTION
Use a vice with brass jaws to hold the rod. Notches,
scratches, or dents in the I-beam area can cause engine
failure.
CAUTION
The number on the connecting rod must be the same as
the number on the rod cap. Never assembly a new cap to a
used rod or a used cap to a new rod.
CAUTION
The connecting rod must be assembled with the cap-
screws tightened to specifications before stamping the cyl-
inder identification number on the rod. Always stamp a
new connecting rod with the cylinder number of the rod
being replaced.
Use clean engine oil. Lubricate the connecting rod capscrews.
Assemble the rod, cap, washers, and new capscrews.
Tighten the capscrews in the following sequence:
Use a dial bore indicator to measure the inside diameter within

a 30 degree arc from each side of the parting line.
Measure the inside diameter at 90 degrees from the parting
line.
Connecting Rod Bearing Bore Inside Diameter

mm in
154.000 MIN 6.063
154.025 MAX 6.064
If any of the three measurements are not within specifications,

the rod must be replaced.
Bearing Bore Out of Round

mm in
0.015 MAX 0.0006
Assemble
CAUTION
Do not use a hammer to install the piston pin. The piston
can distort, causing it to seize in the liner.
Use engine oil. Lubricate the piston pin and connecting rod
bushing.
Align the pin bore of the rod with the pin bore of the piston skirt
and crown, and install the piston pin.
Install connecting rod with oil drilling in connecting rod (1) on
opposite side of oil drilling in bottom of piston (2).
The snap ring must be seated completely in the piston groove

to prevent engine damage during engine operation.
Install a new snap ring in the piston pin bore.
Install the rings onto the piston and the piston into the liner.
Install
Install the connecting rod, piston and liner into the block. Refer
to Procedure 001-028.
QSV27 and QSV36 Crankshaft Gear, Front (Crankshaft Installed) (001-018)
Crankshaft Gear, Front

(Crankshaft Installed) (001-018)
Remove
Remove the five 24 mm capscrews from the crankshaft cover
and remove the cover.
Loosen the eight capscrews that hold the gear in place.

Remove six of the eight capscrews backing the remaining two
out to allow approximately 1/2 inch between the bolt head and
face of the gear.
Using a soft faced hammer, tap around the perimeter of the

gear to free it from the pinion shaft.
Once loose, remove the remaining two capscrews and remove
the gear.
Clean
WARNING
Wear goggles and protective clothing to avoid personal
injury.
WARNING
Wash the gear with solvent and dry with compressed air.
Crankshaft Gear, Front (Crankshaft Installed) (001-018) QSV27 and QSV36
Clean the mating surface between the gear and the pinion sur-
face using solvent and dry with compressed air.
Inspect for Reuse

Inspect the crankshaft gear teeth for any signs of wear or dam-
age.
If damage is found replace the gear.
Install
Insert two alignment dowels for installation.
Slide the gear onto the dowels and onto the shaft.
Coat the threads of the eight capscrews with Loctite 243, and
30/40 oil under the bolt heads. Install and tighten the capscrews
in two stages.
Scrape any remaining sealing material from the crankcase

cover.
Apply one bead of silicone gasket material to the cover.
QSV27 and QSV36 Crankshaft Seal, Rear (001-024)
Install the crankcase cover and five 24 mm capscrews.
Crankshaft Seal, Rear (001-024)

Preparatory
Separate the generator and coupling from the flywheel housing
and flywheel. Refer to Procedure 016-004.
Remove the flywheel. Refer to Procedure 016-005.
Remove
Remove the seal mounting capscrews.
Remove the seal cover.

Crankshaft Seal, Rear (001-024) QSV27 and QSV36
Remove the seal.
Clean and Inspect
WARNING
Use a clean cloth and safety solvent. Clean the crankshaft and
seal mounting area.
Check the crankshaft and seal bore for scratches or other dam-
age.
Install
Apply a thin film of engine oil to the inside diameter of the seal.
Use hand pressure to push the seal on the crankshaft as far as

possible.
QSV27 and QSV36 Cylinder Block (001-026)
Install the seal cover.
Install the four capscrews.

Torque Value: 9 N•m [80 in-lb]
Finishing
Install the flywheel. Refer to Procedure 016-005.
Assemble the generator coupling and generator to the flywheel
and flywheel housing. Refer to Procedure 016-004.
Cylinder Block (001-026)

Inspect for Reuse
Inspect the cylinder block for cracks. If any cracks are found,
the cylinder block must be replaced.
Cylinder Block and Liner Seats (001-027) QSV27 and QSV36
Cylinder Block and Liner Seats

(001-027)
Leak Test
Remove all the cylinder inspection covers. (Both sides)
Pressurize the engine cooling system. Refer to Procedure 008-

018.
NOTE: Apply the air pressure 15 minutes before inspecting the
cylinder liner seats. Be sure the system is holding air pressure
before beginning inspection.
Air Pressure: 138 kPa [20 psi]
Inspect the outside circumference of the cylinder liners and the

area below the cylinder liner seats in the cylinder block for cool-
ant leaks.
If a leak is found:
• Remove the cylinder liners. Refer to Procedure 001-028.
• Inspect the cylinder block liner bore area. If fretting or
wear is found, the cylinder block must be replaced.
Replace all of the cylinder inspection covers.

QSV27 and QSV36 Cylinder Liner (001-028)
Cylinder Liner (001-028)

General Information
The QSV27/36 cylinder liner must be removed as an assembly
with the piston and connecting rod.
The lifting tool #3164397 fastens to the piston and cylinder liner
and extracts them as an assembly. The tool consists of a pilot
flange (5), liner carriage (4), locking ring (1), liner clamping
plate halves (2) and lifting eye (3).
Preparatory
Drain the engine oil. Refer to Procedure 007-025.
Remove the rocker levers. Refer to Procedure 003-008.
Remove the cylinder head. Refer to Procedure 002-004.
Remove
Remove the antipolishing ring from the top of the cylinder liner.
Clean the tapped, M8 X 1.25, holes in the top of the piston for
installation of the lifting tool.
Cylinder Liner (001-028) QSV27 and QSV36
Remove the crankshaft access cover.
Use the barring mechanism to rotate the engine. Rotate the

crankshaft to position the connecting rod cap for loosening the
capscrews through inspection port.
Connecting rods must have the cylinder number marked on

both the rod and the cap on the side positioned toward the cam-
shaft. Check the rods for correct markings. Use a steel stamp
and mark any rod that is not correctly marked.
Remove the connecting rod capscrews and the connecting rod
cap with the bearing insert.
Remove the lower rod bearing. Use an awl and mark the bear-
ing position in the tang area.
Mark the bearing for future identification or for possible failure
analysis.
Use barring mechanism to move piston up. Position top of pis-
ton 30 mm (1.200 in) from the top of the liner.
NOTE: Do not allow the top ring to expand into the antipolish-
ing ring groove.
Attach the pilot flange to the top of the piston.

Install the liner carriage and clamping plate halves over the pilot
flange.
Loosen the locking ring (1) to allow the carriage to seat onto the
pilot flange.
Position the clamping plate halves under the locking ring and
over the cylinder liner. Once the clamping plate halves are in
the cylinder liner groove, fasten the latches (2).
Install the lifting eye (1).
Tighten the locking ring to secure the clamping plate, carriage
and pilot flange.
Use the barring mechanism to rotate the crankshaft to top dead

center for that cylinder.
WARNING
Use a hoist and remove the piston and liner assembly.
NOTE: Keep the assembly aligned with the cylinder block until
removed.
Place the assembly on a pallet or bench.
Remove the lifting tool from the piston and liner assembly.
CAUTION
Do not allow the piston to slide into the antipolishing ring
bore in the liner. The piston rings will expand and trap the
connecting rod in the liner.
Disassemble
Remove the connecting rod from the bottom end of the liner.
Remove and discard the o-ring seals from the liner.
Clean
CAUTION
Do not use a wire brush to clean the inside surface of the
liner. Do not use a hone, aluminum oxide cloth, or sandpa-
per to clean the liner.
Use a high-durability steel wire brush to clean the liner flange
seating area. Do not use a steel wire brush on any other part of
the liner.
WARNING
WARNING
Clean the liner bore in warm water and detergent. Scrub the
liner with a non-metallic brush.
Use steam or a solvent tank to clean the outside of the liner.
Inspect for Reuse

NOTE: Refer to Parts Reuse Guidelines, Bulletin No. 3810303,
for examples of liner condition.
Visually check the liner bore for cracks. Replace the liner if any
are found.
NOTE: Cracks can also be detected by either magnetic inspec-
tion or dye method.
Inspect the liner for cracks under the flange.

NOTE: Cracks can also be detected by using either magnetic
inspection or the dye method.
Check the outside of the liner for excessive corrosion or pitting.
Pits must not exceed 1.6 mm [0.063 in] in depth.
Replace the liner if the pits are deeper than specifications.
Check the liner bore for vertical scratches deep enough to be

felt with a fingernail. Replace the liner if any deep scratches are
found.
Check the liner bore for scuffing or scoring and replace liner if
damage is found.
Check the liner inside diameter for bore polishing.

A light polish produces a bright mirror finish in the worn area
with original hone marks remaining.
A moderate polish produces a bright mirror finish in the worn
area with very light traces of the original hone marks or an indi-
cation of an etch pattern.
A heavy polish produces a bright mirror finish in the worn area
with no traces of hone marks or an etch pattern.
Replace the liner if:

A heavy polish is present over 20% of the piston ring travel
area.
30% of the piston ring travel area has both moderate and heavy
polish, and 1/2 (15%) of the area is heavy polish.
Use a dial bore gauge, Part Number 3375072. Measure the
inside diameter of the liner at the top, the bottom, and the mid-
dle of the piston travel area.
Perform two measurements at each location. The measure-
ments must be 90 degrees apart.
Cylinder Liner Inside Diameter

mm in
170.000 MIN 6.693
170.040 MAX 6.695
The diameter must be no more than 0.020 mm [0.001 in] out-

of-round at all three measuring areas.
If the diameter is not within specifications at any of the three
locations, the liner must be replaced.
WARNING
CAUTION
Be careful to prevent the cleaning solvent or any removed
debris from getting into the crankcase.
Use a hydrocarbon solvent such as naphtha, methyl ethyl
ketone, trichlorethane (methyl chloroform) or equivalent to
clean the liner sealing surface.
NOTE: The cylinder block edge must be clean and dry. The
sealant used in assembly will not dry if oil is present.
Inspect the area of the cylinder block around the liner seating
surface for cracking or porosity.
Install
Assemble the piston and connecting rod. Refer to Procedure
001-014.
Install the rings onto the piston and the piston into the liner.
Mark the multi-duct side of the piston as shown. Attach the pilot
flange to the top of the piston.
Attach lifting tool, Part Number 3164397.

Install the liner carriage and clamping plate halves over the pilot
flange.
Position the clamping plate halves under the locking ring and
over the cylinder liner. Loosen the locking ring (1) to allow the
carriage to seat on the pilot flange. Once the clamping plate
halves are in the cylinder liner groove, fasten the latches and
tighten the locking ring (1).
Install the lifting eye (2).
Use a lint-free cloth. Clean the connecting rod and the bearing
shells.
Install the rod bearing. Be sure the tang is positioned as shown.
The end of the bearing must be even with the cap mounting
surface.
CAUTION
Do not lubricate the back side of the bearing shells.
Use clean engine oil to lubricate the bearing surface. The bear-
ings must be installed in their original location if new bearings
are not used.
Install two locally procured connecting rod guide pins in the rod.
The guide pins will aid the assembly and protect the crankshaft.
Lubricate crankshaft rod journal with clean engine oil.

Rotate the crankshaft until the journal for the rod being installed
is at top dead center (TDC).
Install three new o-ring seals onto the liner.
Lubricate liner seals with clean engine oil.
WARNING
to lift this assembly. Make sure all lifting devices such as
chains, hooks, or slings are in good condition and are of
the correct capacity.
Check coating of Oraseal sealant on bottom of liner support rim.
Lift the liner assembly with hoist and align with cylinder bore.
“CTR” marking on piston crown is to be toward multiduct side of
engine.
The cylinder number marking on the connecting rod pad will be
toward camshaft side of engine.
Lower the assembly into cylinder block.

Guide the connecting rod until seated on the crankshaft journal.
Remove the hoist.
Rotate the crankshaft to lower the piston. When the lifting eye
starts to move downward, the lifting tool can be removed.
Remove the tool.
Use a liner driver, Part Number 3164572, and hammer to seat

the liner into the block.
Install the antipolishing ring.
CAUTION
The connecting rods and caps are not interchangeable.
The rods and the caps are machined as an assembly. Fail-
ure will result if they are mixed.
Install the lower bearing shell in the rod cap. Be sure the tang of
the bearing shell is in the slot of the cap and the end of the
bearing is even with the cap surface.
Remove guide pins, if used.
Install the connecting rod cap.
CAUTION
The cylinder number on the connecting rod and cap must
be the same.
CAUTION
The side of the rod with the cylinder number (bearing tang
side) must be toward the camshaft.
Install new connecting rod capscrews hand tight.
Rotate engine to position the connecting rod for tightening.
Use clean engine oil to lubricate the connecting rod capscrews

as shown. Install the washers and capscrews in the caps.
Lubricate area under the flange with 140 weight EP oil.
NOTE: Do not reuse capscrews.
Tighten the capscrews in the sequence shown in the drawing.

Finishing
Install crankshaft access cover.
Install cylinder head. Refer to Procedure 002-004.
Install rocker levers. Refer to Procedure 003-008.
Fill the oil system. Refer to Procedure 007-025.
Fill the cooling system. Refer to Procedure 008-018.
QSV27 and QSV36 Gear Housing, Front (001-033)
Gear Housing, Front (001-033)

Preparatory
Drain the engine oil. Refer to Procedure 007-025.
Remove the heat exchanger support. Refer to Procedure 010-
054.
Remove the water pump. Refer to Procedure 008-062.
Remove the sea water pump. Refer to Procedure 008-057.
Remove the lubricating oil pump. Refer to Procedure 007-031.
Remove the fuel transfer pump. Refer to Procedure 005-045.

Remove the fuel priming pump. Refer to Procedure 005-076.
Remove the fuel filter housing. Refer to Procedure 005-028.
Remove
Remove the gear housing side cover.
Support the fuel transfer pump drive gear.

Remove the four capscrews from the fuel transfer pump drive
adaptor.
Remove the fuel transfer pump drive gear through the side
access port.
Gear Housing, Front (001-033) QSV27 and QSV36
Support the water pump idler gear.
Remove the capscrew from the idler assembly.
Remove the water pump idler gear through the side access
port.
WARNING
This component weight 23 kg [50 lb] or more. To reduce the
to lift this component.
Remove the interior and exterior nuts and capscrews on the
free-end gear cover.
Access to some fasteners may only be attained through the
gear housing side cover.
Attach a hoist to the gear housing. Using a prybar, rock the

housing off the dowel pins.
NOTE: Care must be taken to prevent damage to the mating
surfaces.
Clean
WARNING
Use steam or solvent to clean the gear housing and dry with
compressed air.
Inspect for Reuse
Inspect the gear housing for cracks or other damage.
Inspect the o-ring grooves for debris or damage.
Install
Install new seals into the gear housing.
Apply a bead of Loctite® 515 to the block and pan sealing sur-
faces of the gear housing.
CAUTION
Use a hoist to raise the gear housing into place.
Align the dowel pins with the housing.
Slide the gear housing onto the block and pan.
Lubricate the threads of the mounting capscrews and studs with

clean engine oil.
Tighten the fasteners evenly.
Gear Housing, Front (001-033) QSV27 and QSV36
Install the water pump idler gear through the side access port.
Install the capscrew.
Install the fuel transfer pump drive gear through the side access
port.
Install the four capscrews through the adaptor and into the
gear.
Install the crankshaft drive gear.

Coat the capscrew threads with Loctite® 243. Lubricate the
contact surface of the capscrew with clean engine oil.
Torque the capscrews in the sequence shown. Tighten all the

capscrews to the first torque value, then tighten again to the
final torque value.
Apply a bead of Loctite 515 to the mating surface of the gear
housing side cover.
Install the cover and capscrews.
Finishing
Install the fuel filter housing. Refer to Procedure 005-028.
Install the fuel transfer pump. Refer to Procedure 005-045.
Install the fuel priming pump. Refer to Procedure 005-076.
Install the water pump. Refer to Procedure 008-062.

Install the sea water pump. Refer to Procedure 008-057.
Install the lubricating oil pump. Refer to Procedure 007-031.
Install the heat exchanger support. Refer to Procedure 010-

054.
Fill the engine lubricating oil system. Refer to Procedure 007-
025.
Fill the engine cooling system. Refer to Procedure 008-018.
Piston (001-043) QSV27 and QSV36
Piston (001-043)
General Information
The QSV27/36 piston must be removed as an assembly with
the connecting rod and cylinder liner.
The lifting tool, Part Number 3164397, fastens to the piston and
cylinder liner and extracts them as an assembly. The tool con-
sists of a pilot flange (5), liner carriage (4), locking ring (1), liner
clamping plate halves (2) and lifting eye (3).
Preparatory
Remove the piston, connecting rod and liner from the engine.
Remove the rings and connecting rod from the piston. Refer to
Procedure 001-014.
Clean
CAUTION
Do not use a metal brush or glass bead blasting to clean
the ring grooves. If using walnut shells or plastic beads,
use the minimum effective pressure and do not concen-
trate the spray in one area for an extended length of time.
Do not brush or blast the piston skirt. Damage to the phos-
phate/graphite coating will occur.
Place the piston top down in a tank of carbon solvent at a level
that does not touch the phosphate/graphite coating of the pis-
ton skirt. Allow the piston to soak for a minimum of 30 minutes.
Remove the piston and use a hot soapy solution and a non-
metallic brush to remove carbon deposits. For heavy deposits in
the ring grooves or on the crown, walnut shell or plastic bead
blasting may be used.
QSV27 and QSV36 Piston (001-043)
WARNING
WARNING
Use steam to clean the piston. Dry with compressed air.
Install a new snap ring in one piston pin bore of the piston.
NOTE: It is not necessary to heat or warm pistons before
assembly. The piston pin is slip-fit. If piston is cold, heat to 30°
(85°F) in an oil bath to aid in wrist pin installation.
CAUTION
Do not use a hammer to install the piston pin. The piston
can distort, causing it to seize in the liner.
Use clean engine oil. Lubricate the piston pin and connecting
rod bushing.
Align the pin bore of the rod with the pin bore of the piston skirt
and crown, and install the piston pin.
Install the connecting rod with the oil drilling in the connecting
rod (1) on the opposite side of the oil drilling in the bottom of the
piston.
Piston (001-043) QSV27 and QSV36
The snap ring must be seated completely in the piston groove
to prevent engine damage during engine operation.
Install a new snap ring in the piston pin bore.
Install the piston rings using expander tool, Part Number

3164401, with “TOP” marking to top of piston.
Stagger the ring end gaps 120 degrees apart.
Place support (1) under the piston and connecting rod assem-
bly.
Lubricate the piston rings with engine oil.
NOTE: Procure and fabricate supports from suitable material
sourced locally.
Position the support (1) for the ring compressor around the pis-
ton.
QSV27 and QSV36 Piston (001-043)
NOTE: Do not align ring gap with gap in compression tool.
Install ring compressor, Part Number 3164399, close tool by
hand. Do not force tool closed.
Slide the tool down against the support (1).
Place the liner into the ring compression tool.

Lubricate the inside of the liner with clean engine oil.
Lift the liner to allow removal of the ring compressor tool sup-
port.
Slide the liner and ring compressor tool down over the piston
until the compressor tool contacts the support table.
Piston Cooling Nozzle (001-046) QSV27 and QSV36
Lift the liner slightly to allow the removal of the ring compressor
tool.
Slide the liner down to the support table.
Coat the bottom of the liner support ledge with Oraseal flexible
sealant.
Install
Install the piston, connecting rod and cylinder liner assembly
into the block. Refer to Procedure 001-028.
Piston Cooling Nozzle (001-046)

Remove
Remove the inspection covers on the left side of the engine.
QSV27 and QSV36 Piston Cooling Nozzle (001-046)
Bar the crankshaft to position the connecting rod away from the
piston cooling nozzle.
Remove the mounting capscrew and the piston cooling nozzle.
Clean
WARNING
WARNING
injury.
Use solvent to clean the piston cooling nozzles. Dry with com-
pressed air.
Blow out the oil passages with compressed air.
Piston Cooling Nozzle (001-046) QSV27 and QSV36
Inspect for Reuse
CAUTION
Any damage to the piston cooling nozzle can result in
major engine damage.
Inspect the cooling nozzle for damage. Check for damage at
the spray tip. A damaged cooling nozzle must be replace if any
damage is found.
Install
WARNING
Use skin and eye protection when handling caustic solu-
tions to reduce the possibility of personal injury.
NOTE: Clean the mounting capscrew with solvent and dry with
compressed air.
Lubricate the capscrew threads with Loctite® 243.
Install the piston cooling nozzle, capscrews, and new o-ring.

Insure the nozzle is seated properly on the guide pin and
tighten the capscrew.
NOTE: If the nozzle is not seated correctly, piston failure will
occur.
Repeat the procedure on remaining cylinders.

Install the inspection covers with a new seal.
QSV27 and QSV36 Vibration Damper (001-052)
Vibration Damper (001-052)

General Information
QSV27 engines are equipped with a single damper and QSV36
engines are equipped with dual vibration dampers.
Preparatory
Remove the front gear cover housing. Refer to Procedure 001-
033.
Remove
WARNING
Attach a lifting strap to a hoist and the damper.
Remove the twelve capscrews and the vibration damper from
the mounting adaptor.
Clean
WARNING
injury.
WARNING
Clean the vibration damper and mounting adaptor shaft with
solvent and dry with compressed air.
Vibration Damper (001-052) QSV27 and QSV36
Inspect for Reuse
Inspect the damper for cracks on the mounting flange.
Inspect for dents or bulges on the housing.
If the damper is damaged, it must be replaced.
Use the crack detection kit, Part Number 3375432, or equiva-

lent, and spray the rolled lip of the damper.
NOTE: The crack detection kit, Part Number 3375432, contains
the necessary cleaner, penetrant, and developer to check for
cracks using the dye penetrant method.
CAUTION
Wear protective clothing to reduce the possibility of per-
sonal injury from burns.
Use an oven with the temperature adjusted to 93°C [200°F].
Put the damper in the over with the rolled lip down. Heat the
damper for two hours.
CAUTION
Wear protective clothing to reduce the possibility of per-
sonal injury from burns.
Remove the damper and check for leakage around the lip. If
there is any leakage the damper must be replaced.
QSV27 and QSV36 Vibration Damper (001-052)
Install
CAUTION
Do not hammer or pry on the vibration damper with sharp
or pointed tools. The damper could be damaged beyond
usability.
WARNING
Insert two 17 mm guide pins into the mounting adapter. Slide
the inside damper over the pins and onto the adapter.
Slide the outer damper over the pins and onto the adapter.
Using clean engine oil, put oil on the twelve 17 mm allen head
capscrew threads and under the bolt head. Install the cap-
screws, removing the guide pins once several have been
started.
Tighten the capscrews.

Eccentricity
Use a dial indicator, Part Number 3376050 and indicator base,
Part Number 3377399, and adjust it as shown to measure radial
alignment of the vibration damper. Turn the crankshaft 360
degrees and record the total indicator runout.
Maximum Eccentricity: 0.46 mm [0.018 in]
If the measurement is not within specifications, be sure the
damper pilot is aligned properly.
Gear Train Backlash (001-055) QSV27 and QSV36
Wobble Check
NOTE: The crankshaft end clearance must be pushed or
pulled in the same direction each time measurement is taken.
Maximum Wobble: 0.56 mm [0.022 in]
NOTE: When the dial indicator is positioned more than 13 mm

[1/2 inch] from the outside diameter, the specification is differ-
ent.
To determine the specification:
• Measure the distance from the center of the crankshaft to
the point the indicator tip touches the damper.
• Multiply the distance by 0.15 mm [0.0006 in] to obtain the
maximum total indicator runout.
• If the measurement is not within specifications, check for
foreign material between the crankshaft and the damper.
Gear Train Backlash (001-055)

Measure
NOTE: If the backlash is not within specifications the gear
must be replaced.
Remove the camshaft gear cover for access.
Camshaft Gear Bushings (001-056)

Clean
Clean the bushings.
QSV27 and QSV36 Camshaft Intermediate Gear (001-072)
Remove
Remove the camshaft gear and bushings.
Inspect for Reuse

Inspect the bushings for reuse.
Install
Install the camshaft gear and bushings.
Camshaft Intermediate Gear (001-072)

Remove
Remove the camshaft gear.
Camshaft Intermediate Gear (001-072) QSV27 and QSV36
Remove the gear lubricating nozzles to prevent it from becom-
ing damaged.
NOTE: The flywheel and flywheel housing have been omitted

from illustrations for clarity.
Remove the intermediate gear cover plate.
Remove the intermediate gear flange plate.
Loosen the four intermediate gear pinion capscrews. Slide the

capscrews into the clearance hole in the flywheel housing.
NOTE: The capscrews and pinion cannot be removed until the
gears are extracted.
Slide the pinion toward the flywheel slightly.
While supporting the small intermediate gear, slide the large

intermediate gear toward the free-end.
Remove the small intermediate gear.

Remove the large intermediate gear.

Remove the pinion and capscrews from the engine.
Remove the intermediate gear thrust bearings from the block.
Remove the intermediate gear bushing with a suitable puller.
Clean
Clean the gears, hubs, bolts, and bearings.
Inspect for Reuse
Inspect the intermediate gears for cracks, chipped or broken
teethe.
Inspect the bushings for reuse.
CAUTION
clothing when handling liquid nitrogen to reduce the possi-
bility of personal injury. Liquid nitrogen can cause freezing
and damage to the skin and eyes.
Cool the new intermediate gear bushing in liquid nitrogen.
Install the intermediate gear bushing into the block.

Lubricate the intermediate gear pinion with clean engine oil.
Place the capscrews in the pinion.
Place the intermediate gear pinion and capscrews into the

clearance hole in the flywheel.
Lubricate the journal of the large intermediate gear and install

into engine block.
NOTE: Use caution when installing the gear. Damage to the
Install the small intermediate gear.

NOTE: Use caution when installing the gear. Damage to the
While supporting the small gear, slide the pinion and capscrews
into place.
Tighten the capscrews, in the sequence shown, to the first
torque value. Repeat the process at the second torque value.
Install the intermediate gear flange plate.

Use a dial indicator, Part Number 3376050 and indicator base,

Part Number 3377399, to measure the end clearance of the
intermediate gear shaft. It it is not within specifications, check
for debris between the components.
Intermediate Shaft End Clearance

mm in
0.15 MIN 0.0059
0.60 MAX 0.0236
Install the intermediate gear cover plate.

Install the gear lubricating nozzle.
Install the camshaft gear.

Set the timing.

QSV27 and QSV36
Section 2 - Cylinder Head - Group 02 Page 2-1
Section 2 - Cylinder Head - Group 02

Section Contents
Page
Crosshead................................................................................................................................................................................. 2-5
Clean .................................................................................................................................................................................... 2-5
Install .................................................................................................................................................................................... 2-6
Remove ................................................................................................................................................................................ 2-5
Cylinder Head ........................................................................................................................................................................... 2-7
Assemble ............................................................................................................................................................................ 2-15
Clean and Inspect ................................................................................................................................................................2-11
Disassemble ........................................................................................................................................................................2-11
Inspect ................................................................................................................................................................................ 2-12
Install .................................................................................................................................................................................. 2-18
Measure .............................................................................................................................................................................. 2-13
Pressure Test ...................................................................................................................................................................... 2-14
Remove ................................................................................................................................................................................ 2-7
Service Tools ............................................................................................................................................................................ 2-3
Cylinder Head ....................................................................................................................................................................... 2-3
Valve Seats ............................................................................................................................................................................. 2-24
Inspect ................................................................................................................................................................................ 2-24
Valves ...................................................................................................................................................................................... 2-24
Inspect ................................................................................................................................................................................ 2-24
QSV27 and QSV36
Page 2-2 Section 2 - Cylinder Head - Group 02

Service Tools
Cylinder Head
Depth Gauge Assembly

Use to measure liner protrusion, injector protrusion, cylinder block
counterbore depths, and valve intrusion and/or protrusion.
3823495
Injector Bore Brush

Use to clean the injector bore in the cylinder head.
3822510
Scotch-Brite 7448
Use to clean carbon from the upper liner bores, removing rust and
corrosion, and scuffing surfaces.
3823258
Valve Guide Extractor

Use to remove valve guides.
3164414
Valve Guide Installer

Use to install the valve guides.
3164417
Valve Spring Compressor

Use to compress the valve springs.
3164418
Valve Seat Removal Tool

Use to remove intake and exhaust valve seats from Phase I cylin-
der heads.
3164412
Valve Seat Installer

Use to install intake and exhaust valve seats in Phase I and II cylin-
der heads.
3164426
Hydraulic Tensioning Tool

Use to loosen and tighten cylinder head studs.
3164395
Cylinder Head Lifting Tool

Use to lift both Phase I and Phase 2 cylinder heads.
3164394
Valve Seat Removal Tool

Used to remove intake and exhaust seats from Phase II cylinder
heads.
Stud Driver M30
3164396
QSV27 and QSV36 Crosshead (002-001)
Crosshead (002-001)
Remove
Remove rocker lever cover. Refer to Procedure 003-011.
Remove rocker lever assembly. Refer to Procedure 003-008.
Remove the crossheads.

NOTE: Phase II crossheads, starting with engine serial number
66300227, are not equipped with guide stems.
Clean
WARNING
WARNING
injury.
Clean the crossheads with solvent. Dry with compressed air.
Crosshead (002-001) QSV27 and QSV36
Inspect for Reuse
Inspect the crossheads for cracks and/or excessive wear on
rocker lever and valve tip mating surfaces.
Install
Lubricate the valve stems and crosshead guides with clean
engine oil. Install the crossheads on the guide.
Install rocker lever assembly. Refer to Procedure 003-008.
Install rocker lever cover and gasket. Refer to Procedure 003-

011.
QSV27 and QSV36 Cylinder Head (002-004)
Run the engine and check for leaks.
Cylinder Head (002-004)

Remove
WARNING
Always disconnect the negative (-) cable first to reduce the
possibility of sparks that can ignite explosive battery
gases.
WARNING
Batteries emit hydrogen gas. To reduce the possibility of
explosion and personal injury, do not smoke or allow igni-
tion source in area when servicing batteries.
Disconnect the batteries or air supply to the air starter to pre-
vent accidental engine starting.
WARNING
Allow the engine to cool before draining to reduce the pos-
sibility of burns from hot liquid.
WARNING
Some coolants are poisonous. Keep away from children
and animals. Save for reuse or dispose of in accordance
with local environmental laws.
Drain the cooling system. Refer to Procedure 008-018.
Remove valve cover (1), rocker levers (2), push tubes (3), and
injection pump cover (4). Refer to Section 4.
Cylinder Head (002-004) QSV27 and QSV36
Remove the push tube covers (1).
Disconnect the oil supply line (1), fuel supply line (2), and drain
lines (3).
Remove the fuel injector. Refer to Procedure 006-026.
Remove six multiduct housing capscrews (1) and spacers (2).

NOTE: Exhaust manifold section shown removed for clarity.
Install the hydraulic tensioners. Install one hydraulic cylinder on
each of the cylinder head mounting studs.
NOTE: The exhaust manifold section and multiduct shown
removed for clarity.
WARNING
Make certain hydraulic cylinders are compressed before
installing studs. Failure to do so can cause personal injury
and equipment damage.
Tighten the tool, then back off 1/2 to 3/4 turn.
Install the hydraulic lines to the hydraulic cylinders and pump as

shown.
Be sure that the fittings and hoses are clean and undamaged.
Use the hand pump to apply 870 bar pressure to the hydraulic
cylinders.
NOTE: If there is any leakage, release pressure, refit the hoses
or fittings, and re-apply pressure.
NOTE: Pivicat tool pressure 870 bar. Hydratite tool pressure
1030 bar.
Once the hydraulic cylinders have tensioned the studs, loosen

the stud locking rings.
Release the pressure on the hydraulic cylinders and remove

the tool.
Remove the stud locking rings.
CAUTION
This component weighs 23 kg [50 lb.] or more. To reduce
the possibility of personal injury, use a hoist or get assis-
tance to lift the component.
Install lifting tool Part Number 3164394.
Remove the cylinder head from cylinder block.
Clean and Inspect
WARNING
When using solvents, acids or alkaline materials for clean-
Clean the head with solvent. Check for broken springs or other
damage.
Visual inspection of the cylinder head chambers is of great

importance. If heavy deposits of scale are found, they have to
be removed with a 10% hydrochloric acid solution as they are
detrimental to cooling. Dip the cylinder head in a cleaning solu-
tion heated to 90°C to remove any remaining pockets or acid.
Disassemble
CAUTION
The valve springs are under compression. Use caution
when using the valve spring compressor. Personal injury
can result.
Use Part Number 3164418 valve spring compressor, to com-
press springs.
Remove the collets.
Slowly loosen the spring compression bolt to release valve

springs. Remove spring compressor tool.
Remove the valve rotators (1), valve springs (2), valves (3) and
valve spring seat (4).
NOTE: Cummins Inc. does not recommend the reuse of valves
at rebuild.
Valve Guide Removal
Use a hydraulic press and a mandrel, Part Number 3164414
(1), to remove the worn valve guide (2).
Intake Valve Seat Removal

Remove the intake valve seats with the special extractor tool,
Part Number 3164412. Screw the nut(1) on the operating screw
(2) and insert the tool behind the intake seat. Put the thrust bell
(3) on the cylinder head flame plate and tighten the operating
nut (1) hand tight. Tighten the operating nut (1), using an open-
end wrench, until the seat is fully extracted.
at rebuild.
Exhaust Valve Seat Removal

Remove the exhaust valve seats with a special extractor tool,
Part Number 3164412. Screw the nut (1) on the operating
screw (2) and insert the tool behind the exhaust seat. Put the
thrust bell (3) on the cylinder head flame plate and tighten the
operating nut (1) hand tight. Tighten the operating nut (1), using
an open-end wrench, until the seat is fully extracted.
at rebuild.
Inspect
Check for cracks extending into the valve seat insert bore.
NOTE: The cylinder head must be replaced if a crack extends
into the bore.
Check for cracks on the combustion surface.
NOTE: If a crack around the injector bore exceeds the maxi-
mum length, the cylinder head must be replaced.
Allowable Crack Length

mm in
6 MAX 0.25
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 is questionable. To
be sure that the cylinder head is reusable, remove the valve
and valve seat.
Inspect the injector bore for cracks or other damage.
Measure
Measure the I.D. of the valve guide bore.
Valve Guide Bore I.D.

mm in
11.991 MIN 0.472
12.043 MAX 0.474
Check seating area of liner on head for fretting.

Use a straight edge to measure the flatness of the head sealing
surface.
The head must be replaced if a feeler gauge larger than 0.08
mm (0.003 in) will fit between the straight edge and the cylinder
head or if excessive fretting is present.
Measure the valve seat to the valve guide concentricity with
service tool 685-4 and arbor.
NOTE: The seat and guide must be concentric.
Valve Seat to Guide Concentricity

mm in
0.10 MAX 0.004
Change the seat if out of specification.

NOTE: The valve seat and valve face surfaces are not to be
ground or lapped due to surface hardness.
NOTE: With the valve seats removed, measure the I.D. of the
insert bore in the head.
Valve Seat Bore Measurements

mm in
3 Intake Diameter 62.000 MIN 2.440
62.019 MAX 2.442
2 Inner Bore 54.200 MIN 2.134
54.800 MAX 2.154
1 Exhaust Diameter 56.000 MIN 2.204
56.019 MAX 2.205
Pressure Test
Fabricate and install blocking plates to seal coolant ports.
WARNING
This component weighs 23 kg [50 lb] or more. To reduce
tance to lift this component.
Install the lifting bracket.
WARNING
injury.
Adjust the air pressure.
Air Pressure
bar psi
7.10 MAX 100
Lower the head into a tank of water.

Bubbles will indicate an air leak.
If the cylinder head leaks, it must be replaced.
Assemble
Valve Guide Install
WARNING
WARNING
injury.
Use solvent to clean the valve guide bores.
CAUTION
Make sure the mandrel does not damage the top of the
valve guide. If the guide is damaged, the valves may stick
causing severe engine damage.
Install guides into the cylinder head using a hydraulic press and
valve guide installation tool, Part Number 3164417.
Measure the distance between the cylinder head top face and
the top of valve guide.
Valve Guide Recess

mm in
0.45 MIN 0.018
0.50 MAX 0.020
Measure the I.D. of the valve guide bore.
Valve Guide Bore I.D.

mm in
11.991 MIN 0.472
12.043 MAX 0.474
Exhaust Valve Seat Install
CAUTION
clothing when handling liquid nitrogen to prevent personal
injury. Liquid nitrogen can cause freezing and damage to
the skin and eyes.
Cool the seats in liquid nitrogen until they are 70°C [158°F]
below the temperature of the cylinder head.
The cylinder head may be heated to raise the temperature.
Place the cooled exhaust seat in the cylinder head and fit the
exhaust valve seat installer, Part Number 3164426, into the
valve guide and seat. Using a soft faced mallet, seat the new
seat by bottoming out the seat in the bore. (Listen for a change
in tone while driving the seat).
Intake Valve Seat Install
Using a soft faced mallet, insert the cooled seat into the cylinder
head. Using the intake valve seat installer, Part Number
3164426, push the seat to the stepped area of the cylinder
head. Listen for a change in tone once seat is bottomed.
CAUTION
Lubricate all the valve guide bores and valve stems with
140W oil. Failure to lubricate guide and stems will result in
premature valve guide wear.
Install new valve guide o-rings into the guide bore.
CAUTION
The valve springs are under compression. Use caution
when using the valve spring compressor. Personal injury
can result.
NOTE: The valve rotator must be soaked in clean engine oil for
at least 15 minutes prior to installation.
Install the following parts:
1. Valve
2. Valve spring seat
3. Valve spring
4. Valve rotator
Use Part Number 3164418 valve spring compressor to com-

press springs. Install the collets. Remove spring compressor
and tap valve stem with a soft face mallet to seat collets.
NOTE: Apply grease to collets and stems to prevent wear and
retain collets during assembly.
Install
NOTE: The exhaust manifold section and multiduct housing
shown removed for clarity.
Using the M30 Stud Extractor, Part Number 3164396, check
and tighten the cylinder head studs.
Ensure the cylinder head mounting surface is free from dirt or

debris.
Install a new copper head gasket (1) and water jacket grommet
(2).
Install cylinder head stud seals. Use Loctite® 5699. Refer to
Section V.
Rivet the multiduct housing gasket to the multiduct with speci-

fied rivets. Refer to Procedure 010-079.
WARNING
Lower the cylinder head back into position. Check all the gas-
kets as the head is lowered to make sure they remain in place
and aligned.
Use a lint free cloth to clean the threads on both the stud and
nut.
Screw on the cylinder head stud nuts.
Place the jacking sleeves over the cylinder head studs so they
are seated against the face of the head.
NOTE: Make sure the base of the sleeve does not contact the
adjacent cylinder head.
Screw the jacking cylinders onto the cylinder head studs.
WARNING
Check that the pistons on the hydraulic jacks are fully
retracted into the cylinders. Equipment or personal injury
can occur if the piston leaves the bore while under pres-
sure.
Connect the hydraulic pressure hoses from the pump to the cyl-
inders as shown in the diagram.
Follow the instructions included with the tool for purging air from
the cylinders.
Close the valve on the pump and apply pressure to the jacking
cylinders. Pressurize the cylinders to 700 bar.
Using the service tool pin that comes with the pressure cylin-
ders, work through the window in the sleeves and tighten the
nuts until snug.
Slowly open the valve on the pump and release the hydraulic
pressure.
Screw the jacking cylinders down against the sleeves. Back off
1/4 turn (90°).
Close the valve on the pump and apply pressure to the jacking
cylinders. Pressurize the cylinders to 870 bar with Pivicat tool or
1030 bar with Hydratite tool.
Using the service tool pin that comes with the pressure cylin-
ders, work through the window in the sleeves and tighten the
nuts until snug.
Slowly open the valve on the pump and release the hydraulic
pressure.
Check nuts for tightness by tapping in loosening direction.
Disconnect and remove all hoses, cylinders, and sleeves.
Lubricate the multiduct to cylinder head capscrews (1) with cop-

per based anti-seize compound. Install the screws (1) and
spacers (2).
Install new push rod protecting tube o-rings (1) in the two open-
ings in the cylinder head.
Lubricate the outside of the push rod protecting tubes (2) with
clean engine oil.Push the tubes down through the o-rings until
the tubes are seated against the follower cover plates.
Lubricate the lower ends of the push rods with clean engine oil.
Insert the push rods into the protecting tubes and make sure
the push rods are seated in the top of the cam follower (little
side to side play, and both at the same height).
Lubricate the valve stems and crosshead guides with clean

engine oil. Install the crossheads on the guide.
Bar engine to top dead center compression stroke prior to

torquing rocker lever capscrews.
Place the rocker arm assembly (2) onto its mounting location on
the cylinder head.
Install the two mounting bolts (1) and tighten.
Phase I:
Phase II head (14 mm capscrews):

Torque Value: Step 1 50 N•m [37 ft-lb]
Torque Value: Step 2 Advance 90°
Torque Value: MIN 85°
Torque Value: MAX 95°
Tighten push rod side capscrew (1) first at each step.
Adjust the crossheads and valves. Refer to Procedure 003-004.
Crossheads adjust on Phase I only.
Install the fuel injector. Refer to Procedure 006-026.
Install the rocker lever cover and engine side covers.

Connect the battery cables. Refer to Procedure 013-009.
Run the engine and check for leaks.
Valve Seats (002-019) QSV27 and QSV36
Valve Seats (002-019)

Inspect
Cummins Inc. does not recommend the reuse of valve seat
inserts at rebuild.
Valves (002-020)
Inspect
Cummins Inc. does not recommend the reuse of valves at
rebuild.
QSV27 and QSV36
Section 3 - Rocker Levers - Group 03 Page 3-1
Section 3 - Rocker Levers - Group 03

Section Contents
Page
Crankcase Breather (External)................................................................................................................................................ 3-4
Clean .................................................................................................................................................................................... 3-4
Install .................................................................................................................................................................................... 3-5
Remove ................................................................................................................................................................................ 3-4
Overhead Set ............................................................................................................................................................................ 3-5
Adjust .................................................................................................................................................................................... 3-6
Crossheads.................................................................................................................................................................. 3-7
Valves .......................................................................................................................................................................... 3-8
Rocker Lever Assembly........................................................................................................................................................... 3-9
Assemble .............................................................................................................................................................................3-11
Disassemble ......................................................................................................................................................................... 3-9
Install .................................................................................................................................................................................. 3-12
Remove ................................................................................................................................................................................ 3-9
Rocker Lever Cover ............................................................................................................................................................... 3-13
Clean .................................................................................................................................................................................. 3-13
Inspect ................................................................................................................................................................................ 3-14
Install .................................................................................................................................................................................. 3-14
Remove .............................................................................................................................................................................. 3-13
Service Tools ............................................................................................................................................................................ 3-3
Rocker Levers....................................................................................................................................................................... 3-3
QSV27 and QSV36
Page 3-2 Section 3 - Rocker Levers - Group 03

Service Tools
Rocker Levers
Valve Setting Gauge Kit

Kit contains two 25.4 mm [1 in] wide feeler gauges for centering
under the swivel foot of the rocker lever when setting the valves.
3164393
The kit contains an intake valve gauge at 0.40 mm [0.016 in] and an
exhaust valve gauge at 0.80 mm [0.032 in].
Crankcase Breather (External) (003-001) QSV27 and QSV36
Crankcase Breather (External)

(003-001)
Remove
Remove the breather vent tubes and check for internal obstruc-
tions or sludge build-up.
Flush the tube with solvent if build-up is present.
WARNING
Remove the four capscrews and breather housing from the

engine.
Clean
Wash the inside of the housing with solvent to remove any
build-up.
WARNING
WARNING
injury.
QSV27 and QSV36 Overhead Set (003-004)
Install
Install the housing gasket and capscrews.
Install the breather vent tubes.
Overhead Set (003-004)

General Information
WARNING
Always disconnect the negative (-) cable first to reduce the
possibility of sparks that can ignite explosive battery
gases.
WARNING
Batteries emit hydrogen gas. to reduce the possibility of
explosion and personal injury, do not smoke or allow igni-
tion source in area when servicing batteries.
Disconnect the batteries or air supply to air starter to prevent
accidental engine starting.
NOTE: Read the entire procedure for overhead adjustment

before attempting to perform this operation.
Intake and exhaust valve rocker lever clearances must be cor-
rectly adjusted for the engine to operate efficiently. Clearances
must be adjusted to the values listed in this section.
QSV27 cylinder numbering sequence is shown in the illustra-
tion. QSV36 is similar.
Overhead Set (003-004) QSV27 and QSV36
Direction of rotation is counterclockwise when viewing the
engine from the flywheel end.
QSV27 intake and exhaust valve locations are shown in the
illustration. QSV36 are similar.
Refer to Section E for firing order. Two crankshaft revolutions
are required to adjust all the valves.
Adjust
All overhead valve adjustments must be made when the
engine is cold (any stabilized coolant temperature at 60°C
[140°F] or below).
NOTE: Crosshead adjustment must always be made before
adjusting the valves.
With the engine stopped, unscrew the retaining knobs (1) and
remove the rocker lever covers (2).
Push the barring gear shaft (1) toward the flywheel and engage
the barring gear teeth with the teeth on the ring gear.
Attach a ¾ in. drive ratchet to the back side of the barring gear
drive shaft.
QSV27 and QSV36 Overhead Set (003-004)
Turn the flywheel until one of the following cylinder pair top
dead center marks on the flywheel is lined up with the inspec-
tion port top dead center (0 degrees) mark (1).
Adjustment can begin on any pair of cylinders at top dead cen-
ter, as viewed in the inspection port.
Crossheads
Wiggle the rocker levers on the two cylinders lined up with the
top dead center mark in the inspection port. The crossheads
and valves on the cylinder where both levers feel loose are
ready to adjust.
The crossheads are adjustable on Phase I heads only.
Loosen the rocker arm adjusting screws (1) locknuts (2).
Back the adjusting screws off at least four turns.
NOTE: Adjust the crossheads on the cylinder that has both

valves closed.
Loosen the crosshead adjusting screw locknuts (2) on the
intake and exhaust valve crossheads.
Turn the crosshead adjusting screw (1) counterclockwise until
the adjustment screw is not in contact with the valve stem.
Use the following procedure to adjust both the intake and

exhaust crossheads.
Turn the adjusting screw (1) out at least one turn.
Hold the crosshead down against its guide.
Turn the adjusting screw (1) in until it touches the top of the
valve stem but does not raise the crosshead.
Overhead Set (003-004) QSV27 and QSV36
Hold the adjusting screw (1) in its position. The adjusting screw
must not turn when the locknut (2) is tightened to its torque
value. Tighten the locknut (2).
Valves
Use the values below to set the intake (1) and exhaust (2)
valves.
Valve Clearance
Intake Exhaust
QSV27, QSV36 0.40 mm 0.80 mm
[0.016 in] [0.032 in]
NOTE: Be sure the crosshead is firmly in place on the valve

stem tips.
NOTE: Be sure the feeler gauge is under the center of the ball
and socket, or the socket can rock or tip, resulting in an incor-
rect adjustment.
Select a feeler gauge for the correct valve lash specification.
Insert the gauge between the rocker lever socket and the cross-
head.
Turn the adjustment screw until a slight drag is felt on the feeler
gauge.
While holding the adjusting screw (1), tighten the adjusting

screw locknut (2).
Repeat the adjustment process until the clearance is correct on
both the intake and exhaust valves.
Check to see that the feeler gauge still moves with a slight drag
after torque.
QSV27 and QSV36 Rocker Lever Assembly (003-009)
Rocker Lever Assembly (003-009)

Remove
Remove the rocker lever cover.
NOTE: Set cylinder at top dead center before removing rocker

tower capscrews to prevent tower damage.
Remove the two (2) 24 mm bolts (1) from the rocker arm tower
(2).
Lift the rocker arm assembly straight up.
Disassemble
Remove the retaining rings (1) from both ends of the support
shaft. Separate the rocker levers (2) from the support (3).
Remove the adjusting screws (1) and locknuts (2) from the
rocker levers. Separate the adjusting screw, contact pads (3),
and circlip (4).
Rocker Lever Assembly (003-009) QSV27 and QSV36
Clean and Inspect
WARNING
WARNING
injury.
Clean the parts with solvent and dry with compressed air
Blow out all oil passages with compressed air.
Inspect the rocker shaft and support for scoring, pitting or other
damage.
Replace if damaged.
Rocker Lever Shaft O.D. (Nominal)

mm in
39.98 MIN 1.574
40 MAX 1.5758
Inspect the rocker lever bushing inside diameter for scoring,

wear or other damage.
Replace if damaged.
Bushing Bore I.D.

mm in
40.025 MIN 1.576
40.064 MAX 1.577
QSV27 and QSV36 Rocker Lever Assembly (003-009)
Inspect the rocker lever, adjusting screw and contact pad for
scoring and abnormal wear. Replace if damaged.
Assemble
Install the adjusting screws (1) and locknuts (2) onto the rocker
lever.
Install circlip (4) into the rocker lever contact pad (3) and install
onto the adjusting screw.
Lubricate the contact pads with clean engine oil.
Lubricate the rocker lever shaft with clean engine oil.
CAUTION
Be sure to assemble the intake and exhaust rocker levers
in the correct location. Failure to do so will result in engine
damage.
Rocker Lever Assembly (003-009) QSV27 and QSV36
Install the rocker levers (2) and retaining rings (2) onto the
rocker lever support (3).
Install
Bar engine to top dead center compression stroke of cylinder
for installation.
Install the two 12 mm bolts (1) and rocker assembly (2) onto the
head.
NOTE: Phase II cylinder heads use 14mm screws and begin
with engine serial number 66300227.
NOTE: Make sure the guide pin between the rocker lever
assembly and head is present and in good condition.
Phase I:
Phase II (14 mm capscrew):
Torque Value: Step 2 Advance 90°
Torque Value: MIN 85°
Torque Value: MAX 95°
Tighten camshaft side capscrew first at each step.
Set the overhead. Refer to Procedure 003-004.

QSV27 and QSV36 Rocker Lever Cover (003-011)
Check the rocker lever cover seal for damage.
Install the rocker lever cover and seal. Refer to Procedure 003-
011.
Rocker Lever Cover (003-011)

Remove
Unscrew the retaining knob and remove the rocker lever cover.
Clean
WARNING
WARNING
injury.
Clean the rocker cover with a solvent that will not harm the alu-
minum cover.
Rocker Lever Cover (003-011) QSV27 and QSV36
Inspect
Check the cover for cracks or other damage, especially around
the seal groove. Inspect the threads on the retaining knob.
Check the rocker cover seal for nicks, cuts and other damage.
Install
Install the seal into the rocker lever cover and install the cover.
Tighten the retaining knob.
QSV27 and QSV36
Section 4 - Cam Followers/Tappets - Group 04 Page 4-1
Section 4 - Cam Followers/Tappets - Group 04

Section Contents
Page
Cam Followers.......................................................................................................................................................................... 4-3
Assemble .............................................................................................................................................................................. 4-5
Clean .................................................................................................................................................................................... 4-4
Disassemble ......................................................................................................................................................................... 4-3
Install .................................................................................................................................................................................... 4-6
Remove ................................................................................................................................................................................ 4-3
Push Tubes ............................................................................................................................................................................... 4-6
Clean .................................................................................................................................................................................... 4-7
Finishing ............................................................................................................................................................................... 4-8
Install .................................................................................................................................................................................... 4-8
Preparatory ........................................................................................................................................................................... 4-6
Remove ................................................................................................................................................................................ 4-6
QSV27 and QSV36
Page 4-2 Section 4 - Cam Followers/Tappets - Group 04

QSV27 and QSV36 Cam Followers (004-001)
Cam Followers (004-001)

General Information
The QSV cam followers are mounted in the injection pump
housing. The injection pump assembly must be removed to
access the cam followers.
Remove
Remove the injection pump assembly. Refer to Procedure 005-
016.
Disassemble
Turn the fuel pump on its side and remove the two 10 mm cap-
screws (1) from the camfollower retainer (2).
Slide the camfollowers out of the fuel pump housing.
NOTE: Mark the camfollowers to make certain they are
returned to the same position when reassembling.
Cam Followers (004-001) QSV27 and QSV36
Clean
WARNING
When using solvents, acid or alkaline materials for clean-
WARNING
injury.
Use solvent to clean the cam followers.
Inspect for Reuse

Inspect the camfollower for damage to the push tube contact
surface.
NOTE: If the contact surface is damaged, the push rod should
be replaced.
Inspect the cam follower skirt for scoring or other damage.
Inspect the camfollowers for any damage to the follower sur-

faces.
Check to see that the roller spins freely and that the roller con-
tact surface is not damaged.
If any of the above checks show any damage, replace the cam-
follower and inspect the camshaft contact surface. Refer to
Section 1.
QSV27 and QSV36 Cam Followers (004-001)
Inspect the camfollower oil holes for obvious dirt or debris.
Assemble
Lubricate the camfollowers with clean engine oil and insert
them into the fuel injection pump.
NOTE: Check to make certain the camfollowers are returned to
the original opening if new followers are not used.
Apply Threadlocker, Part Number 3824040, to the camfollower

retainer capscrew threads and install the capscrews.
Tighten the capscrews.
Lubricate the camfollowers with clean engine oil.

Push Tubes (004-014) QSV27 and QSV36
Install
Install the injection pump. Refer to Procedure 005-016.
Push Tubes (004-014)

Preparatory
Remove the rocker lever cover and injection pump cover.
Remove the two (12mm - Phase I, 14mm - Phase II) bolts (1)
from the rocker arm tower (2).
Lift the rocker arm assembly straight up.
Remove
Mark the push rods so they can be installed in their original
position.
Lift the push rods (1) straight up and out of the head.
Remove the push rod covers (2).
QSV27 and QSV36 Push Tubes (004-014)
Clean
WARNING
WARNING
injury.
Wash the push rods and push tube covers in solvent and dry
with compressed air.
Inspect for Reuse

Check for straightness by rolling the push rods on a flat surface.
Inspect both ends of the push rods for wear or damage.

NOTE: Replace both the rocker lever adjusting screw and the
push rod if the socket surface in the rod or on the adjusting
screw is damaged.
Inspect the push rod covers for damage.

Push Tubes (004-014) QSV27 and QSV36
Install
clean engine oil. Push the tubes down through the o-rings until
the push rods are seated in the top of the camfollower (little side
to side play, and both at the same height).
Finishing
Place the rocker arm assembly (2) onto its mounting location on
the cylinder head.
Install the two mounting (1) bolts and tighten.
Phase I:
Refer to Procedure 003-009 for Phase I and II installation.
Set the overhead. Refer to Procedure 003-004.

QSV27 and QSV36
Section 5 - Fuel System - Group 05 Page 5-1
Section 5 - Fuel System - Group 05

Section Contents
Page
Erosion Plugs ......................................................................................................................................................................... 5-19
Inspect ................................................................................................................................................................................ 5-19
Install .................................................................................................................................................................................. 5-20
Remove .............................................................................................................................................................................. 5-19
Fuel Control Linkage.............................................................................................................................................................. 5-21
Adjust .................................................................................................................................................................................. 5-21
Check.................................................................................................................................................................................. 5-26
Governor Actuator Arm ....................................................................................................................................................... 5-24
Initial Check ........................................................................................................................................................................ 5-21
Verification .......................................................................................................................................................................... 5-24
Fuel Injection Pump Control Shaft Assembly ..................................................................................................................... 5-29
Clean .................................................................................................................................................................................. 5-30
Install .................................................................................................................................................................................. 5-31
Remove .............................................................................................................................................................................. 5-29
Fuel Lift Pump ........................................................................................................................................................................ 5-20
Install .................................................................................................................................................................................. 5-21
Remove .............................................................................................................................................................................. 5-20
Testing ................................................................................................................................................................................ 5-20
Fuel Priming Pump................................................................................................................................................................. 5-33
Install .................................................................................................................................................................................. 5-33
Remove .............................................................................................................................................................................. 5-33
Fuel System .............................................................................................................................................................................. 5-4
Fuel System Pre-Filter ........................................................................................................................................................... 5-27
Clean .................................................................................................................................................................................. 5-27
Install .................................................................................................................................................................................. 5-28
Remove .............................................................................................................................................................................. 5-27
Injection Pump........................................................................................................................................................................ 5-12
Clean .................................................................................................................................................................................. 5-14
Install .................................................................................................................................................................................. 5-15
Remove .............................................................................................................................................................................. 5-12
Installation Recommendations ............................................................................................................................................... 5-8
Overhead Tank Installation Requirements ............................................................................................................................ 5-8
Service Tools ............................................................................................................................................................................ 5-3
Fuel System .......................................................................................................................................................................... 5-3
Specifications ........................................................................................................................................................................... 5-9
Fuel Recommendations ...................................................................................................................................................... 5-10
Fuel System .......................................................................................................................................................................... 5-9
QSV27 and QSV36
Page 5-2 Section 5 - Fuel System - Group 05

Service Tools
Fuel System
Fluorescent Tracer Dye

Add to oil. Use with black light to find oil leaks.
3376891
Blacklight (DC)
Inspect for oil and fuel leaks.
3163337
Vacuum Gauge
Used to check fuel pump filter inlet restriction.
ST-434
Pressure Gauge
Used to check fuel filter restriction.
ST-435-6
Fuel System QSV27 and QSV36
Fuel System
General Information
WARNING
Fuel is flammable. Do not allow cigarettes, flames, sparks,
arcing switches or equipment, pilot lights, or other ignition
sources near the fuel system.
CAUTION
Tampering with the fuel system can void the engine war-
ranty and lower the performance of the engine.
The QSV engine has one injection pump per cylinder. Each
pump is built into a multiple function casting called “multihous-
ing”. This multihousing is comprised of:
• Injection pump.
• Fuel supply and return lines.
• Camfollower guide block.
• Valve mechanism lubricating oil channel.
This multifunctional component is designed to provide maxi-
mum safety and easy maintenance for the injection system.
The injection pumps are single cylinder type. Each pump is fit-
ted with an injection rate fuel rack control. All pumps are fitted
with a pneumatic cylinder to push the fuel rack to the zero flow
position in the event of engine overspeed. This arrangement is
called the overspeed safety mechanism.
The QSV injector is positioned in the center of the head. It is

comprised of a nozzle holder and nozzle. High pressure fuel is
supplied to the side of the holder through an injection pipe.
Conical mating surfaces ensure a tight seal.
The fuel rack is controlled by mechanical linkage connected to

an electronic actuator (1). The actuator is located near the fly-
wheel housing.
QSV27 and QSV36 Fuel System
Fuel System
SYSTEM OPERATION
The fuel system is comprised of a pre-filter, transfer pump, full-flow filter, priming pump, relief valve, fuel rail, injec-
tion pumps, fuel tubes and fuel injectors.
Fuel is drawn through a 60µm pre-filter and sent to a 7µm duplex full-flow fuel filter by a transfer pump. The filters
can be changed while the engine is running and the transfer pump is equipped with a check valve to prevent the pre-filter
from becoming pressurized. Fuel is then delivered to the injection pumps. The injection pump fuel return is regulated to
keep the fuel system at a constant pressure. The engine camshaft actuates the injection pump plungers. Injection flow is
controlled by the rotation of the plungers. A control rack, connected to an electronic actuator, rotates the plungers. The
control rack linkage is designed to keep the plungers in each pump in the same position. The linkage also allows engine
operation and shutdown, even if a control rack becomes jammed.
Each injection pump plunger is at BDC at the start of injection phase. Fuel enters the pumping element. As the plunger is
actuated upward, it closes the fuel supply and return ports to the element and compresses the fuel to injection levels. The
delivery valve in the injection pump opens and the fuel passes through a fuel tube, a fuel pipe and into the injector. The
injector needle valve is lifted open by the pressure and fuel is atomized into the combustion chamber. When the plunger
completes its effective stroke, the supply and return ports are reopened and the delivery port closed. Injection is com-
pleted.
Pressure waves during the injection cycle require the use of a delivery valve damper and erosion plugs. The deliv-
ery valve damper stops pressure waves from reflecting back to the injector and reopening the injector needle valve. Ero-
sion plugs are fitted where pressure waves, from opening fuel inlet ports, create very high mechanical stresses. These
plugs are especially shaped to prevent wave reflection and are easily replaceable.
The QSV has ‘clean’ and ‘contaminated’ fuel returns. The clean returns take fuel from the injectors and injection
pumps through a fuel rail, a fuel cooler and back to the tank. Contaminated fuel is collected under the side covers and
discharged via a hydraulic connection near the flywheel.
Fuel System QSV27 and QSV36
QSV27 and QSV36 Fuel System
System Components
1. Fuel Inlet
2. Pre-filter
3. Priming Pump (electric pump optional)
4. Fuel Lift Pump
5. Fuel Filters
6. Injection Pump
7. Injection Nozzle
8. Fuel Spill, Clean
9. Fuel Spill, Dirty
10. Pressure Regulating Valve
11. Fuel Outlet
Fuel Pump
a. Injection Line (single wall standard, double wall optional)
b. (optional) Double wall injection line breakage fuel spill
c. Injection pump fuel supply
d. Fuel spill, clean
e. Injection pump fuel return
f. Injection pump fuel spill
g. Injection nozzle fuel spill
h. Bleed air screw
Installation Recommendations QSV27 and QSV36
Installation Recommendations
Overhead Tank Installation Requirements
WARNING
If a fuel line shutoff valve is not installed, the overhead tank
can drain when the fuel filter is changed, causing an
extreme fire hazard.
Cummins Inc. recommends a ball-type valve and not a gate-
type valve.
Install a fuel shutoff valve between the filter and the fuel tank.
Install a check valve in the fuel drain line when the maximum
fuel level in the fuel tank is even or above the fuel drain that is in
the cylinder head. Install the valve with the fuel flow arrow
toward the fuel tank.
QSV27 and QSV36 Specifications
Specifications
Fuel System
Maximum Allowable Restriction to Pump with or without Fuel Cooler:
With clean filter .........................................................................................................................................0.3 barG [4.4 psi]
With dirty filter............................................................................................................................................ 1.5 barG [21 psi]
Maximum Allowable Fuel Return Line Restriction.............................................................................................1.0 barG [14.7 psi]
Maximum Allowable Fuel Inlet Temperature ..............................................................................................................50°C [122°F]
Minimum Pressure to High Pressure Pumps ...........................................................................................................4 barG [58 psi]
Specifications QSV27 and QSV36
Fuel Recommendations
WARNING
Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.
CAUTION
Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free
of dirt or water. Dirt or water in the system can cause severe damage to both the fuel pump and the fuel injectors.
CAUTION
Do not use diesel fuel blended with lube oil in engines equipped with a catalytic converter. Damage to the converter
will result.
Cummins Inc. recommends the use of ASTM No. 2 D fuel. The use of No. 2 diesel fuel will result in optimum engine perfor-
mance.
At operating temperatures below 0°C [32°F], acceptable performance can be obtained by using blends of No. 2D and No. 1D.
NOTE: Lighter fuels can reduce fuel economy.
The viscosity of the fuel must be kept above 1.3 cSt at 40°C [104°F] to provide adequate fuel system lubrication.
The following chart lists acceptable alternate fuels.
Acceptable Substitute Fuels - Signature Fuel System

No. 1D No. 2D No. 1K Jet-A Jet-A1 JP-5 JP-8 Jet-B JP-4 CITE
Diesel Diesel Kerosene
1 OK 1 1 1 OK OK NOT OK NOT OK NOT OK
1. Additional information for fuel recommendations and specifications can be found in Fuel for Bulletin No. 3379001. See order-
ing information in the back of this manual.
Fuel Oil Recommended Properties:

Cummins diesel engines are designed to operate on No. 2 diesel fuel. These engines will also operate satisfactorily on fuels
that meet the following specifications:
Recommended
Property Specifications
Viscosity 1.3 to 5.8 centistokes [1.3 to 5.8 mm per second] at 40°C
(ASTM D445) [104°F].
Cetane Number 40 Minimum above 32°F.

(ASTM D613) 45 Minimum below 32°F.
Sulfur Content Not to exceed 0.05 mass percent*.

(ASTM D129 or 1552)
Active Sulfur Copper Strip Corrosion not to exceed No. 2 rating after three
(ASTM D130) hours at 122°F [49°C].
Water and Sediment Not to exceed 0.1 volume percent.

(ASTM D1796)
Carbon Residue (Rams-bottom, ASTM D524 or Not to exceed 0.35 mass percent on 10 volume percent resid-
Conradson, ASTM D189 uum.
Density (ASTM D287) 42 to 30° API gravity at 60°F [0.816 to 0.876 g/cc at 15°C].
Cloud Point 10°F [6°C] below lowest ambient temperature at which the fuel
(ASTM D97) is expected to operate.
Ash Not to exceed 0.02 mass percent (0.05 mass percent with lubri-
(ASTM D482) cating oil blending).
Distillation The distillation curve must be smooth and continuous.

(ASTM D86)
Acid Number Not to exceed 0.1 Mg KOA per 100 MI.

(ASTM D664)
*NOTE: Effective October 1, 1993, the Environmental Protection Agency requires maximum sulfur content not to
exceed 0.05 mass percent.
Injection Pump (005-016) QSV27 and QSV36
Injection Pump (005-016)

Remove
Loosen the handnuts and remove the engine side cover.
Loosen the 24 mm retaining nuts and remove the camshaft
inspection cover.
Using the barring mechanism, rotate the engine so that the fuel
injection pump camshaft follower (1) is riding on the base circle
of the camshaft (2) as viewed through the camshaft inspection
opening.
Remove the rocker cover, side cover, push tubes (1) and push
tube covers (2).
Unscrew the injection line 27 mm coupling nuts (1) from both

the high pressure tube and the fuel pump element. Remove the
high pressure line (2).
Remove the fuel drain tube (3) from the fuel drain fitting.
QSV27 and QSV36 Injection Pump (005-016)
Loosen the 17 mm coupling nuts on the shutdown cylinder air
supply line (1). Remove the line.
Remove the 10 mm locknut (1) from the fuel pump rack pin (2)
and remove the pin and two collars (3).
Unscrew the 17 mm coupling nuts on the rocker lever oil supply

line (1).
Remove the line.
Using retaining ring pliers, slide the fuel transfer tube retaining
rings (1) over against the opposite side of the jumper tubes (2).
Pry the jumper tubes to the side.
To reduce the possibility of damage, remove the rocker lever oil
supply line (1) and injector/fuel pump drain line (2) from the
adjacent cylinders.
WARNING
To reduce the possibility of personal injury, use a hoist or
get assistance when lifting components that weigh 23 kg
[50 lb] or more. Make sure all lifting devices such as
Unscrew the M12 socket headed fuel pump housing mounting
screws (1).
Lift out the fuel pump housing while being careful not to dam-
age the fuel rack or any lines.
Clean
WARNING
WARNING
injury.
Clean the injection pump with clean solvent and brush.
Inspect for Reuse

Inspect the injection pump housing and mounting areas for
cracks or other damage.
Inspect supply and return ports for thread damage.
Check the fuel rack for smooth operation.
Turn the injection pump on its side.
Inspect the injection cam follower roller for damage. The roller
should spin freely. Check the fuel transfer tube o-ring for tears
or cracks.
Install
Using a lint free paper towel, wipe clean the injection pump
mounting area (1) of the cylinder block. Replace the oil supply
o-rings (2).
Inspect the locating dowel (3) for damage.
Check location of camshaft lobes.
Must be on inner base circle of lobes.
CAUTION
Lubricate the cam followers with clean engine oil.
Align the pump with the locating dowel and seat the fuel pump
housing in its mounting location.
Install the 10 mm socket headed mounting capscrews in two

steps using tightening sequence.
Lubricate the exposed o-ring with silicone.
Pry the fuel transfer tubes (1) back into position. Be certain that
each tube is seated properly over the pair of o-rings (2).
CAUTION
Do not cut or tear the o-ring, fuel leaks will result.
Using retaining ring pliers, slide the snap rings (3) back into
position.
Connect and tighten the rocker assembly oil supply line (1) at
the base of the fuel pump housing and the junction near the top
of the cylinder head.
Connect and tighten the engine shutdown cylinder air supply

line (1) to the cylinder and the air manifold.
Press the knurled fitting end (1) of the injector/fuel pump drain
line (2) into the return fuel manifold.
Attach the injector drain line (3) coupling nut to the fitting in the
cylinder head.
Connect the coupling nuts for the injector/fuel drain and injector
drain lines to the tee fitting (4) on the fuel pump.
CAUTION
Excessive tightening will cause binding between the yoke
and fuel rack. This can lead to fuel pump and/or engine
damage.
Connect the throttle lever to the fuel rack, Insert the pin (2), col-
lars (3), and tighten the retaining nut (1).
Check that the throttle lever yoke and collars do not bind on the
rack.
clean engine oil. Push the tubes down through the o-rings until
the push rods are seated in the top of the cam follower (little
side to side play, and both at the same height).
Place the rocker arm assembly onto its mounting location on

the cylinder head.
Install the two mounting bolts and tighten.
Phase I:
Refer to Procedure 003-009 for installation of Phase II (14 mm)
mounting bolts.
Place the injection line into position. Start the threads of both
coupling nuts and tighten both simultaneously to draw the injec-
tion line in evenly.
Adjust the overhead. Refer to Procedure 003-004.
Install the camshaft inspection cover.

Install the injection pump covers.

Install the rocker lever covers.
QSV27 and QSV36 Erosion Plugs (005-017)
Prime the fuel system and vent the fuel filter housing. Refer to
Procedure 006-014.
Erosion Plugs (005-017)

General Information
Due to the very high fuel pressure, violent shock waves reflect
around the pump body. Erosion plugs are fitted at the impact
points to absorb the stress and prevent wave reflection.
Remove
Remove the erosion plugs.
Inspect
Check the plug for pitting and wear. Check the o-rings for cuts
or tears.
Replace the plug if any damage is present.
Fuel Lift Pump (005-045) QSV27 and QSV36
Install
Install the erosion plug.
Fuel Lift Pump (005-045)

Testing
Measure the output pressure of the lift pump with an in line
gauge.
Minimum Pressure: 4 barG [58 psi]
Remove
Remove the fuel inlet (1) and outlet (2) hoses from the transfer
pump.
Remove the two hex socket capscrews (3) that fasten the pump
body to the bearing housing.
Inspect for Reuse

Inspect the pump body for cracks or other damage.
Inspect the drive spline for excessive wear or damage and
make sure it turns freely.
Inspect the inlet and outlet ports for damage.
QSV27 and QSV36 Fuel Control Linkage (005-067)
Install
Install the two hex head capscrews that fasten the pump body
to the pump adapter plate.
Install the fuel inlet (1) and outlet (2) hoses.
Procedure 006-014.
Fuel Control Linkage (005-067)

Initial Check
Lubricate
Clean and lubricate the racks and bearings with lubricating oil.
Grease ball joints with multipurpose grease.
Adjust
The fuel control linkage has a general sequence when being
adjusted. It is as follows:
1. Loosen and back off all linkage stops.
2. Adjust control linkage to A1 pump, then others to A1.
3. Set maximum fuel settings.
4. Check all settings.
Fuel Control Linkage (005-067) QSV27 and QSV36
Disconnect the electrical connection to the actuator.
Loosen the lock nut (2) on all the fuel rack arms and back the
adjusting screw (1) out until there is no contact with the screw
and the control shaft arm.
Pull the engine stop lever (1) down to the “Stop” position.
WARNING
Failure to set the engine stop at 2 mm or less track travel
position can prevent the engine from shutting down and
lead to equipment damage and personal injury.
Check that all fuel racks are fully withdrawn from the injection
pump housings (0 mm [0.0 in] or less). Use a feeler gauge to
check that there is 0.1 mm [0.004 in] clearance between the
end of the fuel rack adjusting screw (1) and the control shaft tab
(3).
With the manual stop lever in the stop position, remove the bolt
that connects the actuator arm (1) to the linkage arm (4).
Turn the fuel rack arm adjusting screw (1) until all the slack
between the fuel rack arm and control shaft arm is removed.
Tighten the lock nut.
A1 linkage is now set.
Move the manual control lever to the run position (1).
Insert the 3 mm rack adjusting pin (1) into the fuel rack (2) on
the A1 injection pump and move the gauge into contact with the
pump stop (3), 29 mm [1.141in] thick.
NOTE: Always adjust remaining pumps to A1.

With the rack setting pin still in A1, insert another pin into the
next fuel rack. Adjust the next fuel pump to A1.
Continue on to each of the remaining pumps, moving the pin
from the last pump adjusted to the next pump leaving A1 pin in
place.
Once all the pumps have been adjusted, remove all the pins
(1).
Verification
Move the manual stop lever (1) to the stop position and check
that the fuel pumps are all reading 2 mm [0.078 in] or less.
CAUTION
Setting the full fuel rack travel greater than 25 mm [1 in]
rack travel can overfuel the engine and result in equipment
damage.
Move the engine stop lever up to the RUN position.
Adjust the control shaft full load set screw (1) to obtain a maxi-
mum rack stroke of 25 mm [1 in] (typical).
Fuel control racks are now set.
Governor Actuator Arm

After the fuel racks are adjusted, the governor needs to be
adjusted to the fuel linkage.
The governor needs to be adjusted so that the fuel control rack
(2) operated within the governor travel limits (1).
NOTE: QSV 73/82 shown, QSV27/36 is similar.
Check to see that the control linkage is positioned correctly.

The link between the actuator and control linkage should be
positioned using the hole furthest from the center linkage pivot
point (1).
Connect the linkage to the actuator output lever using the hole
closest (2) to the pivot point of the actuator.
The fuel control rack has a 100 percent travel (2) within the total
travel of the actuator arm (1).
The actuator requires a 10 degree over travel beyond the full
rack travel to allow the fuel rack to achieve the no fuel position.
Check the ten degree over travel by disconnecting the linkage

(1) from the actuator arm and moving the lever away from the
center line of the engine to the no fuel position.
The actuator arm should be at least ten to twenty degrees
beyond where the control linkage would normally attach.
If the actuator arm is more than twenty degrees past the align-
ment of the two shafts, it will be necessary to remove the actua-
tor arm and move it one tooth of the splined shaft (one spline is
equal to 10 degrees) in a counterclockwise direction and
install it back onto the shaft.
Should the actuator arm be less than ten degrees of the align-
ment of the two shafts, it will be necessary to move the actuator
one tooth of the shaft in a clockwise direction to achieve the
proper setting.
Mark the shaft and actuator arm to identify the original position.
Remove the arm and put it back onto the shaft one spline tooth
from the original position in the direction necessary for adjust-
ment.
Tighten the lock nut.
With the control linkage still disconnected, check the over
travel.
Move the actuator lever to the no fuel position. The actuator
arm should be at least ten to twenty degrees beyond where the
linkage would normally attach.
Attach the control linkage to the actuator arm (1).

Tighten the capscrew and nut.
Check
Move the engine stop lever to the Stop position. Verify the fuel
racks are in the no fuel position.
With the lever in the run position, rotate the actuator output
lever fully counterclockwise (looking at the actuator from the
front of the engine).
Verify that the injection pump fuel racks are at the full fuel posi-
tion setting and are equal.
Rotate the actuator arm output lever to the electrical stop posi-
tion.
Verify that the injection pump fuel racks are at 2 mm [0.078 in]
or less position and are equal.
QSV27 and QSV36 Fuel System Pre-Filter (005-068)
Fuel System Pre-Filter (005-068)

Remove
WARNING
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.
If the engine is running, turn the pre-filter bypass valve (1) to
allow the fuel to bypass the pre-filter and enter the fuel transfer
pump directly.
Remove the fuel drain screw (1), and allow all the fuel con-
tained in the housing to drain out into a container.
Install and tighten the drain plug.
Remove the pre-filter cover (1).

Remove the spring (2).
Lift out the pre-filter assembly (3).
Clean
Remove the wing nut (1) at the bottom of the assembly and
separate the cartridge (2) from the magnetic core (3).
Fuel System Pre-Filter (005-068) QSV27 and QSV36
WARNING
Clean the base and magnetic core with a solvent and a clean,
lint-free cloth.
NOTE: Repeated cleaning may be necessary to remove all
metal traces from the magnetic core.
Inspect the pre-filter cartridge and replace if any tears or exces-
sive plugging is evident.
NOTE: Replace the pre-filter cartridge every 2000 hours
regardless of condition.
Use a lint free cloth to remove any sediment trapped in the

housing.
Replace the pre-filter assembly o-ring (1) and cover o-ring (2).
Install
Place the cartridge over the magnetic core and tighten the wing
nut.
Insert the pre-filter assembly and spring into the housing.
Fill the housing with clean fuel.
QSV27 and QSV36 Fuel Injection Pump Control Shaft Assembly (005-071)
Install and tighten the cover.
Slowly turn the pre-filter bypass valve back to the normal posi-
tion.
Fuel Injection Pump Control Shaft

Assembly (005-071)
Remove
Remove the hot box covers.
Disconnect the governor linkage rod (2) from the control shaft
(1) by removing the self-locking nut and capscrew (3).
Disconnect the air fitting (1) from the cover plate (2).
Remove the three M12 and two M8 capscrews (4) connecting
the cover to the cylinder block.
Remove the cover (2).
Fuel Injection Pump Control Shaft Assembly (005-071) QSV27 and QSV36
Remove the lock nut (1), capscrews (3), and collars (2) to dis-
connect the fuel pumps from the control rack on the bank being
serviced.
Remove the capscrews (1) from the base of each control shaft
bearing housing (2).
Carefully lift and remove the control shaft assembly from the
engine.
Clean
WARNING
WARNING
injury.
Wash the control shaft assembly in solvent and dry with com-
pressed air.
Remove the three o-rings (1) from the inner side cover.
Clean the o-ring area and replace the o-rings with new.
Use petroleum jelly on the o-rings to hold them in position in the
cover.
QSV27 and QSV36 Fuel Injection Pump Control Shaft Assembly (005-071)
Inspect for Reuse
Slide the bearing supports to expose the running portion of the
shaft.
Check for signs of wear and pitting.
Inspect the torsional springs for signs of cracking or distortion.

Check that the retaining pins are not bent.
Install
Lift the control shaft assembly and carefully place it into position
on the engine.
Make certain the base of the bearing supports are aligned with
the 6 mm dowel pins (1) in the injection pump mounting pads.
Install the capscrews and tighten.
Connect the regulator lever to the fuel rack.

Insert the collars (2), capscrew (3), and lock nut (1).
Check that the yoke and fuel rack are free to move and not
binding.
Fuel Injection Pump Control Shaft Assembly (005-071) QSV27 and QSV36
Connect the governor linkage rods to the fuel control shaft.
Lubricate the racks, bearings, yokes, and ball joints with clean
engine oil.
Rotate the control shaft and check for binding.
Check the control shaft for proper adjustment.

Install the hot box covers.

QSV27 and QSV36 Fuel Priming Pump (005-076)
Fuel Priming Pump (005-076)

Remove
Remove the fuel supply hose (1) from the priming pump.
Remove the transfer pump inlet (2) and outlet (3) hoses from
the priming pump.
Remove the three hex socket capscrews (1) that fasten the fuel
filter tube to the priming pump.
Remove the three hex socket capscrews (2) that fasten the
priming pump to the gear housing side cover.
Inspect for Reuse

Inspect the priming pump housing and mounting holes for
cracks or other damage. Inspect all hose connection ports for
damage. Check the priming lever for smooth operation.
Install
Install the three hex socket capscrews (2) that fasten the prim-
ing pump to the engine.
Install the three hex socket capscrews (1) that fasten the fuel fil-
ter tube to the priming pump.
Fuel Priming Pump (005-076) QSV27 and QSV36
Install the fuel transfer pump inlet (2) and outlet (3) hoses to the
priming pump.
Install the fuel supply hose (1) to the priming pump.
Procedure 006-014.
QSV27 and QSV36
Section 6 - Injectors and Fuel Lines - Group 06 Page 6-1
Section 6 - Injectors and Fuel Lines - Group 06

Section Contents
Page
Air in Fuel.................................................................................................................................................................................. 6-7
Test ....................................................................................................................................................................................... 6-7
Venting Fuel Filter ........................................................................................................................................................ 6-8
Venting Injection Pump ................................................................................................................................................ 6-9
Fuel Drain Line ....................................................................................................................................................................... 6-22
Clean .................................................................................................................................................................................. 6-22
Install .................................................................................................................................................................................. 6-23
Remove .............................................................................................................................................................................. 6-22
Fuel Drain Line Restriction.................................................................................................................................................... 6-21
Measure .............................................................................................................................................................................. 6-21
Fuel Filter (Canister Type) ....................................................................................................................................................... 6-9
Maintenance Check .............................................................................................................................................................. 6-9
Priming.................................................................................................................................................................................6-11
Fuel Inlet Restriction.............................................................................................................................................................. 6-12
Fuel Pressure Regulating Valve............................................................................................................................................ 6-25
Install .................................................................................................................................................................................. 6-26
Remove .............................................................................................................................................................................. 6-25
Fuel Supply Lines................................................................................................................................................................... 6-23
Clean .................................................................................................................................................................................. 6-24
Install .................................................................................................................................................................................. 6-25
Preparatory ......................................................................................................................................................................... 6-23
Remove .............................................................................................................................................................................. 6-24
High Pressure Fuel Tube ....................................................................................................................................................... 6-26
Clean .................................................................................................................................................................................. 6-27
Install .................................................................................................................................................................................. 6-28
Preparatory ......................................................................................................................................................................... 6-26
Remove .............................................................................................................................................................................. 6-27
High Pressure Tube Drain Line ............................................................................................................................................. 6-31
Clean .................................................................................................................................................................................. 6-31
Install .................................................................................................................................................................................. 6-32
Remove .............................................................................................................................................................................. 6-31
Injector .................................................................................................................................................................................... 6-16
Install .................................................................................................................................................................................. 6-19
Preparatory ......................................................................................................................................................................... 6-16
Remove .............................................................................................................................................................................. 6-17
Test ..................................................................................................................................................................................... 6-18
QSV27 and QSV36
Page 6-2 Section 6 - Injectors and Fuel Lines - Group 06
Injector/Injection Pump Drain Line ....................................................................................................................................... 6-30

Clean .................................................................................................................................................................................. 6-30
Install .................................................................................................................................................................................. 6-31
Remove .............................................................................................................................................................................. 6-30
Injectors and Fuel Lines .......................................................................................................................................................... 6-5
Installation Recommendations ............................................................................................................................................... 6-7
Overhead Tank Installation Requirements ............................................................................................................................ 6-7
Service Tools ............................................................................................................................................................................ 6-3
Injectors and Fuel Lines........................................................................................................................................................ 6-3
Static Injection Timing ........................................................................................................................................................... 6-13
Adjust .................................................................................................................................................................................. 6-15
Initial Check ........................................................................................................................................................................ 6-13
Preparatory ......................................................................................................................................................................... 6-13
Service Tools
Injectors and Fuel Lines
Injector Puller Adapter

Use to remove injector nozzle.
3164391
Vacuum Gauge
Measures restriction, includes most hose adapters.
ST-434
Pressure Gauge
Measures injector drain line restriction when used with drain
adapter.
ST-1273
In-Line Fuel Sight Glass

Use to check for air in fuel system.
3163270
Fluorescent Tracer
Put in engine oil or fuel. Use black light to locate oil or fuel leaks.
3376891
Injector Test Stand

Use to test injector pop off pressure.
3164372
Injection Timing Tool

Use to indicate injection cam position.
3164411
Top dead center checking tool

Use to find top dead center piston location.
3164410
QSV27 and QSV36 Injectors and Fuel Lines
3
Page 6-5
Injectors and Fuel Lines

General Information
WARNING
Fuel is flammable. Do not allow cigarettes, flames, sparks,
arcing switches or equipment, pilot lights, or other ignition
sources near the fuel system.
Tampering with the fuel system can void the engine war-
ranty and lower the performance of the engine.
The QSV27/36 uses flexible hoses (1) and rigid tubes (2) in
combination with an aluminum fuel rail (3) to deliver fuel to the
engine.
This same combination is also used for fuel returns.
The QSV has “clean” and “contaminated” fuel returns. The
clean returns take fuel from the injectors and injection pumps
through a fuel rail, a fuel cooler and back to the tank. Contami-
nated fuel is collected under the injection pump covers and dis-
charged via a hydraulic connection near the flywheel.
Marine applications are equipped with an additional leakage
drain line and sensor.
NOTE: Use two wrenches to remove all fuel tubes and hoses.
Support the mating fitting(s) with one wrench and loosen the
tube nut with the other.
NOTE: Use two wrenches to install fuel tubes and hoses. Sup-
port the mating fitting(s) with one wrench and torque the tube
nut with the other.
Injectors and Fuel Lines QSV27 and QSV36
System Components Fuel Pump

1. Fuel Inlet A. Injection Line (single wall standard, double wall optional Marine)
2. Pre-filter B. (Marine) Double wall injection line breakage fuel spill
3. Priming pump (electric pump optional) C. Injection Pump Fuel Supply
4. Fuel Lift Pump D. Fuel Spill, Clean
5. Fuel Filters E. Injection Pump Fuel Return
6. Injection Pump F. Injection Pump Fuel Spill
7. Injection Nozzle G. Injection Nozzle Fuel Spill
8. Fuel Spill, Clean H. Bleed Air Screw
9. Fuel Spill, Dirty
10. Pressure Regulating Valve
11. Fuel Outlet
QSV27 and QSV36 Installation Recommendations
Installation Recommendations
Overhead Tank Installation Requirements
WARNING
If a fuel line shutoff valve is not installed, the overhead tank
can drain when the fuel filter is changed, causing an
extreme fire hazard.
Cummins Inc. recommends a ball-type valve and not a gate-
type valve.
Install a fuel shutoff valve between the filter and the fuel tank.
Install a check valve in the fuel drain line when the maximum
fuel level in the fuel tank is even or above the fuel drain that is in
the cylinder head. Install the valve with the fuel flow arrow
toward the fuel tank.
Air in Fuel (006-003)

WARNING
Do not operate a diesel engine where there are or can be
combustible vapors. These vapors can be sucked through
the air intake system and cause engine overspeeding,
which can result in a fire, an explosion and extensive prop-
erty and/or personal injury.
Test
Remove the fuel inlet line.
Install a sight glass in the line.
Operate the engine at high idle with no load.
NOTE: A small air leak will have a “milky” appearance.
NOTE: A large air leak will look like bubbles in the fuel.
Air in Fuel (006-003) QSV27 and QSV36
If an air leak is found, perform the following.
• Tighten the hose connections. Be sure to use two
wrenches.
• Check the drop tube in the fuel tank for damage.
• Check o-rings for damage.
Continue to test and look for source of air until no air bubbles
are visible.
Remove the sight glass.
Tighten the fuel inlet hose.
Venting Fuel Filter
WARNING
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.
With the engine stopped, open both air vent screws (1) on the
fuel filter housing.
Note the location of the fuel filter housing vent tubes (2).
While watching the fuel vent tubes, move the lever of the prim-
ing pump back and forth.
Continue priming until all the air bubbles have stopped and a
steady stream of fuel is coming out of the vents.
Tighten both fuel filter housing vent screws.
QSV27 and QSV36 Fuel Filter (Canister Type) (006-014)
Venting Injection Pump
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.
Perform the following steps anytime the injection pump is
removed.
Open a bleed air screw (1) on the pump body.
Operate the priming pump until air free fuel comes out of the
port openings.
Apply Threadlocker, Part Number 3824040, to the air bleed
screw threads and install.
Fuel Filter (Canister Type) (006-014)

Maintenance Check
Changing of fuel cartridges and cleaning of the housing is most
conveniently done when the engine is not running. However, by
alternately shutting off the fuel supply to one side of the duplex
filter housing, the filters can be changed while the engine is run-
ning.
Engine Running:
Shut off the filter side to be serviced by turning the three-way
valve so that fuel is shutoff from that side of the housing (posi-
tion “B” or “C”).
a. Both Sides In Use
b. Left Side In Use
c. Right Side In Use
Fuel Filter (Canister Type) (006-014) QSV27 and QSV36
Engine Stopped:
Set the three-way valve so both filters are selected (position
“A”).
Perform the following procedures for both filters simultaneously.
Open the air venting screw (1) located on the top of the hous-
ing.
Allow the pressure in the housing to vent.
Open the fuel drain plug (1) on the bottom of the housing.
Allow the fuel trapped in the housing to drain out.
NOTE: Collect and dispose of the drained fuel in accordance
with local regulations.
Install and tighten the drain plug.
Unscrew the four retaining nuts (1) and remove the filter
cover (2).
Remove and discard both filter cartridges.
QSV27 and QSV36 Fuel Filter (Canister Type) (006-014)
Clean the inside of the filter housing with a clean lint free cloth.
Install two new filter cartridges.

Fill the inside of the housing with clean fuel.
Install the filter cover (2), and tighten the retaining nuts (1).
Once tightened, back the retaining nuts off 1/4 of a turn.
Priming
Engine Running:
Open the air vent screw (1) at the top of the housing. Slowly
turn the three-way valve so that the indicator points toward the
filter just serviced. Tighten the vent screw once all trapped air
has been released and a steady stream of fuel is coming from
the vent (2).
Repeat the prior steps to service the remaining cartridges.
Fuel Inlet Restriction (006-020) QSV27 and QSV36
Engine Stopped:
Open both air venting screws (1) at the top of housing. Make
sure the three-way valve indicator is pointing straight down
(both filters in operation).
Note the location of the fuel filter housing vent tubes (2).
While watching the fuel vent tubes, move the level of the prim-
ing pump back and forth.
Continue priming until all the air bubbles have stopped and a
steady stream of fuel is coming out of the vents.
Tighten the vent screws (1) once all the trapped air has been
released and a steady stream of fuel is coming from the vents
(2).
Remove the air bleed screws and allow air to vent from fuel
lines.
Install the bleed screws.
Fuel Inlet Restriction (006-020)

Measure
Install a gauge prior to pre-filter (1) and after the pre-filter (2).
QSV27 and QSV36 Static Injection Timing (006-025)
Operate engine at rated rpm and load. Record pressure differ-
ential. Measure pressure on each filter by turning three-way
valve.
Specification:
Maximum Clean Filter 0.3 barG [4.4 psi]
Maximum Dirty Filter 1.5 barG [21.0 psi]
If above specification, change the fuel filter. Refer to Procedure
006-014.
Static Injection Timing (006-025)

General Information
Basic timing adjustment occurs by changing the orientation of
the cam gear on the camshaft.
Timing is set at the factory and should not be adjusted unless
absolutely necessary.
This operation can be carried out without removing the fly-
wheel.
CAUTION
If the timing is incorrectly set or if the timing gears are
inadequately tightened, the pistons will strike the valves
and cause serious damage to the engine.
Preparatory
Remove the number one cylinder injection pump. Refer to Sec-
tion 5.
Initial Check
Apply clean engine oil to the roller of the timing tool, Part Num-
ber 3164411.
Static Injection Timing (006-025) QSV27 and QSV36
Install the tool on the number one cylinder injection pump cam-
shaft lobe.
Torque the tool capscrews.
Starting with the engine positioned at top dead center on the

compression stroke, bar the engine clockwise 180° before top
dead center.
Set the timing tool gauge to zero.
Bar the engine counterclockwise until the timing tool gauge

reads 4mm [0.1575 in].
Check the following chart for the appropriate crankshaft posi-
tion.
If the crankshaft position is outside specifications, reset the tim-

ing.
Chart is for 15:1 compression ratio pistons.
Crankshaft position for all 16:1 compression ration pistons is
12.5° BTDC for all rpm ratings.
QSV27 and QSV36 Static Injection Timing (006-025)
Adjust
Check the timing. Refer to the previous procedure.
Remove the rear camshaft cover.
Loosen but do not remove the six 12 point camshaft gear pin-
ion capscrews.
With the timing tool still reading 4 mm [0.1575 in], bar the crank-
shaft to the appropriate timing mark on the flywheel. Refer to
the chart in timing check section.
Injector (006-026) QSV27 and QSV36
Rotate the camshaft gear by hand clockwise to remove gear
backlash.
Tighten the six 12 point camshaft gear pinion capscrews in the

sequence shown.
Tighten to the first torque value and repeat at the second torque
value.
Install the camshaft gear cover.

Injector (006-026)
Preparatory
Remove the rocker lever cover.
Remove the injection pump cover.
Remove the high pressure fuel line and transfer tube. Refer to
Procedure 006-051.
QSV27 and QSV36 Injector (006-026)
Remove
Remove the two injector hold down nuts (1).
Remove the injector hold down clamp (2).
Thread the Injector Puller Adapter, Service Tool #3164391, into

the top of the injector.
Remove the injector.
Clean and Inspect

With the injector removed from the engine, remove the o-rings
(1).
Use a lint-free cloth and clean the exterior of the injector.
Carefully check the area where the injector seals (2) against the
injector washer in the cylinder head.
Remove the copper washer (2).
Inspect the tip of the injector for carbon deposits. Light deposits
may be removed with carbon solvent and a brass brush.
NOTE: Do not use a steel wire brush to remove carbon depos-
its. The injector nozzle will be damaged.
Heavy deposits indicate that the injector is in need of overhaul.
Use an injector bore brush and clean the injector nozzle bore.
CAUTION
Take the necessary steps to reduce the possibility of
debris from dropping into the cylinder.
After cleaning, check the area where the injector seals against
the sleeve in the cylinder head for any indication of damage.
Test
WARNING
The fuel coming from the injector is under extreme pres-
sure and can cause serious injury by penetrating the skin.
Keep hands and body parts away from the injector while
performing the testing.
Attach the injector to the test stand.
Be sure that the injector is shielded and away from any person-
nel.
Check the body of the injector for pressure pop off setting.
Open the pressure valve (1) on the test stand.

Pump the lever (2) rapidly to force any debris out of the nozzle
openings.
With the pressure valve (1) open, pump the lever (2) rapidly and
watch the spray pattern of the injector.
An acceptable pattern shows a uniform amount of fuel coming
from each opening.
QSV27 and QSV36 Injector (006-026)
Open the pressure valve. Pump the lever slowly and watch at
what pressure the injector pops off.
Pressure Specifications
bar psi
Generator Set (original) 570 8267
Generator Set (service) 400 5800
Propulsion Engine 400 5800
Pump the nozzle to 380 bar [5510 psi]. Check that no fuel drop-
lets form on the nozzle tip within 10 seconds of attaining the
pressure.
Pump the nozzle to 540 bar [7832 psi]. Time how long it takes
for a pressure drop of 100 bar [1450 psi] to occur.
Replace the injector if:

• the spray pattern is not uniform
• fuel dribbles from the nozzle after injection
• pressure drops 100 bar [1470 psi] in less than 3 seconds
or does not drop 100 bar within 20 seconds
• the opening pressure is outside the specifications.
Pressure adjusting shims are available from 1 mm [0.039 in]

through 2 mm [0.079 in] in 0.10 [0.00039 in] increments.
Nozzle holder torque values

N•m ft-lb
340 MIN 250
400 MAX 295
Install
Install new o-rings (1) onto the replacement or recalibrated
injectors.
Lubricate the o-ring with engine oil. Make sure the o-rings are
not damaged.
Install the new nozzle to cylinder head copper sealing washer.
Sealing washer thickness:
Phase I: 2 mm [0.080 in]
Phase II: 1 mm [0.040 in]
Place the injector in the bore. Position the injector so the high
pressure tube opening is in alignment with the opening in the
cylinder head.
NOTE: Note the reference alignment arrow (1) on the top of the
injector.
Using the injector puller or a heavy piece of pipe, give the injec-
tor a quick, hard push to seat it. A single snapping sound will be
heard when the injector is seated properly.
Install the hold down clamp and nuts hand tight.

Do not tighten the clamp bolts.
Install the high pressure fuel tube and transfer tube (2). Refer to
Procedure 006-051.
Install the high pressure tube fuel drain line (3). Refer to Proce-
dure 006-013.
QSV27 and QSV36 Fuel Drain Line Restriction (006-012)
Tighten the injector hold down clamp nuts in three steps.
Torque Value: Step 1: 8 N•m [72 in-lb]
Install the rocker lever covers and the hot box covers.
Fuel Drain Line Restriction (006-012)

Measure
Remove the fuel drain hose.
Install a pressure gauge between the fuel drain hose and the
engine fuel drain fitting.
NOTE: If the engine has a drain side check valve, install the
adapter between the fuel drain hose and the check valve.
Refer to General Information for fuel tube removal.
Start and operate the engine at high idle, no load.

Maximum 1 barG [14.5 psi]
Fuel Drain Line (006-013) QSV27 and QSV36
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. Refer to General Information for fuel
tube installation.
Tighten the fuel drain line.
Fuel Drain Line (006-013)

Remove
Refer to General Information for fuel tube removal.
Remove the fuel drain line.
Clean
WARNING
injury.
Flush the fuel drain line with compressed air to remove any
debris.
QSV27 and QSV36 Fuel Supply Lines (006-024)
Inspect for Reuse
Check all fuel lines for dirt and debris. Check tube nuts and fit-
tings for damaged seals and threads.
Inspect the hose for bends or loops that may prevent proper
flow. Inspect the hose for cut or frayed wrapping. The hose
must be replaced if damaged.
Inspect the inside of the hose.

• The inner lining of the hose can separate from the center
hose section.
• A separation or flap can cause a restriction in the fuel
flow.
Install
Install the fuel drain line. Refer to General Information for fuel
tube installation.
Tighten the fuel drain line.
Fuel Supply Lines (006-024)

Preparatory
Tag the hoses to ensure correct re-assembly.
Remove any necessary brackets or clamps.
Fuel Supply Lines (006-024) QSV27 and QSV36
Remove
Loosen the tube nuts and remove the fuel lines. Refer to Gen-
eral Information for tube removal.
Clean
WARNING
injury.
Flush the fuel lines with compressed air to remove any debris.
Inspect for Reuse

Check all fuel lines for dirt and debris. Check tube nuts and fit-
tings for damaged seals and threads.
Inspect the hose for bends or loops that may prevent proper
flow. Inspect the hose for cut or frayed wrapping. The hose
must be replaced if damaged.
Inspect the inside of the hose.

• The inner lining of the hose can separate from the center
hose section.
• A separation or flap can cause a restriction in the fuel
flow.
QSV27 and QSV36 Fuel Pressure Regulating Valve (006-044)
Install
Install the fuel supply lines. Refer to General Information for
tube installation.
Replace all brackets and clamps.
Fuel Pressure Regulating Valve

(006-044)
General Information
The fuel pressure regulating valve allows constant pressure to
be maintained throughout the fuel system.
Minimum 4 barG [58 psi]
Remove
Remove the fuel drain line (1).
Remove the two hex head capscrews (2), regulating valve (3)
and o-ring seal (4).
High Pressure Fuel Tube (006-051) QSV27 and QSV36
Clean and Inspect
WARNING
WARNING
injury.
Clean the regulating valve with solvent and dry with com-
pressed air.
Check the valve fittings and mating surfaces for debris and
damage.
Install
Install a new o-ring (4) onto the valve.
Install the valve (3), capscrews (2) and drain line (1).
High Pressure Fuel Tube (006-051)

Preparatory
Remove the rocker lever covers and hot box covers.
QSV27 and QSV36 High Pressure Fuel Tube (006-051)
Remove
Loosen the tube nut on the transfer drain line (3).
NOTE: The transfer tube drain line is Marine applications spe-
cific.
Loosen the tube nuts (1) on the high pressure fuel tube (2).
Remove the high pressure fuel tube (2).
Unscrew and remove the high pressure fuel transfer tube (1)
and tube collar (2).
Clean
WARNING
WARNING
injury.
Clean the high pressure fuel tube with solvent and dry with
compressed air. Flush out the tube with compressed air to
remove any debris.
High Pressure Fuel Tube (006-051) QSV27 and QSV36
Clean the high pressure transfer tube and collar with solvent
and dry with compressed air. Flush out the tube with com-
pressed air to remove any debris.
Inspect for Reuse

Inspect the fuel line for cracks that can cause a loss of pres-
sure.
Inspect the fuel line for sharp bends that can cause a restriction
in pressure.
Inspect the mating surfaces for defects.
Check the high pressure transfer tube contact surfaces for

damage or wear. Check the threads for damage.
Check the high pressure transfer tube and tube cover for cracks
or other damage.
Install
NOTE: To ensure a tight fit of the injector and fuel transfer tube,
the injector hold down clamp must be loose.
Loosen the injector hold down clamp.
QSV27 and QSV36 High Pressure Fuel Tube (006-051)
Install new o-rings (3) on the high pressure transfer tube (1) and
cover tube (2). Insert the tube through the head and into the
injector.
Hand tighten the high pressure tube.
With the injector hold down clamp loosened, tighten the high
pressure transfer tube (1).
Tighten the injector hold down clamp nuts in three steps.

Fuel leakage will occur if ferrule height is not set.

Set ferrule height by turning left hand threaded bushing.
Ferrule Height (A)

mm in
6 MlN 0.236
7 MAX 0.276
Injector/Injection Pump Drain Line (006-058) QSV27 and QSV36
Page 6-30 \
Place the high pressure fuel tube (2) into position. Start the
threads of both coupling nuts (1) and tighten both simulta-
neously to draw the high pressure fuel tube in evenly.
Install the transfer tube drain line (3).
NOTE: The transfer tube drain line is Marine applications spe-
cific.
Injector/Injection Pump Drain Line

(006-058)
Remove
CAUTION
Line ferrules may not be crimped to the drain lines. Be
careful not to lose the ferrules.
Unscrew the 17 mm coupling nuts on the injector (1) and injec-
tor/fuel pump drain line (2).
Remove the injector/fuel pump drain line (2).
Twist the knurled o-ringed drain line fitting (3) and pull it straight
up and out from the return fuel manifold.
Clean
WARNING
WARNING
injury.
Clean the drain lines with solvent and dry with compressed air.
Flush the tubes with compressed air to remove any debris.
Inspect for Reuse

Inspect the fuel drain line for cracks.
Inspect the fuel drain line for sharp bends that can cause a
restriction in fuel flow.
Inspect mating surfaces for defects.
QSV27 and QSV36 High Pressure Tube Drain Line (006-059)
Inspect the tee fitting on the injection pump for damage or
debris.
Install
Press the knurled fitting end (1) of the injector/fuel pump drain
line (2) into the return fuel manifold.
Attach the injector drain line (3) coupling nut to the fitting in the
cylinder head.
Connect the coupling nuts for the injector/fuel drain and injector
drain lines to the tee fitting (4) on the fuel pump.
High Pressure Tube Drain Line

(006-059)
Remove
NOTE: The high pressure tube drain line is Marine applications
specific.
Loosen the high pressure tube drain line from the high pressure
tube. Remove the drain line (1).
Twist the knurled, o-ringed drain line fitting (2) and pull it straight
up and out from the return fuel manifold.
Clean
WARNING
WARNING
injury.
Clean the drain tube with solvent and dry with compressed air.
Flush out the tube with compressed air to remove any debris.
High Pressure Tube Drain Line (006-059) QSV27 and QSV36
Inspect for Reuse
Inspect the high pressure tube drain line for cracks.
Inspect the fuel line for sharp bends that can cause a restriction
in fuel flow.
Install
Push the knurled, o-ringed drain line fitting (2) straight down
into the fuel return manifold. Fasten the high pressure tube
drain line (1) to the high pressure tube.
QSV27 and QSV36
Section 7 - Lubricating Oil System - Group 07 Page 7-1
Section 7 - Lubricating Oil System - Group 07

Section Contents
Page
Flow Diagram, Lubricating Oil System................................................................................................................................... 7-3
Lubricating Oil Analysis ........................................................................................................................................................ 7-41
Maintenance Check ............................................................................................................................................................ 7-41
Lubricating Oil and Filters....................................................................................................................................................... 7-7
Drain ..................................................................................................................................................................................... 7-7
Inspect .................................................................................................................................................................................. 7-9
Install .................................................................................................................................................................................. 7-10
Remove ................................................................................................................................................................................ 7-8
Engine Running ........................................................................................................................................................... 7-8
Engine Stopped ........................................................................................................................................................... 7-9
Lubricating Oil Cooler.............................................................................................................................................................7-11
Assemble ............................................................................................................................................................................ 7-15
Clean .................................................................................................................................................................................. 7-14
Disassemble ....................................................................................................................................................................... 7-13
Install .................................................................................................................................................................................. 7-16
Pressure Test ...................................................................................................................................................................... 7-16
Remove ...............................................................................................................................................................................7-11
Lubricating Oil Dipstick ......................................................................................................................................................... 7-18
Calibrate ............................................................................................................................................................................. 7-18
Lubricating Oil Filter (Canister-Type) ................................................................................................................................... 7-20
Inspect ................................................................................................................................................................................ 7-20
Lubricating Oil Filter (Centrifugal)........................................................................................................................................ 7-42
Assemble ............................................................................................................................................................................ 7-45
Clean .................................................................................................................................................................................. 7-43
Disassemble ....................................................................................................................................................................... 7-43
Install .................................................................................................................................................................................. 7-46
Remove .............................................................................................................................................................................. 7-42
Lubricating Oil Filter Bypass Valve ...................................................................................................................................... 7-20
Assemble ............................................................................................................................................................................ 7-23
Disassemble ....................................................................................................................................................................... 7-21
Test ..................................................................................................................................................................................... 7-25
Install .................................................................................................................................................................................. 7-25
Remove .............................................................................................................................................................................. 7-20
Lubricating Oil Pressure Regulating Valve.......................................................................................................................... 7-26
Adjust .................................................................................................................................................................................. 7-26
Lubricating Oil Leaks............................................................................................................................................................. 7-27
Maintenance Check ............................................................................................................................................................ 7-27
Lubricating Oil Pan ................................................................................................................................................................ 7-29
Clean .................................................................................................................................................................................. 7-30
Fill ....................................................................................................................................................................................... 7-33
Install .................................................................................................................................................................................. 7-31
Remove .............................................................................................................................................................................. 7-29
Lubricating Oil Pressure Gauge ........................................................................................................................................... 7-33
Test ..................................................................................................................................................................................... 7-33
QSV27 and QSV36
Page 7-2 Section 7 - Lubricating Oil System - Group 07
Lubricating Oil Pump ............................................................................................................................................................. 7-34

Clean .................................................................................................................................................................................. 7-35
Install .................................................................................................................................................................................. 7-36
Preparatory ......................................................................................................................................................................... 7-34
Remove .............................................................................................................................................................................. 7-34
Lubricating Oil Recommendations and Specifications ........................................................................................................ 7-4
General Specifications .......................................................................................................................................................... 7-4
Lubricating Oil System ............................................................................................................................................................ 7-6
General Specifications .......................................................................................................................................................... 7-4
Centrifugal Bypass Filter.............................................................................................................................................. 7-6
Lubricating Oil Pump ................................................................................................................................................... 7-6
Oil Module.................................................................................................................................................................... 7-6
Oil Pan ......................................................................................................................................................................... 7-6
Lubricating Oil Thermostat ................................................................................................................................................... 7-39
Install .................................................................................................................................................................................. 7-40
Remove .............................................................................................................................................................................. 7-39
Test ..................................................................................................................................................................................... 7-40
Lubricating Oil Temperature Gauge ..................................................................................................................................... 7-38
Test ..................................................................................................................................................................................... 7-38
Service Tools ............................................................................................................................................................................ 7-5
Lubricating Oil System .......................................................................................................................................................... 7-5
QSV27 and QSV36 Flow Diagram, Lubricating Oil System
Flow Diagram, Lubricating Oil System

Lubricating Oil Recommendations and Specifications QSV27 and QSV36
Lubricating Oil Recommendations and Specifications
General Specifications
Oil Pressure, Main Oil Rifle:
• Idle rpm....................................................................................................................................... 2.25 barG [33 psi] Minimum
• 1500 Rated rpm............................................................................................................................................4.5 barG [66 psi]
• 1800 Rated rpm...............................................................................................................................................5 barG [73 psi]
Allowable Oil Filter Restriction at rated speed (Maximum)
• Clean filter ................................................................................................................................................... 0.3 barG [4.4 psi]
• Dirty filter ...................................................................................................................................................1.5 barG [21.8 psi]
Oil Temperature - after oil cooler (Nominal) ......................................................................................... 83° to 84°C [181° to 183°F]
Oil Temperature Sump (Nominal)......................................................................................................... 90° to 94°C [194° to 201°F]
Oil Temperature modulating range .......................................................................................................80° to 92°C [176° to 198°F]
Oil Sump Capacity - QSV27 (high/low) ................................................................................... 205 liter/160 liter [54 to 42 U.S. gal]
Oil Sump Capacity - QSV36 (high/low) ................................................................................... 220 liter/170 liter [58 to 45 U.S. gal]
Oil System Capacity - QSV27 ........................................................................................................................230 liter [61 U.S. gal]
Oil System Capacity - QSV36 ........................................................................................................................270 liter [71 U.S. gal]
Service Tools
Lubricating Oil System
Fluorescent Tracer
Add to oil. Use with a black light to find oil leaks.
3376891
Blacklight (DC)
Inspect for oil and fuel leaks
3377394
Nylon Lift Sling (2 in x 6 ft)
3375958
Lubricating Oil System QSV27 and QSV36

General Information
Lubricating Oil Pump
The lubricating oil pump is mounted on the free end housing
and is driven through the front gear train. A pressure relief valve
is incorporated into the oil pump housing. The main oil rifle
pressure is controlled by spring pressure on the lower end of
the spool valve and signal pressure to spool valve. High pres-
sure relief is controlled by a signal port on the upper end of the
spool valve. The low pressure safety shutdown switch is
mounted on the oil pump housing. Lubricating oil is transferred
through the free end cover and is sealed with o-rings at the oil
pan and oil transfer tubes.
Oil Pan
The oil pan is fabricated of sheet steel. Sealing is by o-ring
seals at ends and sealant at oil pan flange rail.
Centrifugal Bypass Filter

The filter is mounted on the “A” side of the engine and may be
serviced when the engine is in operation by shutting off the oil
supply to the filter.
Oil Module
The module consists of an oil cooler, full flow oil filters, and oil
thermostatic valves. Lubricating oil is directed through the
cooler, or bypassing the cooler by the thermostatic valves. The
oil is then filtered. The oil filters may be serviced when the
engine is in operation by directing the flow using a three-way
valve mounted on the filter housing.
QSV27 and QSV36 Lubricating Oil and Filters (007-002)
Lubricating Oil and Filters (007-002)

Drain
WARNING
used engine oil can be carcinogenic and can cause repro-
ductive toxicity. Avoid inhalation of vapor, ingestion, and
prolonged contact with used engine oil.
WARNING
Operate the engine until normal operating temperatures are
reached. Shut the engine down.
While the oil is still warm, remove the oil sump drain plugs.
Remove the oil filter housing catch drain plugs.
WARNING
used engine oil can be carcinogenic and can cause repro-
ductive toxicity. Avoid inhalation of vapor, ingestion, and
prolonged contact with used engine oil.
Open the air vent screw (1) and allow the pressure to vent off.
NOTE: Repeat this procedure for each filter being changed.
Lubricating Oil and Filters (007-002) QSV27 and QSV36
Remove the M18 drain plug (1) and drain the oil from the oil
cooler. After the oil has stopped draining, install and tighten the
drain plugs.
Drain Plugs
N•m ft-lb
Sump 135 100
Oil Cooler 100 75
WARNING
Remove the catch pan drain plug (1).
Loosen both filter housing drain plugs and allow oil to drain into
a container.
Tighten the catching pan drain plugs.
Remove
Replacement of the oil filter cartridges should normally be
accomplished while the engine is shut down. However, by shut-
ting off the oil to a cartridge, it can be changed while the engine
is running. The load on the remaining cartridge will increase,
and the change should be accomplished as quickly as possible.
Engine Running
Shut off the filters to be serviced by turning the three-way valve
so the oil supply is closed to that side of the housing.
Remove retaining nuts, cover and filter element.
QSV27 and QSV36 Lubricating Oil and Filters (007-002)
Engine Stopped
Set the three-way valve so that all filters are selected.
Remove the three retaining nuts, filter cover and filter element.
Inspect
CAUTION
Operating the engine with a malfunctioning bypass valve
will lead to premature engine damage due to circulation of
unfiltered lubricating oil.
Place the cover face down on a flat surface.
Press the filter seat (1) down toward the cover. Release the
seat and check that it returns quickly to its original position.
CAUTION
Operating the engine with malfunctioning a bypass valve
will lead to engine damage due to circulation of unfiltered
oil.
Push on the end of the bypass valve and check that the valve
moves freely.
If the valve is binding, the cover must be disassembled and the
components inspected for damage.
Lubricating Oil and Filters (007-002) QSV27 and QSV36
Install a new o-ring (1) onto the filter cover.
Install
Install a new filter cartridge fully into the housing. Position the
filter cover on its mounting studs and press the cover toward
the housing. Start the three cover nuts and tighten.
Install the oil filter vent fittings (1) and spacers (2).
Install the oil filter oil drain fittings (3) and spacers (2).
Open the oil fill tube and pour in an amount of new engine oil,
equal to the minimum system capacity.
Refer to Section V in the Operation and Maintenance Manual
for Lubricating Oil Specifications and capacity.
If the engine is equipped with an automatic filling system, refer
to the OEM supplied documentation for operating instructions.
Check the oil level. Add oil as necessary.
QSV27 and QSV36 Lubricating Oil Cooler (007-003)
Follow the Starting after an Extended Shutdown found in Sec-
tion 1 of the Operation and Maintenance Manual, Bulletin No.
4021309-00.
Lubricating Oil Cooler (007-003)

Remove
Drain the oil from the oil filter housing and from the oil cooler.
Remove the M18 drain plug (1) and drain the oil from the oil
cooler.
Reinstall and tighten the drain plug.
WARNING
Wait until the temperature is below 50°C [120°F] before
removing the coolant pressure cap. Failure to do so can
cause personal injury from heated coolant spray.
NOTE: Despite draining of the cooling and oil systems, some
fluid will be trapped in the housing and connections. Be pre-
pared to collect these trapped fluids as the oil cooler connec-
tions and housing are disassembled.
Drain the cooling system below the level of the oil cooler and
inlet/outlet lines. Refer to Procedure 008-018 in Section 8.
Lubricating Oil Cooler (007-003) QSV27 and QSV36
WARNING
Remove the oil filter unit.
Remove or loosen oil cooler piping.
WARNING
Remove the lube oil cooler.
CAUTION
Be careful opening the lube oil cooler. Although it has been
drained, some oil is always left in the caps and body.
Disassemble
WARNING
Remove the thermostatic box and water and oil caps from the
oil cooler.
Remove the flat seals and o-rings which can be reached on

either side of the tube bundle.
Push the tube bundle in one direction until the o-ring located
opposite is accessible. Remove the o-ring. Push the tube bun-
dle in the other direction and remove the o-ring from the other
end.
WARNING
Carefully extract the tube bundle from the lube oil cooler hous-
ing taking care not to damage the cooler housing with the tube
bundle.
Clean
WARNING
Slight deposits can be cleaned from the tube bundle using a
steam cleaner. Direct a steam jet through the tube bundle. If
there are substantial deposits, clean with a chemical solution.
WARNING
WARNING
Some solvents are flammable and toxic. Read the manufac-
turer’s instructions before using.
Carefully clean the bearing surfaces of the flat seals. Check

particularly that the surfaces are not scratched. Any scratches
at this point can cause water to leak into the oil or oil to leak into
the water.
WARNING
Wear safety glasses or a face shield, as well as protective
clothing, to reduce the possibility of personal injury when
using a steam cleaner or high-pressure water.
NOTE: Apply the pressure washer to the cooler vertically, i.e. in
a parallel direction to the fins. A pressure of 120 bar [1740 psi]
is suitable to be applied at a distance of 2 meters [6.4 ft] from
the tube surface.
Assemble
WARNING
Replace all o-rings. Install new o-rings into the cooler housing.
Lubricate the o-rings to make assembly easier.
Insert the tube bundle into the cooler body. Check to see that
the index pin bore is in vertical axis to the cooler.
NOTE: Newer design has an arrow indicating top for bundle
alignment.
Push the tube bundle in one direction until the o-ring groove at
the opposite end is accessible. Install a new o-ring and push
the tube bundle to expose the groove at the other end. Install a
new o-ring.
Fit the remaining two o-rings in the grooves located at the ends
of the tube bundle.
Install the flat seal on the thermostatic box end first. It may be
necessary to move the tube bundle in order to seat the flat seal
against the lube oil cooler body. Repeat the procedure on the
end cap side.
WARNING
Install the thermostatic box and end cap. Tighten the bolts.
Pressure Test
Install the necessary fittings to pressure check the oil cooler. Fill
the cooler with water. Bleed off any air that may be in the cooler.
Apply pressure to 7 bar [102.2 psi] and close the inlet valve.
The cooler should hold a constant pressure for thirty minutes. If
not, check all system seals and repeat the test.
Install
WARNING
Using new o-rings, install the oil cooler onto the engine block.
Tighten the mounting bolts.
NOTE: Install the long filter mount capscrews through the
cooler housing at front mount position prior to assembly installa-
tion.
Connect the oil and cooling water piping and tighten the flange
bolts.
WARNING
Install the oil filter unit to the oil cooler. Tighten the mounting
capscrews.
Open the filter air vents and start the prelube pump. Once a
solid stream of oil is seen coming from the filter vents, close the
vents and shut off the prelube pump.
Operate the pre-lubricating oil system.

After a minimum of 2 minutes, check the lubricating oil level.
Add oil until the level is again at maximum capacity.
Lubricating Oil Dipstick (007-009) QSV27 and QSV36
Fill the coolant system. Refer to Procedure 008-018.
Start the engine and check for leaks and proper operation.
Lubricating Oil Dipstick (007-009)

Calibrate
WARNING
longed contact with used engine oil. If not reused, dispose
of in accordance with local environmental regulations.
Remove the drain plug and drain the lubricating oil.
Once drained, install drain plug.
Remove the crankcase access cover.
Remove the crankcase access cover.
Fill the engine with clean engine oil.

QSV27 and QSV36 Lubricating Oil Dipstick (007-009)
Looking through the crankcase access opening, add oil until the
level is even with the top of the oil pan.
Install the dipstick fully into the dipstick tube.
NOTE: The dipstick will break if the scribe mark is made too
deep.
Remove the dipstick and scribe a mark across the dipstick at
the oil level.
Mark the high level with an “H”.
NOTE: The dipstick will break if the scribe mark is made too
deep.
Wipe the dipstick dry and measure down from the “H” (high)
mark, 75 mm [3 in] and scribe a mark across the dipstick and
mark it with an “L” for the low level.
Lubricating Oil Filter (Canister-Type) (007-012) QSV27 and QSV36
Install the dipstick.
Install the crankcase access cover.

Lubricating Oil Filter (Canister-Type)

(007-012)
Inspect
Inspect the full flow filter cartridges and covers, inspecting seals
and gaskets.
Inspect the filter elements for evidence of moisture or metal par-
ticles.
Lubricating Oil Filter Bypass Valve

(007-014)
Remove
Remove the filter cover.
QSV27 and QSV36 Lubricating Oil Filter Bypass Valve (007-014)
Disassemble
Cover
Remove the retaining ring (1).
Remove the filter seat (2) and spring (3).
Remove the o-ring (1) from the groove in the bore of the filter
seat (2).
Remove the filter cover o-ring (1).
Bypass Valve
Remove the retainer ring (1).
Remove the valve guide (2), spring (3), and bypass valve (4)
from the cover shaft bore.
Lubricating Oil Filter Bypass Valve (007-014) QSV27 and QSV36
Clean and Inspect
WARNING
WARNING
injury.
Clean all the removed parts and cover shaft bore and dry with
compressed air.
Inspect the cover shaft for scratches or other damage.

Replace as necessary.
Inspect for broken or damaged spring seats.

Inspect the bypass valve, valve guide, and valve seat in the
base of the cover shaft bore for scratches, pitting or other dam-
age.
Inspect for a broken or damaged spring.

Assemble
Bypass Valve
Lubricate the seating surface area and shaft of the bypass
valve with clean engine oil.
Install the bypass valve (4), spring (3), guide (2), and retaining
ring (1).
Lubricating Oil Filter Bypass Valve (007-014) QSV27 and QSV36
moves freely.
Cover
Install a new filter cover o-ring (1).
Install a new o-ring (1) in the filter seat (2).
CAUTION
Do not damage the filter seat o-rings during installation of
the seats. Failure of the filter cover bypass valve will result.
Lubricate the cover shaft and o-rings with clean engine oil.
Install the spring (3), filter seat (2), and retaining ring (1).
Check that the filter seat (1) moves freely on the cover shaft.
Test
Place the cover face down.
Press the filter seat (1) away from the retaining ring.
Release the tension and check that the safety filter seat returns
quickly to its original position against the retaining ring.
NOTE: If the filter cartridge seat does not return or returns
slowly, the cover must be disassembled and the components
inspected for damage.
CAUTION
Operating the engine with malfunctioning bypass valve will
lead to engine damage due to circulation of unfiltered oil.
moves freely.
If the valve is binding, the cover must be disassembled and the
components inspected for damage.
Install
Install the filter cover.
Lubricating Oil Pressure Regulating Valve (007-021) QSV27 and QSV36
Lubricating Oil Pressure Regulating

Valve (007-021)
Adjust
The oil pressure regulating valve comes from the manufacturer
preset to 8 bar [116 psi]. If it should become necessary to adjust
the relief pressure, refer to the following procedure.
If the oil relief pressure is below 5 bar [73 psi], loosen the 19
mm lock nut and turn the adjusting screw clockwise to increase
the relief pressure.
NOTE: Turn the adjusting screw in small increments until the oil
pressure is at the desired setting.
If the oil pressure is not relieving at 8 bar [116 psi] set point,
loosen the 19 mm lock nut and turn the set screw counterclock-
wise until the relief valve dumps the pressure at 8 bar [116 psi].
Once the relief pressure is set, tighten the lock nut and check
the relief valve for proper operation.
NOTE: If the valve is damaged, replace with new assembly.
QSV27 and QSV36 Lubricating Oil Leaks (007-024)
Lubricating Oil Leaks (007-024)

Maintenance Check
WARNING
Use a steam cleaner or high pressure washer to clean the
engine.
Check the engine breather for restriction.
Check for a loose, broken, or missing dipstick tube, dipstick, or

filter cap.
NOTE: Before replacing any gaskets, check the capscrews to

make sure they are tightened to the correct torque values.
Refer to capscrew torque specifications in Section V.
Operate the engine until the coolant temperature reaches 80°C
[180°F].
Inspect the exterior of the engine for leaking gaskets, seals, o-
rings, pipe plugs, or fittings.
Stop the engine if no visible leaks are noted.
Lubricating Oil Leaks (007-024) QSV27 and QSV36
Add one unit of Part Number 3376891 Fluorescent Tracer to
each 38 liters (10.0 U.S. gallons) of engine lubricating oil. Refer
to the engine specification for oil capacity.
Operate the engine at low idle for 10 minutes.
Shut the engine off.
Use a high intensity black light, Part Number 3377394, to

inspect for oil leakage. Oil will glow a dark blue color. Fuel will
glow a yellow color.
If an oil leak into the coolant is suspected, check the coolant.

QSV27 and QSV36 Lubricating Oil Pan (007-025)
Lubricating Oil Pan (007-025)

Remove
Place the fuel control lever in the “Stop” position, shut down the
pre-lubricating oil pump, shut down the coolant heater circulat-
ing pump, engage the starter interlock, and tag the engine out
of service.
WARNING
If the lubricating oil is not to be reused, dispose of in
accordance with local environmental regulations.
Drain the oil from the pan. Refer to Procedure 007-002.
Remove the crankcase hand hole covers on the right side of the
engine.
Pressure relief cover shown.
WARNING
get assistance when lifting components what weigh 23 kg
the correct capacity. Make sure hooks are positioned cor-
rectly. Always use a spreader bar when necessary. The lift-
ing hooks must not be side-loaded.
Support the weight of the oil sump and remove the 87, M12
socket head capscrews (1) from the oil pan.
Remove the pan from under the engine.
Lubricating Oil Pan (007-025) QSV27 and QSV36
Clean
WARNING
WARNING
injury.
Clean the sump with solvent and dry with compressed air.
Remove all silicone gasket material from the block and oil pan
mating surfaces.
Inspect for Reuse

Inspect the oil pan for any sign of damage to the casing and the
piping inside.
Check the oil pan, baffles and tubing for cracking or any other
damage.
Inspect the sealing surface on the sump mounting flange (1)

and free end sealing surface (2) for any damage.
QSV27 and QSV36 Lubricating Oil Pan (007-025)
Install
WARNING
Place the oil sump under the engine.
Place new o-rings on the suction and discharge tube connec-

tions on the free-end cover. Use grease to hold the o-rings in
place.
Place a thin layer of Loctite 515 on the mating surfaces of the

sump.
WARNING
Support the weight of the sump and raise into place.
CAUTION
Make sure the o-rings on the free-end cover remain in
place during installation.
Lubricating Oil Pan (007-025) QSV27 and QSV36
Install the 87, M12 socket head capscrews using Threadlocker,
Part Number 3824040, on the capscrew threads.
Tighten the capscrews in a crossing pattern, beginning at the

center of the oil sump rail. Tighten the sump to free-end cover
capscrews in a crossing pattern. Tighten the capscrews to the
first torque value and repeat at the second torque value.
Fill the pan with the recommended oil. Refer to Procedure 007-
025.
Open fuel and air valves to the engine.
Operate the pre lubricating oil pump.
Start the engine and allow to idle to ensure oil pressure.

If no pressure is noticed within 15 seconds, shut down the
engine and refer to the Lubricating Oil Pressure Low trouble-
shooting chart in Section TS.
QSV27 and QSV36 Lubricating Oil Pressure Gauge (007-028)
Fill
Open the oil fill tube (1) and pour in new engine oil.
Refer to Section V for the lubricating oil system capacity.
Run the pre-lubricating oil pump for a minimum of 5 minutes.
CAUTION
To reduce the possibility of engine damage, never operate
the engine with the oil level below the “L” (low) mark or
above the “H” (high) mark.
Start the engine and allow it to reach normal operating tempera-
ture.
Check for leaks.
With the engine running at low idle, remove the dipstick. Check
the oil level. Add oil as necessary to bring the level up to the “H”
(high) mark on the dipstick.
Lubricating Oil Pressure Gauge

(007-028)
Test
Check the following for defects:
a. Electrical wiring broken
b. Sending unit malfunction.
c. Plumbing loose or broken.
Use a reference gauge of known accuracy to verify the reading

of the suspect gauge.
Connect a line from the master gauge at a location in the sys-
tem other than at the gauge mounting.
Minimum Gauge Capacity: 830 kPa [120 psi]
Replace the sending unit if defective.
Lubricating Oil Pump (007-031) QSV27 and QSV36
Lubricating Oil Pump (007-031)

Preparatory
WARNING
WARNING
Drain the oil. Refer to Procedure 007-002.
Disconnect the lube oil regulator and relief valve piping. Refer
Install pipe plugs or blank flanges to close off the ports and
avoid spillage.
NOTE: Even though the sump is drained, some of the compo-
nents still retain oil.
Remove
WARNING
Attach a lifting sling secure to the oil pump module.
WARNING
Remove the ten (10) M12 socket head capscrews (1) connect-
ing the pump housing to the block.
Push the pump away from the block. Once the pump is free,
pull straight forward to clear the drive gear from the gear hous-
ing and free-end cover.
QSV27 and QSV36 Lubricating Oil Pump (007-031)
Remove the nine socket head capscrews (1) and the pressure
plate (2) from the drive gear.
CAUTION
Use care not to damage the gear.
Gently tap the perimeter of the drive gear with a soft faced ham-
mer.
Pull the gear off the shaft and remove the friction rings (1) from
the inside diameter of the gear.
Clean
Clean all the old gasket off the cover plate.
Inspect for Reuse

Inspect the outside diameter of the shaft and the inside diame-
ter of the gear for wear or other damage.
Lubricating Oil Pump (007-031) QSV27 and QSV36
Install
Lubricate the friction rings (1), shaft (3), and inside diameter of
the pump drive gear (2) with engine oil.
Apply anti-seize to the under side of the capscrew head and
engine oil to threads.
Position the friction rings (1) into the bore of the drive gear as
shown in the drawing.
Position split in rings 180° apart.
Install the gear on the shaft.
NOTE: Early engines were built with two thrust rings, an inner
ring and an outer ring.
Install the pressure plate (2) and screws (1).
Measure the gear spacing from the pump body gear housing
mating surface to the rear of gear.
Gear Spacing Clearance (2)

Shaft O.D. (1) mm in
28 mm (1.10 in) 52.5 2.067
35 mm (1.38 in) 56.5 2.224
Set the gear spacing.

QSV27 and QSV36 Lubricating Oil Pump (007-031)
NOTE: Repeat each stage until all screws reach the value
stated.
Tighten the screws in the following stages and in the order
shown in the drawing.
Torque Value: Step 1 5 N•m [45 in-lb]
Torque Value: Step 2 10 N•m [88 in-lb]
Install new o-rings around the oil suction/discharge ports.

Apply Loctite® A312 or equivalent around the outer bolting
flange of the lube oil pump module.
WARNING
Support the oil pump module. Lift and install the module using
care not to damage the drive gear. Align the dowel pins to the
alignment holes in the block.
Install the ten (10) M12 socket head capscrews and tighten.
Install oil regulator and relief valve piping. Refer to Procedure
007-029.
Remove any pipe plugs and blank flanges installed during
removal.
Lubricating Oil Temperature Gauge (007-038) QSV27 and QSV36
Open the fill tube (1) and fill the engine with the required
amount of oil.
CAUTION
Once the engine is started, if no oil pressure is noted
within 15 seconds, shutdown the engine to reduce the pos-
sibility of internal damage.
Start the pre-lubricating oil pump and pressurize the system to
0.5 bar [7 psi].
Start the engine. Refer to the Operations and Maintenance
Manual.
Adjust the oil pressure regulating valve. Refer to Procedures

007-021.
Lubricating Oil Temperature Gauge

(007-038)
Test
Check the wiring from the gauge (or engine control system) to
the sending unit for a broken connection.
QSV27 and QSV36 Lubricating Oil Thermostat (007-039)
Use a temperature gauge of known accuracy to check the exist-
ing gauge (or engine control system).
Replace the faulty gauge.
Lubricating Oil Thermostat (007-039)

Remove
WARNING
Drain the lube oil module and cooler.
Remove the M18 capscrews (1). Thread one of the capscrews

along with the washer into the threaded hole in the center of the
thermostat holder (2).
Use a locally procured slide hammer to unseat the thermostat

holder. Remove the thermostat holder and thermostat from the
housing.
Lubricating Oil Thermostat (007-039) QSV27 and QSV36
Remove the thermostat (1), o-ring (2), and thermostat seal (3)
from the holder.
Inspect for Reuse

Check for wear and damage.
Test
Place the thermostat in a container of water. Heat the water to
80°C [176°F].
Check that the thermostat has begun to open.
Continue to heat the water to 82°C [180°F].
Check that the thermostat is fully open.
Install
Install thermostat (1), new o-ring (2), and thermostat seal (3)
into the holder.
QSV27 and QSV36 Lubricating Oil Analysis (007-051)
Place a new o-ring on the sleeve and install the sleeve. Install
the three capscrews and tighten.
Use Loctite™ 243.
Repeat this on both holders.
Open the vents on the oil filters and start the prelube pump.
Run the pump until there is a steady stream of oil (no bubbles)
coming from the vents. Close the filter vents and shut down the
prelube pump.
Start the engine and bring temperatures up to normal operating

parameters to check the operation of the oil thermostats. If the
temperatures are OK, shut down the engine.
Lubricating Oil Analysis (007-051)

Maintenance Check
A used oil analysis can help diagnose internal damage and
determine if is was caused by one of the following:
• Intake air filter malfunction
• Coolant leaks
• Oil diluted with fuel
• Metal particle causing wear.
For additional oil analysis information, refer to “Diesel Engine
Oil Quality and Engine Oil Analysis”, Bulletin No. 3810232.
Lubricating Oil Filter (Centrifugal) (007-059) QSV27 and QSV36
NOTE: Do not disassemble an engine for repair based only on
the results of an oil analysis. Inspect the oil filters also. If the oil
filter shows evidence of internal damage, find the source od the
problem and repair the damage. Refer to the appropriate sec-
tion(s) based on the following oil filter inspection.
Lubricating Oil Filter (Centrifugal)

(007-059)
General Information
A centrifugal type bypass filter is included with the engine to
complement the main oil filter cartridges.
Part of the oil from the engine (1) is discharged through a pair of
nozzles (2). This action causes the rotor assembly (3) to spin.
Centrifugal force acts on the remaining portion of the oil and
forces any contaminates to collect on the wall of the rotor
assembly. The filtered oil drains through and returns to the oil
pan (4).
Remove
If the engine is running, close the filter oil supply line.
NOTE: Wait 60 seconds after closing the oil supply line before
removing the filter cover to allow the pressure to bleed off.
Loosen and remove the filter cover clamp (1). Loosen the T-
handled cover nut (2). Spin the nut and cover (3) until loose. Lift
and remove the cover.
QSV27 and QSV36 Lubricating Oil Filter (Centrifugal) (007-059)
Disassemble
Hold the rotor cover nut (1) and unscrew the rotor body (2).
Separate the rotor top (1) from the rotor base and remove the
central stand tube (2).
Remove the filter liner (3), if so equipped, from the rotor cover
and clean the inside of the cover with solvent.
NOTE: if the build-up on the filter liner is greater than 8 mm
[0.31 in], clean the centrifugal filter more often than every 500
hours or 3 months.
WARNING
Clean and wash the central stand tube, making certain that the
strainer holes are not plugged.
Clean
CAUTION
Do not use steel wire to clean the nozzles. This will cause
damage to the nozzles and affect the performance of the fil-
ter.
Clean out the nozzles (1) with a brass brush.
Check that the spindle bore is clear and free of sludge build up.
Examine the spindle journals (1) to make certain they are free
from damage or excessive wear.
Examine the rotor o-ring (1) for damage. Replace if necessary.
Examine the bottom bearing (1) for wear and damage.
Inspect for Reuse

Inspect the top bearing and thrust pad in the cover for wear or
damage.
QSV27 and QSV36 Lubricating Oil Filter (Centrifugal) (007-059)
Examine the filter cover o-ring (1) for damage and replace if
necessary.
Assemble
Assemble the central stand tube (2) over the center spindle until
it seats in the rotor base.
Install the paper liner (3) into the rotor cover (1), if so equipped.
Assemble the rotor and tighten the top nut.

NOTE: Overtightening of the rotor top nut can lead to rotor
imbalance which will effect filter performance.
Install the rotor assembly (1) on the center spindle. Check that
the rotor assembly is free to rotate.
Install
Replace the filter body cover (3) and tighten the T-handled
cover nut (2). Install the cover clamp (1) and tighten.
Open the oil supply valve to allow oil into the filter.
QSV27 and QSV36
Section 8 - Cooling System - Group 08 Page 8-1
Section 8 - Cooling System - Group 08

Section Contents
Page
Air or Combustion Gas Test.................................................................................................................................................. 8-27
Leak Test - Air in Cooling System ....................................................................................................................................... 8-27
Anode ...................................................................................................................................................................................... 8-38
Install .................................................................................................................................................................................. 8-38
Remove .............................................................................................................................................................................. 8-38
Coolant Hoses ........................................................................................................................................................................ 8-28
Coolant Recommendations..................................................................................................................................................... 8-9
Antifreeze.............................................................................................................................................................................. 8-9
Coolant Additives................................................................................................................................................................ 8-10
Fully Formulated Coolant...................................................................................................................................................... 8-9
Sealing Additives ................................................................................................................................................................ 8-10
Soluble Oils......................................................................................................................................................................... 8-10
Supplemental Coolant Additive (SCA) ................................................................................................................................ 8-10
Coolant Temperature Gauge ..................................................................................................................................................8-11
Maintenance Check .............................................................................................................................................................8-11
Coolant Thermostat ................................................................................................................................................................8-11
Assemble ............................................................................................................................................................................ 8-15
Clean .................................................................................................................................................................................. 8-13
Disassemble ....................................................................................................................................................................... 8-13
Install .................................................................................................................................................................................. 8-15
Remove ...............................................................................................................................................................................8-11
Test ..................................................................................................................................................................................... 8-14
Coolant Thermostat Housing ................................................................................................................................................ 8-16
Clean .................................................................................................................................................................................. 8-18
Install .................................................................................................................................................................................. 8-19
Remove .............................................................................................................................................................................. 8-16
Cooling System ........................................................................................................................................................................ 8-4
Flow Diagram, Cooling System............................................................................................................................................. 8-5
QSV36 Heat Exchanger Assembly, With Fuel Cooler .......................................................................................................... 8-7
QSV36 Heat Exchanger Assembly, Without Fuel Cooler ..................................................................................................... 8-6
Specifications........................................................................................................................................................................ 8-8
Cooling System ...................................................................................................................................................................... 8-21
Clean .................................................................................................................................................................................. 8-21
Drain ................................................................................................................................................................................... 8-21
Fill ....................................................................................................................................................................................... 8-22
Pressure Test ...................................................................................................................................................................... 8-24
Heat Exchanger Cooling Plates ............................................................................................................................................ 8-29
Clean .................................................................................................................................................................................. 8-30
Install .................................................................................................................................................................................. 8-31
Remove .............................................................................................................................................................................. 8-29
QSV27 and QSV36
Page 8-2 Section 8 - Cooling System - Group 08
Heat Exchanger Support Housing ........................................................................................................................................ 8-32

Clean .................................................................................................................................................................................. 8-33
Install .................................................................................................................................................................................. 8-34
Remove .............................................................................................................................................................................. 8-32
Pressure Cap .......................................................................................................................................................................... 8-28
Install .................................................................................................................................................................................. 8-29
Remove .............................................................................................................................................................................. 8-28
Test ..................................................................................................................................................................................... 8-28
Sea Water Pump ..................................................................................................................................................................... 8-35
Clean .................................................................................................................................................................................. 8-36
Install .................................................................................................................................................................................. 8-37
Remove .............................................................................................................................................................................. 8-35
Sea Water Strainer ................................................................................................................................................................. 8-48
Clean .................................................................................................................................................................................. 8-48
Service Tools ............................................................................................................................................................................ 8-3
Cooling System..................................................................................................................................................................... 8-3
Transfer Housing.................................................................................................................................................................... 8-39
Clean .................................................................................................................................................................................. 8-40
Install .................................................................................................................................................................................. 8-41
Remove .............................................................................................................................................................................. 8-39
Water Pump ............................................................................................................................................................................ 8-42
Assembly ............................................................................................................................................................................ 8-45
Clean .................................................................................................................................................................................. 8-44
Disassemble ....................................................................................................................................................................... 8-44
Install .................................................................................................................................................................................. 8-47
Remove .............................................................................................................................................................................. 8-42
Service Tools
Cooling System
Cooling System Test Kit

The Fleetguard® Coolant Test Kit is used to check the con-
centration of coolant additives in the cooling system.
CC-2602
Fluke Digital Temperature Measuring Instrument

Use to read the temperature of the coolant.
3822666
Thermocouple Kit
Use to measure cylinder and exhaust temperatures.
3822988
Cooling System QSV27 and QSV36
Page 8-4 3
Section 8 - Cooling System - Group 08
Cooling System
General Information
The functions of the cooling system are to:
• Absorb heat from the engine components
• Circulate the coolant in the engine
• Dissipate the heat through the heat exchanger
• Control coolant temperature with the thermostat
The coolant must be made up of the correct proportions of
water, antifreeze and supplemental coolant additives (SCA) to
properly perform these functions.
Refer to the coolant flow diagram which illustrates the coolant
flow through the engine.
QSV27 and QSV36 Cooling System
Flow Diagram, Cooling System
1. LT Flow from LT Pump 11. HT Flow from HT Pump to Thermostat Housing

2. LT Flow from LT Pump to Thermostat Housing 12. HT Flow from Thermostat Housing to Heat Exchanger
3. LT Flow from Thermostat Housing to Heat Exchanger 13. HT Flow from Thermostat Housing to CAC
4. LT Flow from Thermostat Housing to CAC 14. HT Flow through CAC
5. LT Flow from CAC to Oil Cooler 15. HT Flow to Cylinder Liners
6. Oil Cooler 16. HT Flow around Cylinder Liners
7. LT Flow from Oil Cooler to LT Pump 17. HT Flow to Cylinder Head
8. Sea Water Inlet from Sea Water Pump 18. HT Flow through Cylinder Head to Multiduct
9. Heat Exchanger 19. HT Flow from Multiduct to Thermostat Housing
10. Sea Water Outlet 20. HT Flow from Thermostat Housing to HT Pump
QSV36 Heat Exchanger Assembly, Without Fuel Cooler

QSV27 and QSV36 Cooling System
QSV36 Heat Exchanger Assembly, With Fuel Cooler

Specifications
Coolant Capacity (Engine ONLY):
QSV27 .................................................................................................................................................... 152 liters [40 U.S. gal]
QSV36 .................................................................................................................................................... 182 liters [48 U.S. gal]
High Temperature (HT) Thermostat Modulating Range ..................................................................... 88° to 100°C [190° to 212°F]
Low Temperature (LT) Thermostat Modulating Range:
Gen Set........................................................................................................................................... 52° to 64°C [126° to 147°F]
Propulsion .......................................................................................................................................59° to 71°C [138° to 160°F]
HT Coolant System Pressure:

Idle ................................................................................................................................................................1.2 barG [17.4 psi]
Rated ...............................................................................................................................................................3.8 barG [55 psi]
LT Coolant System Pressure (Nominal):
Idle ................................................................................................................................................................ 0.8 barG [11.6 psi]
Rated ...............................................................................................................................................................2.8 barG [41 psi]
Coolant Temperatures at HT Outlet (Maximum)........................................................................................................100°C [212°F]

QSV27 and QSV36 Coolant Recommendations
Coolant Recommendations
Fully Formulated Coolant
Cummins Inc. recommends using a 50 to 50 mixture of good
quality water and fully formulated coolant when filling the cool-
ing system.
Always use good quality soft water in the coolant mixture.

Excessive levels of calcium and magnesium contribute to scal-
ing problems, and excessive levels of chlorides and sulfates
cause cooling system corrosion.
Water added to the cooling system must meet the specifica-
tions given in the accompanying chart.
Cummins Inc. recommends using Fleetguard® Compleat. It is

available in glycol forms (ethylene and propylene).
Antifreeze
NOTE: Antifreeze over-concentration reduces freeze protec-
tion. Do not use more than 68 percent antifreeze. Fifty percent
water is sufficient for freeze protection to -37°C [-34°F].
NOTE: Use ethkylene glycol antifreeze year-round to provide
freeze point and boil-over protection.
NOTE: Do not use a high silicate antifreeze. A silicate-gel
(hydro-gel) formation can occur when a cooling system con-
tains an over-concentration of high silicate antifreeze and/or
supplemental coolant additives. Engine damage will result.
Coolant Recommendations QSV27 and QSV36
Sealing Additives
Do not use sealing additives in the cooling system. Using addi-
tives will cause a buildup in coolant low flow areas.
Soluble Oils
Do not use soluble ails in the cooling system. The use of solu-
ble oils will:
• Allow cylinder liner pitting
• Corrode brass and copper
• Damage heat transfer surfaces
• Damage seals and hoses
Coolant Additives
Diesel coolant additives (DCA4 or equivalent) are required to
protect the cooling system from fouling, solder blooming, and
general corrosion.
Supplemental Coolant Additive (SCA)

NOTE: Inadequate concentration of coolant additives can result
in major corrosive damage to cooling system components.
Over-concentration can cause the formation of “gel” that can
cause restriction/plugging of passages, over-heating or water
pump leakage.
The DCA 4 concentration must not fall below 1 unit per 3.8
liters [1 U.S. gallon] nor exceed 2 units per 3.8 liters [1 U.S. gal-
lon].
QSV27 and QSV36 Coolant Temperature Gauge (008-004)
Use Fleetguard Coolant Test Kit, Part Number CC2602, to
check the supplemental coolant additive concentration level.
Follow the instructions included in the test kit. Refer to Coolant
Recommendations and Specifications for the correct SCA level.
CAUTION
Under-concentration of coolant additives can result in liner
pitting and system corrosion. Over-concentration can
result in water pump seal leakage.
NOTE: If above test kit is not available, use equivalent.
Coolant Temperature Gauge (008-004)

Maintenance Check
Check the wiring from the gauge (or engine control system) to
the sending unit for a broken connection.
Use a temperature gauge to known accuracy to check the exist-

ing gauge (or engine control system).
Replace the faulty gauge.
Coolant Thermostat (008-013)

Remove
WARNING
WARNING
with local authorities.
Coolant Thermostat (008-013) QSV27 and QSV36
Close sea water inlet and outlet valves.
Remove the heat exchanger cooling plates. Refer to Procedure

008-053.
Remove the heat exchanger support housing. Refer to Proce-
dure 008-054.
NOTE: The same procedure is used for replacing the high tem-
perature circuits (HT) thermostat (1) and the low temperature
circuits (LT) thermostat (2).
Remove the three M8 capscrews (1).

QSV27 and QSV36 Coolant Thermostat (008-013)
Thread one of the capscrews and a washer into the threaded
hole in the center of the thermostat holder (2).
Use a locally procured slide hammer to unseat the thermostat

holder.
Remove the thermostat holder and thermostat from the hous-
ing.
Disassemble
Remove the thermostat (1), o-ring (2), and guide ring (3) from
the holder.
Clean
WARNING
WARNING
injury.
Clean the thermostat holder in solvent. Dry with compressed
air.
Coolant Thermostat (008-013) QSV27 and QSV36
Inspect for Reuse
Inspect the thermostat holder for cracks or other damage.
Inspect for obstructions that would interfere with thermostat
movement.
If the holder is damaged, it must be replaced.
Inspect the thermostats for wear or damage.

If the thermostat is damaged, it must be replaced.
Inspect the thermostat housing for cracks or other damage.
Test
Suspend the thermostat and a thermometer into a container of
water. Do not allow the thermostat or the thermometer to touch
the sides of the container.
Heat the water.
NOTE: Write down the temperatures at which the thermostat
begins to open and when it is fully open.
QSV27 and QSV36 Coolant Thermostat (008-013)
Thermostat operation must meet the specifications given in the
accompanying chart.
Assemble
Lubricate two new o-rings (2) with clean engine oil.
Install the thermostat (1), o-ring (2), and guide ring (3) into the
holder.
Install
Install the thermostat holder into the housing. Seat the holder
with a rubber mallet.
Install the three M8 capscrews.
Install the heat exchanger support housing. Refer to Procedure

008-053.
Install the heat exchanger cooler plates. Refer to Procedure
008-054.
Coolant Thermostat Housing (008-014) QSV27 and QSV36
Open the sea water inlet and outlet valves.

Operate the engine and check for leaks.
Coolant Thermostat Housing

(008-014)
Remove
WARNING
WARNING
QSV27 and QSV36 Coolant Thermostat Housing (008-014)
Close the sea water inlet and outlet valves.

008-053.
dure 008-054.
Remove the three 10 mm hex socket capscrews and one nut

from the inlet pipe.
Remove the transfer housing. Refer to Procedure 008-061.

Remove the low temperature and the high temperature outlet
tubes.
Remove the seven remaining nuts from the studs.
Slide the thermostat housing off of the studs.
Clean
WARNING
WARNING
injury.
Clean the thermostat housing mating surfaces with solvent and
a brush. Dry with compressed air.
QSV27 and QSV36 Coolant Thermostat Housing (008-014)
Inspect for Reuse
Inspect the housing for cracks or other damage.
Install
Install the two o-rings.
Carefully slide the thermostat housing onto the studs.
Install the seven nuts with washers.

Install the transfer housing. Refer to Procedure 008-061.

Check alignment to prevent cracking housing.
Install the inlet pipe using the three 10 mm hex socket cap-
screws and one nut with washer.

008-053.
Install the heat exchanger cooler plates. Refer to Procedure
008-054.

QSV27 and QSV36 Cooling System (008-018)
Cooling System (008-018)

Drain
WARNING
removing the coolant system pressure cap. Failure to do
so can cause personal injury from heated coolant spray.
Remove the pressure cap after the engine is cool.
WARNING
Drain the cooler or radiator and pipework according to the OEM
instructions.
Remove the circuit drain plugs located under the charge air
cooler.
Remove the drain plug from the bottom of the lubricating oil
cooler.
Clean
WARNING
Flush the system with clean water. If the system shows mineral
buildup, scale, rust or oil, clean with a heavy duty engine cool-
ant cleaner and follow the manufacturer’s directions.
Cooling System (008-018) QSV27 and QSV36
Fill
Install the circuit drain plugs under the charge air cooler.
Install the plug into the bottom of the lubricating oil cooler.
Open all engine coolant system vents located on the top of the
charge air cooler and the top of the heat exchanger.
Slowly fill the cooling system with coolant to approximately 25.4

mm [1 in] from the top of the site glass.
Close the vents on top of the charge air cooler and the heat
exchanger once a steady stream of coolant is coming out.
Install the pressure cap and operate the engine for 10 minutes
at normal operating temperature.
Check for leaks.
WARNING
Check the coolant level only when the engine is stopped.
Shut the engine off and allow to cool.
CAUTION
Do not add cold coolant to a hot engine. Engine castings
can be damaged. Allow the engine to cool below 50°C
[120°F] before adding coolant.
Remove the radiator cap or fill cap and check the coolant level.
Add coolant if necessary.
Install the pressure cap and operate the engine for 10 minutes
at normal operating temperature.
Check for leaks.
Pressure Test
WARNING
CAUTION
can be damaged. Allow the engine to cool below 50°C
[120°F] before adding coolant.
Remove the radiator cap or fill cap and check the coolant level.
CAUTION
Do not apply more than 350 kPa [51 psi] air pressure to the
cooling system. The water pump seal can be damaged.
If the radiator is equipped with a pressure relief valve, install a
plug in the overflow tube.
Install the pressure tester on the radiator fill neck or surge tank
(if equipped).
Apply 350 kPa [51 psi] maximum air pressure.
NOTE: While pressure is on the coolant system, pre lube the

engine and place the fuel control to the “no fuel” position. Check
the pressure gauge to see if any change has occurred.
Maintain pressure on the system for a minimum of 5 minutes
and check for leaks.
If the pressure does not change, no external leaks are visible
and an internal leak is not suspected, remove the test equip-
ment and install the radiator cap.
If the pressure on the system can not be maintained, it will be

necessary to pressure test the oil cooler.
Check the oil cooler housing for coolant leakage.
Remove the oil drain plug from the bottom of the oil cooler
housing. Drain the oil and check for coolant in the oil. If coolant
is present, the oil cooler will need to be pressure tested. Refer
If the oil cooler is not leaking, drain the oil pan. Refer to Proce-
dure 007-002.
Check the oil for coolant contamination.
If the oil does not contain coolant, check the charge air cooler.
If the oil contains coolant, drain the oil pan. Refer to Procedure
007-002.
Remove the crankcase access covers and wipe out and dry the
oil sump.
Check for leakage on the inside and outside of the cylinder lin-
ers.
Replace all cylinder liner seals that are leaking. Refer to Proce-
dure 001-028.
Remove the multi-ducts and check the intake ports for coolant.
A defective cylinder head must be replaced. Refer to Proce-
dure 002-004.
A defective multi-duct must be replaced. Refer to Procedure
010-079.
Once all of the leaks are corrected, pressure test the system
again.
If no leaks are present, remove the test equipment and install
the radiator cap.
QSV27 and QSV36 Air or Combustion Gas Test (008-019)
Air or Combustion Gas Test (008-019)

Leak Test - Air in Cooling System
WARNING
Wait until the temperature is below 50°F [120°F] before
Allow the engine to cool and remove the radiator or fill cap.
NOTE: The pressure cap must make a tight seal.

Install a radiator pressure cap which has had the spring and
pressure relief valve removed.
Attach a rubber hose to the radiator overflow connection.
Place the free end of the hose into a container of water.
Operate the engine at rated rpm until it reaches a temperature

of 80°C [180°F] with the thermostat open.
Check for continuous flow of air bubbles from the end of the
hose in the water container.
A continuous flow of air bubbles can be caused by one of the

following:
• cracked or porous cylinder liners
• defective cylinder head water passage seal.
Coolant Hoses (008-045) QSV27 and QSV36
Coolant Hoses (008-045)

Inspect for Reuse
CAUTION
Do not bend or deform the hoses during inspection. This
can weaken the hoses and cause them to crack.
NOTE: Engine overheating or coolant overflow can result from
internal deterioration of the coolant hoses. Refer to the “Coolant
Temperature Above Normal” Troubleshooting Logic Chart. Par-
ticles of deteriorated hose can restrict or completely stop the
coolant flow.
Inspect all hoses for cracks and cuts, and for signs of balloon-
ing or collapsing.
Pressure Cap (008-047)

Remove
WARNING
Do not remove the pressure cap until the coolant tempera-
ture is below 50°C [120°F]. Failure to do so can cause per-
sonal injury from heated coolant spray.
Remove the pressure cap after the engine is cool.
Inspect for Reuse

Be sure that the correct pressure cap is being used. Refer to
“Cooling System Specifications”.
Inspect the rubber seal of the pressure cap for damage.
Inspect the fill neck for cracks or other damage.
Refer to the OEM manual for instructions if the fill neck is dam-
aged.
Test
Pressure test the radiator cap.
The pressure cap must seal within 14 kPa [2 psi] of the value
stated on the cap, or it must be replaced.
QSV27 and QSV36 Heat Exchanger Cooling Plates (008-053)
Install
Install the pressure cap.
Heat Exchanger Cooling Plates

(008-053)
Remove
WARNING
WARNING

Heat Exchanger Cooling Plates (008-053) QSV27 and QSV36
Remove the drain plug and drain the sea water from the heat
exchanger housing.
Fabricate guide pins for positions 7 and 8 using mild steel.
Install guide pins at end locations to hold plates in position.

Carefully tag each plate and note direction of embossed arrow
in center.
Remove the clamping capscrews and remove the cover, spac-
ers and cooling plates.
Clean
Clean the plates with a nylon brush and water.
CAUTION
Do not use high pressure spray as the nitrite seals will be
damaged.
QSV27 and QSV36 Heat Exchanger Cooling Plates (008-053)
Inspect for Reuse
Inspect the plates for cracks or other damage.
Install
Install the cooling plates, spacers and cover with the clamping
capscrews.
Use guide pins in position 7 and 8.
Refer to system diagrams for plate assembly information on
pages 8-6 and 8-7. QSV36 shown, QSV27 similar.
Torque in two steps in the sequence shown.

Install the drain plug into the heat exchanger support housing.
Heat Exchanger Support Housing (008-054) QSV27 and QSV36

Heat Exchanger Support Housing

(008-054)
Remove
WARNING
WARNING

QSV27 and QSV36 Heat Exchanger Support Housing (008-054)
exchanger housing.
WARNING
Remove the heat exchanger plates. Refer to Procedure 008-
053.
WARNING
Remove the four hex socket capscrews and two nuts.
Carefully slide the support housing off of the studs.
Clean
WARNING
Starting fluid is highly flammable and explosive. Keep
flames, sparks, and arcing switches away from starting
fluid.
Steam clean the housing.
Heat Exchanger Support Housing (008-054) QSV27 and QSV36
Inspect for Reuse
Inspect the housing for corrosion, pitting or other damage.
Install
WARNING
Slide the support housing onto the studs.
Install the two mounting nuts and the four hex socket cap-
screws.
WARNING
Install the heat exchanger cooling plates. Refer to Procedure
008-053.
QSV27 and QSV36 Sea Water Pump (008-057)
Open sea water inlet and outlet valves.

Sea Water Pump (008-057)

Remove
Remove the sea water pump drain plugs and drain the water
from the pump.
Sea Water Pump (008-057) QSV27 and QSV36
Remove all piping from the sea water pump.
WARNING
Remove the six capscrews that fasten the pump to the gear
housing.
Remove the sea water pump.
Clean
Clean the sea water pump and the gear housing mounting sur-
faces to ensure that no debris enters the gear housing.
Inspect for Reuse

Inspect the sea water pump gear for cracks, pitting or other
damage.
QSV27 and QSV36 Sea Water Pump (008-057)
Install
WARNING
Apply a bead of Loctite® 115 to the sea water pump mounting
surface.
Install the sea water pump and six mounting capscrews.
Install all piping and fasteners.

Install the sea water pump plugs.

Anode (008-059) QSV27 and QSV36
Anode (008-059)
Remove
Remove the anode assembly (1) from the heat exchanger.
Inspect for Reuse

Inspect the anode surface for material loss.
The anode must be replaced if less than 2/3 of the anode
remains.
Install
Install the new anode (1) on the support (2).
Install a new o-ring (3).
Install the anode assembly into the heat exchanger.
QSV27 and QSV36 Transfer Housing (008-061)
Transfer Housing (008-061)

Remove
WARNING
WARNING
exchanger housing.
WARNING
008-053.
dure 008-054.
Transfer Housing (008-061) QSV27 and QSV36
WARNING
Remove the eight capscrews from the water pump connection
and remove the transfer housing.
Remove the low temperature and high temperature outlet tubes

from the thermostat housing and the free end gear housing.
Clean
Scrape the transfer housing mounting surfaces.
Inspect for Reuse

Inspect the transfer housing for cracks or other damage.
QSV27 and QSV36 Transfer Housing (008-061)
Check that the anti-flowback valves are functioning properly.
Install
Install new o-rings on the low temperature and high tempera-
ture outlet tubes.
Use petroleum jelly to hold the o-rings in position.
Install tubes in the thermostat housing and gear housing.
WARNING
Check the alignment to prevent cracking.
Install the transfer housing using the eight capscrews.
WARNING
Install the heat exchanger cooling plates. Refer to Procedure
008-053.
008-054.
Water Pump (008-062) QSV27 and QSV36

Water Pump (008-062)

Remove
WARNING
WARNING
QSV27 and QSV36 Water Pump (008-062)
WARNING
008-053.
dure 008-054.
Remove the three 10 mm hex socket capscrews and one nut

from the inlet pipe.
Remove the v-band clamp.

Remove the inlet pipe.
WARNING
Remove the eight capscrews connecting the transfer housing to
the water pump.
Remove the low temperature and the high temperature outlet
tubes.
WARNING
To avoid personal injury, use a hoist or get assistance
when lifting components that weight 23 kg [50 lb] or more.
Make sure all lifting devices such as chains, hooks or
slings are in good condition and are of the correct capac-
ity.
Support the weight of the pump.
Remove the seven hex socket capscrews that attach the pump
to the free end cover.
Remove the pump by pulling it straight out from the engine.
Take care not to damage the drive gear or the free end cover.
Disassemble
Remove the drive gear (1) by removing the four retaining bolts
(2) and pressure plate (3). The gear should separate from the
shaft. Tap the gear with a dead blow hammer if necessary, to
aid in freeing the gear from the shaft.
Remove both sets of friction ring pairs (4).
Clean
Clean the end of the drive shaft and inside diameter of the gear
with a lint free cloth.
Inspect for Reuse
Inspect the gear bore and shaft for wear or damage.
The pump must be replaced if any marks can not be removed
with a fine crocus cloth.
Inspect the pump housing for cracks or other damage.
Inspect the gear for cracks, pitting or other damage.
Assembly
Lubricate the shaft and the inside diameter of the pump drive
gear with engine oil.
Install the drive gear onto the shaft.
Lubricate and install both sets of friction ring pairs (1).
Lubricate the capscrews with engine oil.
Install the pressure plate onto the drive gear using the four
retaining bolts. Snug down the retaining bolts.
Check the alignment of the gear on the shaft.
The gear is seated against shaft bearing.
Tighten the capscrews in the sequence shown.

Install the o-rings.

Use petroleum jelly on the o-rings to hold them in position dur-
ing the installation of the pump.
Install
Install new o-rings on the low temperature and the high temper-
ature outlet tubes.
Use petroleum jelly to hold the o-rings in place.
Install the tubes in the thermostat housing and front cover.
WARNING
To avoid personal injury, use a hoist or get assistance
when lifting components that weight 23 kg [50 lb] or more.
Make sure all lifting devices such as chains, hooks or
slings are in good condition and are of the correct capac-
ity.
Align the pump bolting flange with the stud (1).
Position and install the pump drive gear through the opening in
the free end cover.
Check that the gear teeth are lined up with the crankshaft gear
teeth.
Install the mounting bolts and draw the pump in evenly.

Tighten the mounting bolts.
WARNING
Install the transfer housing.
Check the alignment to prevent cracking.
Sea Water Strainer (008-067) QSV27 and QSV36
Install the pump inlet housing.
Tighten the v-band clamp.
Install the inlet pipe using the three 10 mm hex socket cap-
screws and one nut and washer.

Sea Water Strainer (008-067)

Clean
NOTE: Most sea water systems for heat exchanger cooled
engines use a sea water strainer. The strainer removes debris
from the sea water before it enters the sea water pump.
QSV27 and QSV36 Sea Water Strainer (008-067)
If the sea water strainer is below the sea water level (as on
some marine applications), close the sea water inlet and outlet
valves.
Loosen and or remove the sea water strainer wing nuts as
required.
Remove the sea water strainer basket.

Empty the debris and clean the strainer basket.
Prime the sea water strainer.

Install the sea water strainer. Install and tighten the wing nuts.
Open the sea water inlet and outlet valves, if these are part of
the system.
Sea Water Strainer (008-067) QSV27 and QSV36
NOTES
QSV27 and QSV36
Section 9 - Drive Units - Group 09 Page 9-1
Section 9 - Drive Units - Group 09

Section Contents
Page
Drive Units - General Information ........................................................................................................................................... 9-3
Engine Barring Device ............................................................................................................................................................. 9-4
Assemble .............................................................................................................................................................................. 9-5
Clean and Inspect for Reuse ................................................................................................................................................ 9-4
Install .................................................................................................................................................................................... 9-5
Remove ................................................................................................................................................................................ 9-4
QSV27 and QSV36
Page 9-2 Section 9 - Drive Units - Group 09

QSV27 and QSV36 Drive Units - General Information
Drive Units - General Information

The Drive Units section consists of the removal, cleaning, inspection, testing and assembly of these components not previously
covered in the troubleshooting and repair of the various engine system. The rebuild of these components are not covered in this
section.
Engine Barring Device (009-035) QSV27 and QSV36
Engine Barring Device (009-035)

Remove
Remove the two 6 mm allen headed capscrews (1) and lift the
micro switch bracket and switch (2).
Remove the collar holding the barring device.
Pull out on the barring device locking pin and slide the barring
gear, shaft and spring out of the flywheel housing.
Clean and Inspect for Reuse

WARNING
WARNING
injury.
Clean the parts of the barring device in solvent and dry with
compressed air.
QSV27 and QSV36 Engine Barring Device (009-035)
Inspect the gear and spring for wear or damage.
Assemble
Using clean engine oil, lubricate the guide shaft.
Place the spring over the guide shaft and collar onto the barring
gear.
Install
Pull out on the locking pin and slide the barring device into the
flywheel housing.
Engine Barring Device (009-035) QSV27 and QSV36
Place the micro switch and bracket (2) in place and install the
two 6 mm allen headed capscrews (1) and tighten.
Engage the barring device and check for proper operation.
Pull out on the lock pin to check that the barring device disen-
gages from the flywheel.
QSV27 and QSV36
Section 10 - Intake Air System - Group 10 Page 10-1
Section 10 - Intake Air System - Group 10

Section Contents
Page
Air Cleaner Element ............................................................................................................................................................... 10-6
Assemble ............................................................................................................................................................................ 10-7
Clean .................................................................................................................................................................................. 10-7
Disassemble ....................................................................................................................................................................... 10-6
Remove .............................................................................................................................................................................. 10-6
Inspect ................................................................................................................................................................................ 10-7
Install .................................................................................................................................................................................. 10-7
Air Intake Restriction ........................................................................................................................................................... 10-16
Measure ............................................................................................................................................................................ 10-16
Air Intake System ................................................................................................................................................................... 10-4
Air Leaks, Air Intake and Exhaust ........................................................................................................................................ 10-5
Initial Check ........................................................................................................................................................................ 10-5
Charge Air Cooler (CAC) ....................................................................................................................................................... 10-8
Assemble ...........................................................................................................................................................................10-11
Clean ................................................................................................................................................................................ 10-10
Disassemble ..................................................................................................................................................................... 10-10
Fill Cooling System ........................................................................................................................................................... 10-14
Inspect ...............................................................................................................................................................................10-11
Install ................................................................................................................................................................................ 10-12
Leak Test .......................................................................................................................................................................... 10-12
Preparatory ......................................................................................................................................................................... 10-8
Pressure Differential Test.................................................................................................................................................. 10-16
Remove .............................................................................................................................................................................. 10-8
Temperature Differential Test ............................................................................................................................................ 10-15
Multiduct ............................................................................................................................................................................... 10-34
Clean ................................................................................................................................................................................ 10-35
Inspect .............................................................................................................................................................................. 10-36
Install ................................................................................................................................................................................ 10-36
Preparatory ....................................................................................................................................................................... 10-34
Remove ............................................................................................................................................................................ 10-35
Specifications ......................................................................................................................................................................... 10-3
Air Intake System................................................................................................................................................................ 10-3
Turbocharger ........................................................................................................................................................................ 10-18
Clean ................................................................................................................................................................................ 10-19
Inspect for Reuse.............................................................................................................................................................. 10-19
Install ................................................................................................................................................................................ 10-21
Remove ............................................................................................................................................................................ 10-18
Turbocharger Axial Clearance ............................................................................................................................................ 10-22
Measure ............................................................................................................................................................................ 10-22
Turbocharger Bearing.......................................................................................................................................................... 10-30
Assemble .......................................................................................................................................................................... 10-32
Clean ................................................................................................................................................................................ 10-32
Disassemble ..................................................................................................................................................................... 10-30
Finishing ........................................................................................................................................................................... 10-34
Inspect .............................................................................................................................................................................. 10-31
Preparatory ....................................................................................................................................................................... 10-30
QSV27 and QSV36
Page 10-2 Section 10 - Intake Air System - Group 10
Turbocharger Blade Damage .............................................................................................................................................. 10-23

Turbocharger Compressor Seal Leaks .............................................................................................................................. 10-24
Leak Test .......................................................................................................................................................................... 10-24
Turbocharger Oil Drain Line................................................................................................................................................ 10-24
Clean ................................................................................................................................................................................ 10-25
Initial Check ...................................................................................................................................................................... 10-24
Install ................................................................................................................................................................................ 10-26
Remove ............................................................................................................................................................................ 10-25
Turbocharger Radial Bearing Clearance............................................................................................................................ 10-26
Measure ............................................................................................................................................................................ 10-26
Turbocharger Turbine Seal Leaks....................................................................................................................................... 10-27
Leak Test .......................................................................................................................................................................... 10-27
Turbocharger Wastegate Valve ........................................................................................................................................... 10-28
Clean ................................................................................................................................................................................ 10-29
Inspect .............................................................................................................................................................................. 10-29
Install ................................................................................................................................................................................ 10-30
Remove ............................................................................................................................................................................ 10-28
Test ................................................................................................................................................................................... 10-29
Specifications
Air Intake System
Maximum Intake Restriction (clean air filter element) ..............................................................................300 mm H2O [12 in H2O]
Maximum Intake Restriction (dirty air filter element) ................................................................................635 mm H2O [25 in H2O]
Air Intake System QSV27 and QSV36
Air Intake System

General Information
The combustion air system consists of intake air piping, turbo-
charger, charge air cooler (CAC) piping, CAC, and exhaust pip-
ing.
The turbocharger uses exhaust gas energy to turn the turbine

wheel. The turbine wheel drives the compressor impeller that
provides pressurized air to the engine for combustion. The
additional air provided by the turbocharger allows more fuel to
be injected to increase the power output from the engine.
NOTE: The correct turbocharger must be used. Providing too
much additional air will increase the cylinder pressures and
shorten the life of the engine.
The turbine and compressor wheels and the shaft are sup-
ported by two rotating bearings in the bearing housing. Pas-
sages in the bearing housing direct filtered, pressurized engine
oil to the shaft bearings and thrust bearings. The oil is used to
lubricate and cool the rotating components to provide for
smooth operation. The oil then drains from the bearing housing
to the engine sump through the oil drain line.
NOTE: An adequate supply of good, filtered oil is very important
to the life of the turbocharger.
As the intake air is compressed by the turbocharger, the air

temperature increases. This heated air is then passed through
the charge air cooler which cools the air. Cool air is more dense
which allows more air to be compressed into the cylinder, yield-
ing a much greater combustion efficiency.
QSV27 and QSV36 Air Leaks, Air Intake and Exhaust (010-024)
Air Leaks, Air Intake and Exhaust

(010-024)
Initial Check
CAUTION
Engine intake air must be filtered to prevent dirt and debris
from entering the engine. If intake air piping is damaged or
loose, unfiltered air will enter the engine and cause prema-
ture wear.
Inspect for loose clamps or damage between the air cleaner,
turbocharger, and CAC.
Replace damaged components and tighten loose clamps.
Operate the engine at full throttle and maximum load, and

check for air leaks. Listen for a whistling noise caused by high-
pressure air leaks.
The noise can be caused by an air leak from the following:

Turbocharger to CAC flange connection.
• Inspect the flange for damage or loose connections.
• Tighten loose capscrews.
Any CAC connection.

• Inspect the ducts and cooler for damage or loose con-
nections.
• Tighten loose capscrews.
Air Cleaner Element (010-014) QSV27 and QSV36
Turbocharger to exhaust manifold mounting.
Turbocharger to wastegate mounting.
Wastegate to exhaust manifold.
Turbine or compressor housing sealing surface air leak.

• Tighten the v-band clamp.
• Loosen and retorque.
• Check for an air leak.
• If an air leak is still present, remove and replace the tur-
bocharger.
Air Cleaner Element (010-014)

Remove
Clean the area around the air cleaner before removing. Loosen
and remove the v-band clamp (1) that attaches the air cleaner
to the turbocharger. Remove air cleaner.
Cover the intake area of the turbocharger to prevent foreign
matter from entering the opening.
Disassemble
Remove the foam filter ring (4) from the assembly. Remove the
two band clamps (3) that hold the filter elements (2) in the hous-
ing (1).
QSV27 and QSV36 Air Cleaner Element (010-014)
Clean
CAUTION
Clean the filter housing, filter elements and foam filter ring with
compressed air. Direct the compressed air in the opposite direc-
tion of intake air flow.
Inspect
Inspect the filter housing, elements and filter ring for damage.
Replace any damaged components.
Assemble
Place the cleaned or new filter element (2) into position in the
housing (1) and install and tighten the two band clamps (3).
Install the filter ring (4) over the filter elements.
Install
Install the filter assembly and v-band clamp (1) onto the turbo-
charger and tighten the v-band clamp.
Charge Air Cooler (CAC) (010-027) QSV27 and QSV36
Charge Air Cooler (CAC) (010-027)

Preparatory
WARNING
Wait until the temperature is below 50°C (120°F) before
Remove the radiator cap after the engine is cool.
NOTE: Coolant must be collected and disposed of as per local

environmental guidelines.
Drain the cooling system.
Remove the circuit drain plugs located under the charge air
cooler and the plug located under the lube oil cooler.
Remove
Remove the cooling pipe.
Remove the CAC top cover.
Remove the exhaust support at the wastegate.
QSV27 and QSV36 Charge Air Cooler (CAC) (010-027)
WARNING
This assembly weighs 23 kg 50 lb] or more. To reduce the
Install the lifting eyelets (1) to the top of the cooler. Attach an
approved sling or chain to the eyelets on the cooler and place a
light strain on the hoist.
Remove upper CAC to block support capscrews (2).
Remove the nuts and bolts from the flange between the bellow
and the turbocharger.
NOTE: Remove the turbocharger drain tube for access.
Remove the capscrews from the outlet duct where it connects

to the block.
Remove the remaining mounting capscrews.

Remove the charge air cooler.
Disassemble
Remove the inlet and outlet ducting from the cooler.
Remove the bottom cover.
Clean
WARNING
Wear safety glasses or a face shield, as well as protective
clothing, to reduce the possibility of personal injury when
using a steam cleaner or high-pressure water.
CAUTION
When using solvents, acid, or alkaline materials for clean-
Clean the cooler core and covers by immersing them in a chem-
ical cleaning bath for 24 hours. Circulate the bath water for best
results.
Flush the cooler by using a water pressure washer.

NOTE: Apply the pressure washer to the cooler vertically, i.e.,
in a parallel direction to the fins. A pressure of 120 bar [1740
psi] is suitable to be applied at a distance of 2 meters [6.5 ft]
from fin surface.
Inspect
Inspect the core for corrosion and damage.
Repair or replace the core if needed.
Inspect the ducts for cracks or other damage.

Inspect the top and bottom cooler covers for cracks and corro-
sion.
Inspect the cooling pipes for cracks, corrosion and other dam-
age. Check for missing or damaged o-rings.
Assemble
Assemble the inlet and outlet ducting using Loctite® Ultra Gray
RTV silicone.
Assemble the bottom cover using silicone sealant.
Leak Test
Install cover plates to seal the duct openings.
Install pressure gauge.

Apply 207 kPa [30 psi] of air pressure to the cooler. Close the
air pressure regulator.
Use a spray bottle filled with soapy water and apply to all duct
connections. Watch for bubbles to appear at the location of the
leak.
Repair any leaky connections and repeat the test.
Apply 207 kPa [30 psi] of air pressure to the cooler. Close the
air pressure regulator.
Monitor the pressure gauge and determine the rate of pressure
drop with a stopwatch.
If the pressure drop is greater than 49 kPa [5 psi] in 15 sec-
onds, the CAC must be replaced.
NOTE: Three similar readings must be obtained to confirm
pressure drop.
NOTE: Charge air coolers are not designed to be 100 percent
leak free. If the pressure drop is less than 49 kPa [5 psi] in 15
seconds, then the CAC does not need to be replaced.
Install
WARNING
Install the lifting eyelets to the top of the cooler. Refer to Section
10, Cooler Removal. Place the cooler on the engine using new
o-rings and gasket at air connection to block.
Install the bottom cover capscrews to the engine block.
NOTE: Place turbo drain and wastegate support in position
prior to CAC installation.
While supporting the cooler assembly with eye hooks (1), install
the capscrews (2) on the upper cover that attach the cooler to
the top of the block.
Install wastegate support bracket.
Install the capscrews from the outlet duct where it connects to

the block, check gasket location.
Install the nuts and bolts from the flange between the bellow
and the turbocharger. Use anti-seize compound on threads.
Install turbocharger oil drain tube.
Install the CAC top cover, use Loctite® Ultra Gray RTV.
Install the cooling pipes.
Fill the cooling system.
Fill Cooling System
Close the drains.
Install the plugs removed from the:
• Charge air cooler
• Lube oil cooler
Open all engine coolant system vents located on the top of the
charge air cooler and highest points on the engine.
Slowly fill the cooling system with coolant to approximately 25.4

mm [1 in] from top of site glass.
Close the vent on top of the charge air cooler once a steady
stream of coolant is coming out.
Close other vents as coolant appears.
Install the radiator cap and operate the engine for 10 minutes at
normal operating temperature.
Check for leaks.
Shut the engine off and allow to cool.
WARNING
Check the coolant level only when the engine is stopped.
removing the pressure cap. Failure to do so can cause per-
sonal injury from heated coolant spray.
CAUTION
may be damaged. Allow the engine to cool to 50°C [120°F]
before adding coolant.
Remove the radiator or fill cap, check the coolant level.
Temperature Differential Test

Install a fluke digital thermometer, Part Number 3822666, and
thermocouple wire kit, Part Number 3822988, into the CAC inlet
and outlet ducts.
Run the engine at peak power.

Record the intake air temperature on the outlet duct. Record the
air temperature on the inlet duct.
Calculate the differential temperature:
Turbocharger Charge Air Differential

Outlet – Cooler = Temperature
Temperature Temperature
Minimum differential temperature = 28°C [50°F]
Air Intake Restriction (010-031) QSV27 and QSV36
If the temperature differential is less than the specifications,
check the CAC for dirt and debris on the fins and clean as nec-
essary.
Pressure Differential Test

Measure the CAC system pressure drop with a manometer.
Install one end of the manometer to the tap in the turbocharger
compressor outlet elbow.
Install the other end of the manometer to the tap in the intake
air connection.
Operate the engine at the maximum advertised horsepower

and correlating rpm. Record the readings on the manometer.
If the differential pressure is greater than 152 mm Hg [6 in Hg]
or 21 kPa [3 psi], visually check the CAC and associated piping
for debris. Clean or replace if necessary.
Air Intake Restriction (010-031)

Measure
Install a vacuum gauge or water manometer in the intake air
duct.
QSV27 and QSV36 Air Intake Restriction (010-031)
Operate the engine at full throttle and rated rpm with maximum
load.
Record the reading on the gauge or manometer.
NOTE: Restriction must not exceed 500 mm H20 [20 in H20].
If the restriction exceeds specifications, do the following:

• Replace or clean the air filter element. Refer to the equip-
ment manufacturer’s instructions.
• Inspect the intake air duct for damage or loose connec-

tions. Refer to the equipment manufacturer’s repair
instructions.
Remove the test equipment.

Turbocharger (010-033) QSV27 and QSV36
Turbocharger (010-033)
Remove
Remove the v-band clamp (1) and air filter assembly.
Remove the heat shields.
Loosen and remove the four capscrews connecting the intake

bellows to the compressor outlet flange.
Disconnect the oil drain tube.

QSV27 and QSV36 Turbocharger (010-033)
Remove the exhaust flange bellows capscrews and wastegate
connection capscrews.
CAUTION
Attach a lifting hook to the cast strap at the top of the turbo-
charger.
Apply tension to the lifting hook and remove the remaining
mounting capscrews (1).
Clean
Clean the turbocharger and exhaust manifold gasket surfaces.
Inspect for Reuse

Inspect the turbocharger casings and replace if through cracks
are found in the outer walls.
Turbocharger (010-033) QSV27 and QSV36
Cracks on the turbocharger mounting flange or the exhaust
flange are not acceptable.
Replace any cracked manifold sections or the turbocharger.
Inspect the turbocharger v-band clamping surfaces for dents or
fretting.
Replace the turbocharger or discharge elbow, if damaged.
Inspect the turbocharger compressor impeller blades and tur-

bine wheel blades for damage.
Rebuild or replace the turbocharger if damage is found. Refer to
Procedure 010-033.
If the compressor impeller is damaged, inspect the filter ele-

ment for damage.
NOTE: Repair any damage before operating the engine.
QSV27 and QSV36 Turbocharger (010-033)
Install
CAUTION
Install the oil supply o-ring (1) and drain o-ring (2) into mounting
base. Install new turbocharger mounting gasket.
Raise turbocharger into position in front of the base.
Carefully guide the turbocharger onto the base.
Install the 2 capscrews (3) connecting the turbocharger onto the
base.
Align and install the four capscrews connecting the outlet flange
to the intake bellow. Use the anti-seize compound on threads.
Use new gaskets. Install waste gate flange capscrews. Use

anti-seize compound on threads.
Install wastegate connection capscrews.
Turbocharger Axial Clearance (010-038) QSV27 and QSV36
Install a new o-ring and connect the oil drain tube.
Apply Threadlocker, Part Number 3824040, to the capscrews
and install.
Install the heat shields.
Install the air filter assembly and v-band clamp (1).

Run the pre-lubricating oil pump for at least three cycles to build
oil pressure in the turbocharger.
Turbocharger Axial Clearance

(010-038)
Measure
Install a turbo dial depth gauge, #ST537, on the turbocharger
as shown.
Push the rotor assembly away from the gauge and set the
gauge to zero.
QSV27 and QSV36 Turbocharger Blade Damage (010-039)
Push the rotor assembly toward the gauge, and record the
reading.
Axial Clearance Specifications

mm in
TPS48 (QSV27) 0.08 MIN 0.003
0.16 MAX 0.006
TPS52 (QSV36) 0.10 MIN 0.004
0.18 MAX 0.007
Replace the turbocharger if the clearance does not meet the
specifications. Refer to Procedure 010-033 for the replacement
procedure.
Install the air filter assembly (1).

Tighten the v-band clamp.
Install the exhaust piping (2) and tighten.
Turbocharger Blade Damage

(010-039)
Inspect for Reuse
Inspect the turbocharger compressor impeller blades and tur-
bine wheel blades for damage.
Rebuild or replace the turbocharger if damage is found. Refer to
Procedure 010-033.
If the compressor impeller is damaged, inspect the filter ele-

ment for damage.
NOTE: Repair any damage before operating the engine.
Turbocharger Compressor Seal Leaks (010-040) QSV27 and QSV36
Turbocharger Compressor Seal Leaks

(010-040)
Leak Test
Remove the v-band clamp (1) and air filter assembly.
Examine the compressor intake and discharge for oil.

If oil is present in the compressor intake as well as the dis-
charge, check upstream of the turbocharger for the source of
the oil.
If oil is present only in the discharge side, check for intake
restriction. Refer to Procedure 010-031.
If no intake restriction is found, replace the turbocharger. Refer
Install the air filter assembly and v-band clamp (1).

Run the pre-lubricating oil pump for at least three cycles to build
oil pressure in the turbocharger.
Turbocharger Oil Drain Line (010-045)

Initial Check
Inspect the line for oil leaks or damage.
Repair or replace as necessary.
QSV27 and QSV36 Turbocharger Oil Drain Line (010-045)
Remove
Remove the capscrews from the turbocharger oil drain tube.
Clean
WARNING
WARNING
injury.
Clean the tube with solvent and dry with compressed air.
Clean the engine block and turbocharger support oil drain pas-
sages. Make sure they are free of dirt and debris.
Inspect for Reuse

Inspect the line for cracks, wear, and damage.
Inspect the o-ring for fretting and cracking and replace as nec-
essary.
Turbocharger Radial Bearing Clearance (010-047) QSV27 and QSV36
Install
Apply a thin film of oil to the drain line o-rings.
Push the drain line into the drain line boss. Be sure both o-rings
are completely seated in the bore.
Install the drain line capscrews.
Turbocharger Radial Bearing

Clearance (010-047)
Measure
Remove the air filter assembly and exhaust pipe from the turbo-
charger. Refer to Procedure 010-033.
Measure radial clearance of the shaft.
Radial Clearance Specifications

mm in
TPS48 (QSV27) 1.01 MAX 0.039
TPS52 (QSV36) 1.12 MAX 0.044
Replace the turbocharger if the radial bearing clearance does

not meet the specifications. Refer to Procedure 010-033 for the
replacement procedure.
Install the air filter assembly (1) and tighten the v-band clamp.
Install the exhaust piping and tighten.
QSV27 and QSV36 Turbocharger Turbine Seal Leaks (010-049)
Turbocharger Turbine Seal Leaks

(010-049)
Leak Test
Add one unit of fluorescent tracer, Part Number 3376891, to
each 38 liters [10 gal] of engine lubricating oil.
Operate the engine at low idle for 10 minutes.
Shut off the engine.

Allow the turbocharger to cool.
Remove the exhaust pipe from the turbine housing.

inspect the turbine outlet for leaks.
A dark blue glow indicates a fuel leak. A yellow glow indicates
an oil leak.
If oil is found on the turbine housing, remove the oil drain line
and check for restrictions. Clear any restrictions found, or
replace damaged components as required.
If the engine is equipped with a turbocharger oil drain fitting with
a screen, remove the fitting and check to make sure the screen
is clean.
Turbocharger Wastegate Valve (010-050) QSV27 and QSV36
If the oil drain line is not restricted, remove the turbocharger.
Refer to Section 10.

inspect the turbine inlet for leaks.
A yellow glow indicates an oil leak from the engine.
If a yellow glow is not seen in the turbine inlet, replace the tur-
bocharger. Refer to Procedure 010-033.
Turbocharger Wastegate Valve

(010-050)
Remove
Remove the heat shields.
Remove the wastegate signal line (1).

Remove the four wastegate-to-exhaust manifold hex socket
capscrews (2).
Remove the four wastegate to turbocharger hex head cap-
screws (3).
Remove the wastegate valve (4).
QSV27 and QSV36 Turbocharger Wastegate Valve (010-050)
Clean
Use a scraper to remove any gasket material from the waste-
gate and exhaust manifold mounting surfaces.
Inspect
Check the wastegate housing and capsule for cracks or other
damage.
Test
Connect clean, regulated air pressure and a pressure gauge to
the wastegate valve.
NOTE: No air should be heard (i.e., leaking noise) through a
functional wastegate capsule.
Apply a maximum of 2.75 barG [40 psi] to make sure the waste-
gate is functioning properly.
Turbocharger Bearing (010-077) QSV27 and QSV36
Install
Install the wastegate value (1) and new gaskets (2).
Use anti seize compound on threads.
Install the four wastegate to turbocharger hex head capscrews
(3).
Install the four wastegate to exhaust manifold hex socket cap-
screws (4).
Install the wastegate signal line (5).
Install the heat shields.
Turbocharger Bearing (010-077)

Preparatory
Remove turbocharger from engine. Refer to Procedure 010-
033.
Secure to fixture.
Loosen v-band clamps.
Disassemble
CAUTION
Install lifting straps.
Remove compressor (1) and turbine (2) housings.
Remove nozzle ring (3).
QSV27 and QSV36 Turbocharger Bearing (010-077)
Inspect
Check radial and axial clearance.
A. Maximum radial: 0.21 mm [0.008 in]
B. Maximum axial: 1.26 mm [0.050 in]
Remove diffuser plate (1), compressor wheel (2), bearing cover

(3), and seal(4). The bearing cover fasteners can be used as
jack screws to remove the cover.
Remove snap ring (5) from cover.
Remove shaft and impeller (1).

Remove the four capscrews (2) that hold the bearing assembly
(3) in the bearing case (4). Use two of the capscrews (2) as jack
screws to remove the bearing assembly (3).
Separate the front (A) and rear (B) bearing supports. Remove
the thrust plate (1), thrust bearing (2), and bearing (3).
Remove the three bearing retainer screws (4) from the front
support (5) and slide out the bearing (6).
Remove the two snap rings (7) and three bearing retainer
screws (8) from the (10) rear support (9) and slide the bearing
out.
Turbocharger Bearing (010-077) QSV27 and QSV36
Clean
WARNING
WARNING
injury.
Clean all components with solvent and dry with compressed air.
Inspect for Reuse

Inspect the wheels for nicks or cracks.
Inspect the shaft for damage or wear.
Assemble
Install a new bearing (1) and two snap rings (2) into the rear
bearing support (3).
Align the bearing with the support and install the bearing
retainer capscrews (4).
Install a new bearing (1) into the front bearing support (2).
Align the bearing with the support and install the bearing
retainer capscrews (3).
Lubricate the outside diameter of the shaft adaptor (4) with
clean engine oil and install.
QSV27 and QSV36 Turbocharger Bearing (010-077)
Lubricate the thrust bearing (2).
Lubricate the inside diameters of the bearings.
Assemble the rear bearing support assembly (1), thrust plate
(2), thrust bearing (3), and front bearing support assembly (4).
Install this assembly in the bearing casing with four capscrews
(5).
Install the exhaust side bearing casing cover (1). Apply a high
temperature lubricant to the casing cover seal ring (2) and
install.
Lubricate the impeller shaft (3) and install into bearing casing
(4).
NOTE: Do not lubricate the threads on the impeller shaft.
Install the seal ring (1) and seal (2).

Install seal ring (3), casing (4), and capscrews (5).
Install seal (7) diffuser plate (8), and screw (9).
Install the compressor wheel.

NOTE: Use a hex tool to hold the shaft.
Install the speed pickup screw (if equipped).
Multiduct (010-079) QSV27 and QSV36
Install new gaskets (1) on turbine housing. Install the nozzle
ring (2).
Install a new o-ring (3) on the compressor housing. Install the
wall insert (4).
Install the turbine housing and v-band clamps. Install the com-
pressor housing and v-band clamp. Torque clamps evenly.
Loosen and retorque.
Finishing
Remove the turbocharger from the fixture.
Install the turbocharger onto the engine. Refer to Procedure
010-033.
Multiduct (010-079)
Preparatory
Remove the heat shield. Refer to Procedure 011-015.
Remove the exhaust manifold section adjacent to the multiduct
to be removed. Refer to Procedure 011-007.
QSV27 and QSV36 Multiduct (010-079)
Remove
Remove the multiduct air venting line.
Remove the six socket head capscrews (1) that hold the multi-
duct to the block. Remove the six socket head capscrews (2)
and spacers (3) that hold the multiduct to the cylinder head.
Remove the multiduct.
Clean
Use a scraper and carefully remove any gasket material from
the sealing surfaces of the multiduct.
Completely remove the rivets used to hold the gasket in place.
The rivet holes must be clear of old rivets and debris.
WARNING
WARNING
injury.
Use a solvent and a wire brush to clean the multiduct.
Inspect
Inspect the mounting holes and area around coolant passage
for cracks.
Inspect the coolant passage for pitting or debris.
Inspect the mounting holes for visible thread grooves.
Install
Install the rivets and gasket to the multiduct.
Install the multiduct onto the block with 6 socket head cap
screws and a new gasket.
Put anti-seize compound on the four socket head capscrews (1)

and install with spacers (2) into the head.
QSV27 and QSV36 Multiduct (010-079)
Install the exhaust ring onto the multiduct.
Install the multiduct vent line.

Install the exhaust manifold section, clamps and bellows. Refer

Install the exhaust shielding. Refer to Procedure 011-015.

NOTES
QSV27 and QSV36
Section 11 - Exhaust System - Group 11 Page 11-1
Section 11 - Exhaust System - Group 11

Section Contents
Page
Exhaust Manifold.....................................................................................................................................................................11-4
Clean ...................................................................................................................................................................................11-5
Inspect for Reuse.................................................................................................................................................................11-5
Install ...................................................................................................................................................................................11-6
Remove ...............................................................................................................................................................................11-4
Exhaust Restriction.................................................................................................................................................................11-7
Measure ...............................................................................................................................................................................11-7
Exhaust Shielding ...................................................................................................................................................................11-4
Install ...................................................................................................................................................................................11-4
Remove ...............................................................................................................................................................................11-4
Exhaust System ......................................................................................................................................................................11-4
General Information .............................................................................................................................................................11-4
Specifications ..........................................................................................................................................................................11-3
Exhaust System ...................................................................................................................................................................11-3
QSV27 and QSV36
Page 11-2 Section 11 - Exhaust System - Group 11

Specifications
Exhaust System
Maximum Back Pressure from Piping and Silencer (combined):
Hg .............................................................................................................................................................. 38 mm Hg [1.5 in Hg]
H2O....................................................................................................................................................500 mm H2O [19.5 in H2O]
Exhaust Pipe Size (normally acceptable inside diameter) .........................................................................................205 mm [8 in]
Exhaust System (011-999) QSV27 and QSV36
Exhaust System (011-999)

General Information
The exhaust system consists of the exhaust manifold shielding,
exhaust manifold sections, exhaust manifold piping and multi-
duct housings. The multiduct carries exhaust gasses away from
the cylinder, intake gasses to the cylinder and coolant from the
head to the block.
The exhaust manifold sections are connected with expansion or
“bellows” joints. These bellows allow for a tight seal during
expansion of the exhaust manifold.
NOTE: The bellows are directional and marked with an arrow.
Make sure they are installed with the arrows pointing in the
direction of the escaping gas.
Exhaust Shielding (011-015)

Remove
Remove the exhaust shielding screws and washers.
Remove the exhaust shielding.
Install
Install the exhaust shielding. Install the exhaust shielding
screws and washers.
Exhaust Manifold (011-007)

Remove
WARNING
Remove the mounting nuts.
Remove the exhaust manifold sections and the gaskets.
Discard the gaskets.
QSV27 and QSV36 Exhaust Manifold (011-007)
Clean
Use a 240 grit emery cloth to clean all of the exhaust manifold
mounting surfaces.
WARNING
When using a steam cleaner, wear protective clothing and
safety glasses or a face shield. Hot steam can cause seri-
ous personal injury.
Use steam and a wire brush to clean the manifold sections.
Clean the sealing joint inside and outside diameters to remove
any scale that has accumulated.
Inspect for Reuse

Inspect for cracks in the areas shown.
Inspect the mounting stud holes in each section for damage.

NOTE: The manifold has been subjected to high temperatures
if the mounting stud threads are visible on the side of the holes.
High temperature can cause the manifold to shrink.
Measure the center-to-center distance between the same posi-
tion mounting stud holes of the two flanges on each section to
determine if the manifold is too short.
Exhaust Manifold Capscrew Holes

mm in
191.5 MIN 7.54
193.5 MAX 7.62
Exhaust Manifold (011-007) QSV27 and QSV36
Check the bellows and clamps for damage.
Install
Install the exhaust rings into the groove in the multiduct hous-
ing.
Apply an anti-seize compound on mounting stud threads.

Install the exhaust manifold sections, bellows, and clamps.
NOTE: The bellows are directional and marked with an arrow.
Make sure they are installed with the arrow pointing in the direc-
tion of the escaping gas.
Tighten the mounting nuts.

QSV27 and QSV36 Exhaust Restriction (011-009)
Exhaust Restriction (011-009)

Measure
Connect a manometer or pressure gauge in the exhaust piping.
The gauge must have a capacity of 152 mm Hg [6 in Hg] or
2070 mm H20 [81.5 in H20].
NOTE: The 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 25 mm [10.0 in]
after the turbocharger.
The adapter must not extend through the wall of the exhaust
tubing.
NOTE: 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 value will not be accurate.
Connect a 13 mm [1/2 in] piece of metal tubing between the
gauge adapter and the gauge hose. This will prevent damage to
the hose from extreme heat.
Operate the engine at rated rpm and load and record the
manometer reading.
NOTE: The exhaust pressure must not exceed 300 mm H2O
[12 in H2O].
NOTE: Stall speed is not full power.
If the exhaust pressure exceeds the specification, visually

inspect the exhaust piping for damage. Refer to the equipment
manufacturer’s instructions.
NOTE: If no damage is visible, check the size and routing of the
exhaust piping. Refer to the Installation Recommendation Bul-
letin.
Exhaust Restriction (011-009) QSV27 and QSV36
NOTES
QSV27 and QSV36
Section 12 - Compressed Air System - Group 12 Page 12-1
Section 12 - Compressed Air System - Group 12

Section Contents
Page
Air Starting Motor................................................................................................................................................................... 12-5
Install .................................................................................................................................................................................. 12-5
Remove .............................................................................................................................................................................. 12-5
Compressed Air System - General Information .................................................................................................................. 12-3
Specifications ......................................................................................................................................................................... 12-4
Compressed Air System ..................................................................................................................................................... 12-4
QSV27 and QSV36
Page 12-2 Section 12 - Compressed Air System - Group 12

QSV27 and QSV36 Compressed Air System - General Information
Compressed Air System - General Information

Compressed air is used on the QSV engine for two different functions:
1. To spin an air-turbine starter motor for engine starting.
2. To extend the fuel pump injection racks to a no-fuel position by means of air cylinders if an engine shutdown fault occurs
(e.g. overspeed).
The QSV engine does not have an engine driven air compressor. Starting and control air are supplied by a compressed air
source at the operating sits.
Specifications
Compressed Air System
Type: Compressed Air
Nominal Receiver Pressure..............................................................................................................30 to 49 barG [440 to 585 psi]
Starter Inlet Pressure:
QSV27/36 Minimum.........................................................................................................................................7 barG [100 psi]
QSV27/36 Maximum...................................................................................................................................... 11 barG [160 psi]
Minimum Cranking Speed .................................................................................................................................................. 150 rpm
QSV27 and QSV36
Air Starting Motor (012-022)
Remove
WARNING
To reduce the possibility of equipment damage and per-
sonal injury, secure the air and electric circuits to the
starter.
Remove the air (1) and electric (2) connections.
WARNING
This component weights 23 kg [50 lb] or more. To reduce
Remove the three mounting bolts (1).
Pull the starter away from the flywheel housing.
Remove the starter spacer plate (if installed).
Inspect for Reuse

Check the bendix gear for chipped, broken, or missing gear
teeth.
Replace the starter if damaged.
Install
Install the starter and spacer plate (if one was installed).
Install the three 14 mm socket head mounting bolts.
Air Starting Motor (012-022) QSV27 and QSV36
Connect the air lines and electrical power.
QSV27 and QSV36
Section 14 - Engine Testing - Group 14 Page 14-1
Section 14 - Engine Testing - Group 14

Section Contents
Page
Crankcase Blowby, Measure ................................................................................................................................................. 14-8
Measure .............................................................................................................................................................................. 14-8
Engine Testing - General Information .................................................................................................................................. 14-3
In-Service Run-in ................................................................................................................................................................ 14-3
Engine Testing (In Chassis) .................................................................................................................................................. 14-8
Test ..................................................................................................................................................................................... 14-8
Service Tools .......................................................................................................................................................................... 14-6
Engine Testing .................................................................................................................................................................... 14-6
Specifications ......................................................................................................................................................................... 14-5
Engine Testing .................................................................................................................................................................... 14-5
QSV27 and QSV36
Page 14-2 Section 14 - Engine Testing - Group 14

QSV27 and QSV36 Engine Testing - General Information
Engine Testing - General Information

General Information
The engine test is a combination of the engine run-in period and
the performance check. The engine run-in period procedure
provided an operating period that allows the engine parts to
achieve the final finish and fit. The performance check provides
an opportunity to perform final adjustments needed to optimize
the engine performance.
The engine run-in can be performed with an engine dynamome-
ter. If a dynamometer is not available, the engine run-in must
be performed in a manner that simulates a dynamometer test.
Check the dynamometer before beginning the test. The dyna-
mometer must have the capability to test the performance of
the engine when the engine is operating at the maximum rpm
and horsepower range (full power).
The crankcase pressure, often referred to as engine blowby, is
an important factor that indicates when the piston rings and the
valves have achieved the proper finish and fit to put the engine
into a service application. Rapid changes of blowby, or values
that exceed specifications more than 50 percent, indicate that
something is wrong. The engine test must cease until the
cause has been determined and corrected.
CAUTION
Incorrect or insufficient break-in of the piston rings will
lead to early oil consumption or high blowby complaints.
Adherence to these run-in guidelines will allow the full
durability of new pistons, liners, and rings.
This section outlines engine testing and engine run-in for the
QSV27/36 engine. All engines must be run-in after a rebuild or
a repair involving the replacement of one or more piston ring
sets, cylinder liners, or pistons.
Before running the engine, make sure the cooling system is
filled with the proper coolant and that the lubricating oil system
is filled and primed.
In-Service Run-in
The in-service run-in is recommended when an engine dyna-
mometer run-in can not be performed.
NOTE: The majority of heavy-duty diesel applications will pro-
vide sufficient run-in under normal loaded operations. Light
load, high rpm operation must be avoided during the run-in
period.
Engine Testing - General Information QSV27 and QSV36
Engine Dynamometer Run-in
This is the preferred method of engine run-in for engines that
have been rebuilt out of chassis. It is not practical or recom-
mended that an engine be removed from the application to con-
duct the run-in after a rebuild or cylinder repair has been
performed in-chassis. There is no requirement or recommen-
dation for an engine that has been run-in and tested on an
engine dynamometer to be run in again after it has been rein-
stalled in the vehicle or equipment.
Specifications
Engine Testing
Maintain the following limits during the engine test/run-in procedures:
Due to variations in ratings of different engine models, refer to the specific Engine Data Sheet for the particular engine model
being tested.
Intake Restriction (maximum at advertised horsepower):
• Clean Air Filter..................................................................................................................................300 mm H2O [12 in H2O]
• Dirty Air Filter....................................................................................................................................635 mm H2O [25 in H2O]
Exhaust Back Pressure (maximum at advertised horsepower with 15 mm [0.600 in] orifice)....................... 38 mm Hg [1.5 in Hg]
Blowby * (maximum at advertised horsepower):
• Used Engines (maximum) (over 3600 hours)...................................................................................600 mm H2O [26 in H2O]
Oil Pressure (with 15W-40 oil at 107°C [225°F]):
• Low Idle (minimum allowable) .......................................................................................................................2.3 barG [33 psi]
• At 1500 rpm (minimum allowable) .................................................................................................................4.5 barG [66 psi]
• At 1800 rpm ......................................................................................................................................................5 barG [73 psi]
Fuel Inlet Restriction (maximum at advertised horsepower):
• Dirty Prefilter Elements.................................................................................................................................0.2 barG [2.9 psi]
• Maximum Allowable Fuel Inlet Temperature................................................................................................. 50 barG [122 psi]
• Maximum Fuel Filter Restriction ....................................................................................................................1.5 barG [21 psi]
NOTE: * The used engine limit blowby numbers are intended to be used as a guideline only, not as s hard-set rebuild limit.
Basis for engine rebuild can be derived by trending blowby over time.
Service Tools
Engine Testing
Vacuum Gauge
Used to check fuel pump inlet restriction.
ST-434
Manometer
Used with blowby check tool for measuring blowby. Also, used
to measure air inlet restriction and exhaust restriction.
ST-1111-3
Digital Optical Tachometer

Used to measure engine speed (rpm)
3377462
Blowby Check Tool (15 mm [0.600 in] orifice)

Used with manometer, Part Number ST-1111-3, to measure the
engine crankcase pressure.
Pressure Gauge
Used to measure fuel pressure.
ST-435-6
Pressure Gauge
Used to measure intake manifold pressure.
ST-1273
Pressure Gauge (0-160 psi)

Used to measure oil pressure.
3375275
Engine Testing (In Chassis) (014-008) QSV27 and QSV36
Engine Testing (In Chassis) (014-008)

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.
• Engine speed rpm with a verified tachometer
• Fuel pressure
• Fuel temperature
• Fuel inlet restriction
• Fuel drain line restriction
• Intake manifold pressure.
• Intake air restriction

• Exhaust air restriction
• Coolant temperature
• Engine blowby
• Lubricating oil pressure
• Coolant pressure
• Inlet manifold air temperature
• Turbocharger inlet air temperature.
Engine Speed (rpm) With a Verified Tachometer

Use an electrical tachometer to check engine speed.
Crankcase Blowby, Measure

(014-010)
Measure
NOTE: Excessive blowby indicates a turbocharger or an engine
malfunction allowing combustion gases or air to enter the crank-
case and build a pressure higher than normal.
This procedure describes how to measure crankcase pressure
and helps determine the component which is malfunctioning.
For this procedure, use the blowby service tool, and a manome-
ter of 1270 mm H2O [50 in H2O] minimum capacity.
QSV27 and QSV36 Crankcase Blowby, Measure (014-010)
Using a length of hose, attach a (15 mm [0.600 in] orifice) to the
crankcase breather.
Attach a line from the blowby tool to the manometer (Service
Tool No. 1111-3).
Operate the engine at rated rpm and full load 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 reading to new engine specifications that follow:
NOTE: 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).
Measure the maximum engine blowby.

Maximum: 660 mm H2O [26 in H2O]
If the blowby is higher than normal, check the crankcase

breather and breather tube to see if either is plugged. Refer to
Procedure 003-001.
Crankcase Blowby, Measure (014-010) QSV27 and QSV36
Check the engine oil level. If the level is too high it can cause a
higher than normal crankcase pressure.
A gradual increase in blowby indicates general engine or com-

ponent wear.
Measure the turbocharger axial clearance. Refer to Procedure
010-038. Replace any turbocharger not meeting specification.
Use oil analysis and inspect oil filters for an indication of possi-
ble power cylinder failure. Refer to Procedure 007-051.
A sudden increase in blowby or a high reading that is not

steady indicates that there is internal damage in the engine.
Remove all fuel injectors. Refer to Procedure 006-026.
Fuel Supply Pressure
Fuel Rate
Use a fuel measuring device to measure the rate of fuel con-
sumption.
Fuel Inlet Restriction

Use the pressure gauge ST-434 to measure the fuel restriction
between the fuel filter and the gear pump inlet.
Fuel Drain Line Restriction

Use pressure gauge, Part Number ST-1273, to measure fuel
drain line restriction.
Intake Manifold Pressure
Measure the intake manifold pressure (turbocharger boost).
Minimum: 2.75 barG [40 psi]
Maximum: 3.25 barG [47 psi]
Intake Manifold Temperature

Monitor the intake manifold air temperature using a Fluke digital
thermometer, Part Number 3822666, and thermocouple wire
kit, Part Number 3822988, into the intake manifold.
Maximum: 65°C [149°F]
Intake Air Restriction

Measure the inlet air restriction. Install a manometer, Part Num-
ber ST-1111-3, in the intake air piping.
NOTE: 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.
Exhaust Restriction
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.
Lubricating Oil Pressure
Use pressure gauge, Part Number 3375275, to measure lubri-
cating oil pressure.
Install the pressure gauge to the oil filter head.
Lubricating Oil Pressure

barG psi
Low Idle 2.25 33
(Minimum Allowable)
At 1500 rpm 4.5 66
At 1800 rpm 5.0 73

NOTES
QSV27 and QSV36
Section 16 - Mounting Adaptations - Group 16 Page 16-1
Section 16 - Mounting Adaptations - Group 16

Section Contents
Page
Generator Coupling................................................................................................................................................................ 16-3
Clean .................................................................................................................................................................................. 16-3
Install .................................................................................................................................................................................. 16-4
Remove .............................................................................................................................................................................. 16-3
QSV27 and QSV36
Page 16-2 Section 16 - Mounting Adaptations - Group 16

QSV27 and QSV36 Generator Coupling (016-004)
Generator Coupling (016-004)

General Information
Power from the engine is transferred to the generator by a flexi-
ble drive coupling assembly consisting of a rubber tyre drive
wheel, coupling hub and connection ring.
Remove
Remove the 24 socket head capscrews (1) from the alternator
coupling hub (2). Carefully remove the rubber tyre drive assem-
bly (3) from the coupling hub. Remove the coupling hub key (4)
from the alternator drive shaft.
Clean
WARNING
WARNING
Use solvent to clean the parts.
Use a solvent that will not harm rubber.
Dry the parts with compressed air.
Generator Coupling (016-004) QSV27 and QSV36
Inspect for Reuse
Inspect the hub and tyre for burrs and cracks between bolt
holes and shaft bore.
Install
Fit the coupling hub carrier clamp ring (1) to the coupling hub
(2) to lift the hub into and out of the heating oven.
After the hub drive has been heated to the correct temperature,
the hub bore must be aligned concentrically and in parallel to
the shaft before pushing it onto the alternator shaft.
Gently tap the hub flange at pressure points 180° apart until the
hub is against the shaft collar.
Avoid side-to-side pressure on the hub.
Allow the hub (2) to cool down before removing the coupling
hub carrier ring, then fit the disc tyre (1) onto the coupling hub
flange.
Maintain the correct orientation then install the 24 socket head
capscrews (3).
QSV27 and QSV36 Generator Coupling (016-004)
Tighten the 24 socket head capscrews in the sequence shown:
Install the steel alloy connecting ring (2) in its correct orientation
onto the engine flywheel with 12 socket head capscrews (1).
Tighten the 12 socket head capscrews in the sequence shown:

Generator Coupling (016-004) QSV27 and QSV36
NOTES
QSV27 and QSV36
Section 19 - Electronic Engine Controls - Group 19 Page 19-1
Section 19 - Electronic Engine Controls - Group 19

Section Contents
Page
Fuel Leakage Indicator Switch.............................................................................................................................................. 19-3
Install .................................................................................................................................................................................. 19-4
Remove .............................................................................................................................................................................. 19-3
QSV27 and QSV36
Page 19-2 Section 19 - Electronic Engine Controls - Group 19

QSV27 and QSV36 Fuel Leakage Indicator Switch (019-150)
Fuel Leakage Indicator Switch

(019-150)
Remove
Remove the free end fuel pump cover.
Disconnect the electrical lead from the switch.
Remove the three M12 capscrews (1) and the three M8 cap-
screws (2).
Remove the end cover (3).
Remove the retaining clip (1) and float (2) from the switch post.
Fuel Leakage Indicator Switch (019-150) QSV27 and QSV36
Unscrew and remove the switch from the end cover.
Install
WARNING
WARNING
injury.
Inspect the float chamber for debris.
Clean with solvent and dry with compressed air.
Install the switch into the end cover.
Install the float and retaining clip onto the switch post.
QSV27 and QSV36 Fuel Leakage Indicator Switch (019-150)
Install the end cover (3).
Install and tighten the three M8 capscrews (2).
Install and tighten the three M12 capscrews (1).
Connect the electrical lead (1) to the switch.
Install the engine side cover.

Fuel Leakage Indicator Switch (019-150) QSV27 and QSV36
NOTES
QSV27 and QSV36
Section TS - Troubleshooting Symptoms Page TS-1
Section TS - Troubleshooting Symptoms

Section Contents
Page
Troubleshooting Procedures and Techniques.................................................................................................................... TS-3
Troubleshooting Symptoms Charts..................................................................................................................................... TS-3
Coolant Temperature is Below Normal............................................................................................................................... TS-4
Coolant Temperature Above Normal .................................................................................................................................. TS-5
Engine Difficult to Start or Will Not Start (Exhaust Smoke) ................................................................................................ TS-6
Engine Difficult to Start or Will Not Start (No Exhaust Smoke) .......................................................................................... TS-7
Engine Power Output Low ................................................................................................................................................. TS-8
Engine Starts But Will Not Keep Running ........................................................................................................................ TS-10
Engine Will Not Crank or Cranks Slowly (Air Starter)........................................................................................................TS-11
Engine Will Not Reach Rated Speed (RPM).................................................................................................................... TS-12
Engine Will Not Shut Off................................................................................................................................................... TS-13
Lubricating Oil Pressure Low ........................................................................................................................................... TS-14
Smoke, Black — Excessive.............................................................................................................................................. TS-15
Smoke, White — Excessive ............................................................................................................................................. TS-16
QSV27 and QSV36
Page TS-2 Section TS - Troubleshooting Symptoms

QSV27 and QSV36 Troubleshooting Procedures and Techniques
Troubleshooting Procedures and Techniques

A thorough analysis of the customer's complaint is the key to successful troubleshooting. The more information known about a
complaint, the faster and easier the problem can be solved.
The Troubleshooting Symptom Charts are organized so that a problem can be located and corrected by doing the easiest and
most logical things first. Complete all steps in the sequence shown from top to bottom.
It is not possible to include all the solutions to problems that can occur; however, these charts are designed to stimulate a
thought process that will lead to the cause and correction of the problem.
Follow these basic troubleshooting steps:
• Get all the facts concerning the complaint
• Analyze the problem thoroughly
• Relate the symptoms to the basic engine systems and components
• Consider any recent maintenance or repair action that can relate to the complaint
• Double-check before beginning any disassembly
• Solve the problem by using the symptom charts and doing the easiest things first
• Determine the cause of the problem and make a thorough repair
• After repairs have been made, operate the engine to make sure the cause of the complaint has been corrected
Troubleshooting Symptoms Charts

Use the charts on the following pages of this section to aid in diagnosing specific engine symptoms. Read each row of blocks
from top to bottom. Follow through the chart to identify the corrective action.
WARNING
Troubleshooting presents the risk of equipment damage, personal injury or death. Troubleshooting must be per-
formed by trained experienced technicians.
Troubleshooting Symptoms Charts QSV27 and QSV36
Coolant Temperature is Below Normal
Cause Correction
Check the shutters and engine compartment air. Refer

Engine is operating at low ambient temperature .....
to Cold Weather Operation, Bulletin No. 3387266.
OK
Check or replace the temperature gauge. Refer to the

Temperature gauge malfunction .....
OEM service manual.
OK
Coolant thermostat failure Check or replace thermostat. Refer to section 8.

QSV27 and QSV36 Troubleshooting Symptoms Charts
Coolant Temperature Above Normal
Cause Correction
Inspect the engine for external coolant leaks. Repair if

Coolant level is below specification ......
necessary. Add coolant. Refer to Section V.
OK
Inspect the heat exchanger fins. Clean and repair the

Heat exchanger fins are damaged or obstructed with
. . . . . . fins as necessary. Refer to the manufacturer’s instruc-
debris
tions.
OK
Radiator cap is not correct, is malfunctioning, or has low Check the pressure cap. Refer to the OEM service
......
pressure rating manual.
OK
Hose is collapsed, restricted, or leaking . . . . . . Inspect the hoses. Refer to Section 4.
OK
Check oil level. Add or drain oil if necessary. Refer to

Lubricating oil level is above or below specification ......
Section 3. Check the dipstick calibration.
OK
Check or replace coolant thermostats. Refer to Section

Coolant thermostat failure ......
8.
OK
Contact a Cummins Authorized Repair Facility

Engine Difficult to Start or Will Not Start (Exhaust Smoke)
Cause Correction
If the cranking speed is slower than 150 rpm, refer to

Engine cranking speed is too slow ..... the Engine Will Not Crank or Cranks Slowly symptom
tree.
OK
Engine-driven units are engaged ..... Disengage engine-driven units.
OK
Check the air intake system for restriction. Clean or

Air intake system restriction is above specification ..... replace the air filter and inlet piping as necessary. Refer
to Section 4.
OK
Replace the fuel filter. Refer to Section 6. Check the

Fuel filter, fuel pre-filter, or fuel suction line is restricted .....
fuel suction line for restriction.
OK
Check for air in the fuel system. Tighten or replace the

Air in the fuel system ..... fuel connections, fuel lines, fuel tank stand pipe, and
fuel filters as necessary.
OK
Operate the engine from a tank of high-quality fuel.

Fuel grade is not correct for the application, or the fuel
..... Refer to Fuel Recommendations and Specifications in
quality is poor
Section V.
OK

Engine Difficult to Start or Will Not Start (No Exhaust Smoke)
Cause Correction
Fuel level is low in the tank . . . . . . Fill the supply tank.
OK

Air in the fuel system . . . . . . fuel connections, fuel lines, fuel tank stand pipe, and
OK
Check the shutdown indicator on the control panel. If

the shutdown device is activated, check that the engine
Automatic shutdown device is activated ......
barring device is not engaged. Refer to Normal Starting
Procedure in Section 1.
OK

Fuel filter, fuel pre-filter, or fuel suction line is restricted ......
OK
Fuel connections are loose . . . . . . Tighten all fuel fittings and connections.
OK

Air intake system restriction is above specification . . . . . . replace the air filter and inlet piping as necessary. Refer
to Section 4.
OK
Check the exhaust system for any restrictions. Refer to

Exhaust system restriction ......
Section V for specifications.

Engine Power Output Low
Cause Correction
Reduce the load on the engine. Refer to the OEM spec-

Load is excessive for engine horsepower rating .....
ifications.
OK

OK
Check the oil level. Verify the dipstick calibration and oil
Lubricating oil level is above specification ..... pan capacity. Fill the system to the specified level.
Refer to Section 3.
OK

to Section 4.
OK

Exhaust system restriction .....
OK

OK
Inspect the fuel drain lines for restrictions. Remove any

Fuel drain line is restricted .....
restrictions found.
OK
Remove and clean the tank vents. Replace the vents if

Fuel tank vents are plugged or damaged .....
necessary. Refer to the OEM service manuals.
OK
Operate the engine from a tank of good fuel. Refer to

..... Fuel Recommendations and Specifications in Section
quality is poor
V.
OK
(Continued)
Engine Power Output Low (Continued)
Cause Correction
Measure and adjust the overhead settings. Refer to

Overhead adjustments are not correct ......
Section 7.
OK
Measure the temperature of the ambient air in the

Engine is operating at high ambient temperature ......
engine enclosure. Reroute the air intake, if necessary.
OK
Fill the fuel tanks. Turn off or bypass the fuel heater, if
Fuel temperature is above specification ......
equipped.
OK

Engine Starts But Will Not Keep Running
Cause Correction

OK

ifications.
OK

OK

quality is poor
V.
OK

to Section 4.
OK

Exhaust system restriction .....
OK

Engine Will Not Crank or Cranks Slowly (Air Starter)
Cause Correction
Verify the correct starting procedure. Refer to Section 1

Starting procedure is not correct . . . . . . and OEM service manual to review the engine and
vehicle starting procedures.
OK
Release the engine barring mechanism. Refer to Sec-

Engine barring mechanism is engaged ......
tion 1.
OK
Air pressure is low in the air tanks . . . . . . Increase air pressure with an external air source.
OK
Check crankshaft for ease of rotation. Refer to Over-

Crankshaft rotation is impaired . . . . . . head Set in Section 8 for instructions to rotate the
crankshaft.
OK
Check the starting circuit components. Refer to the

Starting circuit component is malfunctioning ......
OEM service manual.
OK
Check the starting motor operation. Compare the start-

Starting motor is malfunctioning, or starting motor is not
. . . . . . ing motor with the engine and vehicle specifications.
correct
Refer to the manufacturer’s instructions.
OK

Engine Will Not Reach Rated Speed (RPM)
Cause Correction

ifications.
OK
Compare the tachometer reading with a handheld

tachometer or an electronic service tool reading. Cali-
Tachometer is not calibrated or is malfunctioning .....
brate or replace the tachometer as necessary. Refer to
the OEM service manuals.
OK

OK

OK

Engine Will Not Shut Off
Cause Correction
Check the air intake ducts. Locate and isolate the

Engine is running on fumes drawn into the air intake . . . . . . source of the fumes. Repair as necessary. Refer to the
OEM service manuals.
OK
Fuel shutdown linkage broken or out of adjustment . . . . . . Contact a Cummins Authorized Repair Facility.
OK

Lubricating Oil Pressure Low
Cause Correction
Check the oil level. Add or drain oil, if necessary. Refer

Lubricating oil level is above or below specification .....
to Section 3. Check the dipstick calibration.
OK
Check the oil pressure switch, gauge, or sensor for cor-

Lubricating oil pressure switch, gauge, or sensor is mal-
..... rect operation and location. Refer to the OEM service
functioning or is not in the correct location
manual.
OK
Lubricating oil filter three way valve is in the wrong posi- Turn the valve so that all four lubricating oil filters are
.....
tion. operating. Refer to Section 6.
OK
Lubricating oil does not meet specifications for operating Change the oil and filters. Refer to Section 6. Use the
.....
conditions oil recommended in Section V.
OK
Lubricating oil temperature is above normal (120°C

..... Refer to the Coolant Temperature Above Normal chart.
[250°F])
OK
Change the oil. Refer to Section 6. If the oil becomes

Lubricating oil is diluted with fuel ..... diluted again, contact an Authorized Cummins Repair
Facility.
OK

Smoke, Black — Excessive
Cause Correction

Load is excessive for engine horsepower rating ......
ifications.
OK

Air intake system restriction is above specification . . . . . . replace the air filter and inlet piping as necessary. Refer
to Section 6.
OK
Check for loose or damaged piping connections and

Air intake or exhaust leaks . . . . . . missing pipe plugs. Check the turbocharger and
exhaust manifold mounting. Refer to Section 8.
OK
Inspect the fuel drain lines for restrictions. Remove any

Fuel drain line is restricted ......
restrictions found.
OK

Overhead adjustments are not correct ......
Section 7.
OK

Smoke, White — Excessive
Cause Correction
Refer to the Coolant Temperature Below Normal symp-

Coolant temperature is below specification .....
tom tree.
OK

quality is poor
V.
OK

Overhead adjustments are not correct .....
Section 7.
OK

QSV27 and QSV36
Section L - Service Literature Page L-1
Section L - Service Literature

Section Contents
Page
Additional Service Literature .................................................................................................................................................. L-3
QSV27 and QSV36
Page L-2 Section L - Service Literature

QSV27 and QSV36 Additional Service Literature
Section L - Service Literature Page L-3
Additional Service Literature
Region Ordering Location

United States and Canada Cummins Distributors
or
Contact 1-800-DIESELS
(1-800-343-7357)
U.K., Europe, Mid-East, Africa, Cummins Engine Co., Ltd.
and Eastern European Countries Royal Oak Way South
Daventry
Northants, NN11 5NU, England
South and Central America Cummins Americas, Inc.
(excluding Brazil land Mexico) 16085 N.W. 52nd Avenue
Hialeah, FL 33104
Brazil and Mexico Cummins Engine Co., Inc.
International Parts Order Dept., MC 40931
Box 3005
Columbus, IN 47202-3005
Far East (excluding Australia and New Zealand) Cummins Diesel Sales Corp.
Literature Center
8 Tanjong Penjuru
Jurong Industrial Estate
Singapore
Australia and New Zealand Cummins Diesel Australia
Maroondah Highway, P.O.B. 139
Ringwood 3134
Victoria, Australia
Obtain current price information from your local Cummins Distributor.
Bulletin Title of Publication

4021309 QSV27 and QSV36 O&M Manual
Additional Service Literature QSV27 and QSV36
Page L-4 Section L - Service Literature
NOTES
QSV27 and QSV36
Section V - Maintenance Specifications Page V-1
Section V - Maintenance Specifications

Section Contents
Page
Application of Sealants and Lubricants ............................................................................................................................... V-3
Helerine o-ring lubricant ...................................................................................................................................................... V-5
Loctite 243 - Blue - Stud/Screw locking............................................................................................................................... V-4
Loctite 515 - Purple - Normal temperature standard sealant .............................................................................................. V-3
Loctite 5699 Ultra Grey - Grey - RTV Silicone - high temperature, large gap fill sealant .................................................... V-3
Loctite 577 - Yellow - Medium strength thread sealant ....................................................................................................... V-4
Loctite 641 - Yellow - Sealant.............................................................................................................................................. V-4
Loctite 620 - Green - High temperature high strength sealant ............................................................................................ V-4
Mobilplex 47 - brown multipurpose grease.......................................................................................................................... V-5
Molykote 111 - clear - Silicone based lubricant ................................................................................................................... V-5
Oraseal - Zero clearance sealant ........................................................................................................................................ V-5
Rocol J166 - Copper - Copper based high temperature antiseize compound .................................................................... V-5
Capscrew Markings and Torque Values ............................................................................................................................. V-19
Capscrew Markings and Torque Values - Metric ............................................................................................................... V-20
Capscrew Markings and Torque Values - U.S. Customary ............................................................................................... V-27
Coolant Recommendations and Specifications ................................................................................................................ V-13
Coolant Replacement Requirements ................................................................................................................................ V-17
Supplemental Coolant Additive (SCA) .............................................................................................................................. V-14
Test Intervals ..................................................................................................................................................................... V-16
Testing SCA Concentration Level CC-2602 Test Kit ......................................................................................................... V-15
Engine Component Torque Values ..................................................................................................................................... V-18
Torque Table...................................................................................................................................................................... V-18
Fuel Recommendations and Specifications ....................................................................................................................... V-11
Lubricating Oil Recommendations and Specifications .................................................................................................... V-12
QSV27/36 Torque Tightening of Threaded Fasteners ....................................................................................................... V-21
Specifications ......................................................................................................................................................................... V-7
Air Intake System .............................................................................................................................................................. V-10
Compressed Air System.................................................................................................................................................... V-10
Cooling System ................................................................................................................................................................... V-9
Exhaust System ................................................................................................................................................................ V-10
Fuel System ........................................................................................................................................................................ V-9
General Specifications ........................................................................................................................................................ V-7
Cylinder Numbering Sequence .................................................................................................................................. V-8
Intake and Exhaust Valve Locations .......................................................................................................................... V-8
Lubricating Oil System ........................................................................................................................................................ V-9
QSV27 and QSV36
Page V-2 Section V - Maintenance Specifications

QSV27 and QSV36 Application of Sealants and Lubricants
Application of Sealants and Lubricants

Loctite 515 - Purple - Normal temperature standard sealant
Application:
Oil pan to cylinder block
Free end housing to cylinder block
Flywheel housing to cylinder block
V engine air cooler to air cooler support
V engine air cooler support to cylinder block
Gas engine multihousing to cylinder block
Diesel engine fuel injection pump to cylinder block
Other general purpose applications where alternative sealants are not specified.
Surface preparation:
Surfaces should be cleaned with solvent before application of sealant. Preferred solvent is Loctite 7063. Solvent must be fully
dried before application of sealant.
Cure time:
For 515 minimum 3 hours at 22°C
For 518 minimum 1 hour at 22°C
Time from start of application of sealant to completion of tightening must be within 15 minutes.
Loctite 5699 Ultra Grey - Grey - RTV Silicone - high temperature, large gap fill sealant
Applications:
V engine intercooler side water covers and air inlet cover.
V engine joints on charge air pipework before charge air cooler where required.
L engine intercooler top and bottom water covers, and air pipework where required.
Cylinder head stud shanks after fitting to cylinder block apply sealant below o-ring.
Surfaces, except head studs, should be cleaned with solvent before application of sealant.
Preferred solvent is Loctite 7063. Solvent must be fully dried before application of sealant.
Cure time:
Minimum 4 hours at 22°C.
Note:
Time from application to joint faces and completion of tightening must be less than 15 minutes.
Before each use hardened sealant must be removed from the applicator tip.
Application of Sealants and Lubricants QSV27 and QSV36
Loctite 641 - Yellow - Sealant

Application:
All cup plugs
Surfaces should be commercially clean before application.
Cure time:
Minimum 3 hours at 22°C or 30 minutes at 40°C.
Cure time for high pressure water test:

Loctite 620 - Green - High temperature high strength sealant

Application:
Cooled valve seats
Injector cups
Spark plug cups
For cooled valve seats, injector cups and spark plug cups, surfaces must be cleaned with solvent before application of sealant.
Preferred solvent type is Loctite 7063. Solvent must be fully dried before application of sealant.
Cure time for low pressure air test:

Minimum 3 hours at 22°C or 15 minutes at 55°C.
Cure time for high pressure water test:

Loctite 243 - Blue - Stud/Screw locking

Application:
Internal and external engine fasteners where specified and all studs, see Torque Tightening of Fasteners standard 3424716.
Parts should be commercially clean before application.
Loctite 577 - Yellow - Medium strength thread sealant

Application:
General purpose thread sealant.
Gas engine speed pickup transducer on B side camshaft.
QSV27 and QSV36 Application of Sealants and Lubricants
Parts should be commercially clean before application.
Cure time:
Minimum 1 hour at 22°C or 30 minutes at 40°C.
Oraseal - Zero clearance sealant

Application:
Cylinder liner to cylinder block. This may be substituted with Wellseal. These are zero clearance non setting sealing com-
pounds.
Parts should be commercially cleaned before application.
Cure time:
Minimum 3 hours at 22°C or 1 hour at 40°C.
Molykote 111 - clear - Silicone based lubricant

Application:
High temperature lubricant with good electrical resistance.
V engine charge air system o-rings before charge air cooler.
Gas engine spark plug rubber boot to spark plug.
All engines lube oil filter pre load plate o-ring mounted in filter head cover.
Water cooled exhaust valve seat o-ring lubrication.
Note:
Molycote 111 must not be used in conjunction with silicone seals.
Helerine o-ring lubricant

Application:
All o-ring and rubber seals where a sliding fit is required, excluding high temperature or electrical connections or seals covered
by Molycote 111 above.
Rocol J166 - Copper - Copper based high temperature antiseize compound

Application:
Exhaust manifold connections and Vee band clamp surfaces.
See also Document 3424716 Torque tightening of threaded fasteners.
Mobilplex 47 - brown multipurpose grease

Application:
General purpose lubrication of bearings during assembly.
Valve collet adherence to valve stem.
Application of Sealants and Lubricants QSV27 and QSV36
Valve stem lubrication in valve guide.

Lubriplate 505 can be used as a substitute.
Lubriplate DS-ES lithium soap mineral oil grease service part number 3822934
All electrical harness connectors where no lubricant is pre-applied. See CES20061.
Do not use this product if dielectric grease is specified.
Use dielectric grease on connector. Do not use lubriplate on electrical connections.
Specifications
General Specifications
Aspiration:.................................................................................................................... Single stage turbocharged and aftercooled
Bore and Stroke:.................................................................................................................... 170 mm x 200 mm [6.69 in x 7.87 in]
Compression Ratio: ............................................................................................................................................. 15.5:1 and 16.5:1
Displacement:
QSV27: .....................................................................................................................................................27 liters [1662 cu in]
QSV36: .....................................................................................................................................................36 liters [2216 cu in]
Firing Order:
QSV27: ................................................................................................................................................................... 1-4-2-6-3-5
QSV36: .............................................................................................................................................................1-2-4-6-8-7-5-3
Type:
QSV27: ............................................................................................................................................................. 4 cycle, L6 cyl.
QSV36: ............................................................................................................................................................. 4 cycle, L8 cyl.
Weight:................................................................................................................................ Refer to Engine Weight in this section.
Crankshaft Rotation: ................................................................. Counterclockwise (viewed from the flywheel end of the engine)
Idling speed: .......................................................................................................................................................................750 rpm
Rated Speeds:
Generator: .................................................................................................................................................... 1500 & 1800 rpm
Marine Propulsion: ....................................................................................................................................... 1600 & 1650 rpm
Intake and Exhaust Valve Settings:
Intake Valve Adjustment ............................................................................................................................. 0.40 mm [0.016 in]
Exhaust Valve Adjustment.......................................................................................................................... 0.80 mm [0.032 in]
Crankshaft Web Deflection:
Solid Mount: ............................................................................................................................................. 0.04 mm [0.0016 in]
Flexible Mount: ......................................................................................................................................... 0.06 mm [0.0024 in]
Cylinder Numbering Sequence

NOTE: QSV27 shown, QSV36 similar
Intake and Exhaust Valve Locations

NOTE: QSV27 shown, QSV36 similar
Fuel System
NOTE: For performance and fuel rate values, refer to the engine data sheet, or the fuel pump code for the particular model
involved.
Fuel Pre-filter Restriction (Maximum) .................................................................................................................. 0.2 barG [2.9 psi]
Allowable Fuel Filter Restriction to Pumps (Maximum):
• With Clean Filter........................................................................................................................................ 0.3 barG [4.4 psi]
• With Dirty Filter........................................................................................................................................ 1.5 barG [21.0 psi]
Allowable Return Line Restriction (Maximum)...................................................................................................... 1 barG [14.7 psi]
Pressure before High Pressure Pumps (Minimum) ................................................................................................. 4 barG [58 psi]
Allowable Fuel Inlet Temperature (Maximum) ............................................................................................................ 50°C [122°F]
Oil Pressure, Main Oil Rifle:
• Idle rpm .....................................................................................................................................2.25 barG [33 psi] Minimum
• 1500 Rated rpm ......................................................................................................................................... 4.5 barG [66 psi]
• 1800 Rated rpm ............................................................................................................................................ 5 barG [73 psi]
Allowable Oil Filter Restriction at rated speed (Maximum)

• Clean filter ................................................................................................................................................. 0.3 barG [4.4 psi]
• Dirty filter ................................................................................................................................................. 1.5 barG [21.8 psi]
Oil Temperature - after oil cooler (Nominal)......................................................................................... 83° to 84°C [181° to 183°F]
Oil Temperature sump (Nominal)......................................................................................................... 90° to 94°C [194° to 201°F]
Oil Temperature modulating range ..................................................................................................... 80° to 92°C [176° to 198°F]
Oil Sump Capacity - QSV27 (high/low)....................................................................................205 liter/160 liter [54 to 42 U.S. gal]
Oil Sump Capacity - QSV36 (high/low)....................................................................................220 liter/170 liter [58 to 45 U.S. gal]
Oil System Capacity - QSV27........................................................................................................................ 230 liter [61 U.S. gal]
Oil System Capacity - QSV36........................................................................................................................ 270 liter [71 U.S. gal]
Cooling System
Coolant Capacity (Engine ONLY) QSV27.....................................................................................................152 liters [40 U.S. gal]
Coolant Capacity (Engine ONLY) QSV36.....................................................................................................182 liters [48 U.S. gal]
High Temperature (HT) Thermostat Modulating Range (Single Cooler):........................................... 88° to 100°C [190° to 212°F]
Low Temperature (LT) Thermostat Modulating Range
Gen Set ........................................................................................................................................ 52° to 64°C [126° to 147°F]
Propulsion .................................................................................................................................... 59° to 71°C [138° to 160°F]
HT Coolant System Pressure

Idle.............................................................................................................................................................. 1.2 barG [17.4 psi]
Rated ............................................................................................................................................................. 3.8 barG [55 psi]
LT Coolant System Pressure
Idle...............................................................................................................................................................0.8 barG [11.6 psi]
Rated ............................................................................................................................................................. 2.8 barG [41 psi]
Coolant temperatures at HT outlet (Maximum):........................................................................................................ 100°C [212°F]

Coolant temperatures at HT outlet (Nominal): ..................................................................................... 92° to 95°C [190° to 203°F]
Air Intake System

NOTE: Engine intake air must be filtered to prevent dirt and debris from entering the engine. If intake air piping is damaged or
loose, unfiltered air will enter the engine and cause premature wear.
Allowable Intake Restriction (Maximum):
• With Clean Filter Element..............................................................................................................300 mm H2O [12 in H2O]
• With Dirty Filter Element................................................................................................................635 mm H2O [25 in H2O]
Intake Manifold Pressure (Nominal)............................................................................................... 2.75 to 3.25 barG [40 to 47 psi]
Charge Temperature Before Cylinders (Maximum)..................................................................................................... 65°C [149°F]
Exhaust System
Back Pressure - (Maximum)..................................................................................................................500 mm H2O [19.5 in H2O]
Exhaust Gas Temperature after cylinder, 1500 rpm Rated (Maximum) .................................................................. 625°C [1157°F]
Exhaust Gas Temperature after cylinder, 1800 rpm Rated (Maximum) .................................................................. 675°C [1247°F]
Exhaust Temperature after turbocharger (Maximum) ............................................................................................. 550°C [1022°F]
Compressed Air System
Receiver Pressure (Nominal) ........................................................................................................... 30 to 40 barG [435 to 580 psi]
Starter Inlet Pressure:
• QSV27 ...................................................................................................................................................... 8.5 barG [125 psi]
• QSV36 ...................................................................................................................................................... 8.5 barG [125 psi]
Minimum Cranking Speed.................................................................................................................................................. 150 rpm
QSV27 and QSV36 Fuel Recommendations and Specifications
Fuel Recommendations and Specifications

The QSV series engines are tailored to provide optimum performance when using a specific ISO (International Organization for
Standardization) classification of fuel. Three ISO fuel class options DMX, DMA, and DMB are available for the QSV Series
Engines. The customer or equipment manufacturer selects one of the three fuel classes during the engine ordering process.
Cummins Inc., recommends the use of fuel having the following characteristics. Cummins does not recommend using a classifi-
cation of fuel other than the fuel type specified for the engine. Refer to the engine datatag, or contact your local Cummins
Authorized Service Provider to determine which fuel class option has been specified for the engine.
Designation Designation Designation

Characteristic Test Method Limit
ISO-F DMX ISO-F DMA ISO-F DMB
Density at 15°C (kg/
ISO 3675 Maximum - 890.0 900.0
m3)
Kinematic Viscosity
ISO 3104 Minimum 1.40 1.50 -
at 40°C(cSt)
Maximum 5.50 6.00 11.0
Flash Point (°C) ISO 2719 Minimum 43 60 60
Pour Point (upper)
ISO 3016 Maximum - -6 0
(°C) Winter quality
Summer quality ISO 3016 Maximum - 0 6
Cloud Point (°C) ISO 3015 Maximum -16 - -
Carbon Residue
Ramsbottom %
ISO 4262 Maximum 0.20 0.20 -
(m/m) on 10% resi-
due
Carbon Residue
Ramsbottom % ISO 4262 Maximum - - 0.25
(m/m) residue
Ash % (m/m) ISO 4262 Maximum 0.01 0.01 0.01
Sediment by extrac-
ISO 3735 Maximum - - 0.07
tion % (m/m)
Water % (m/m) ISO 3733 Maximum - - 0.30
Cetane Number ISO 5165 Minimum 45 40 35
Sulphur % (m/m) ISO 8754 Maximum 1.0 1.5 2.0
NOTE: ASTM No. 2 Diesel and British Standard 2869 Class A1 and A2 are fuels which meet the ISO-F DMX specifications.
NOTE: The recommended lubricating oil is dependent on the classification of fuel used in the engine. Refer to Lubricating Oil
Recommendations/Specifications in this section.
Fuel Inlet Temperature (maximum) 50°C [122°F]
Lubricating Oil Recommendations and Specifications QSV27 and QSV36
Lubricating Oil Recommendations and Specifications

Cummins Inc., recommends the use of a high quality SAE 40W heavy duty diesel engine oil which meets or exceeds the Amer-
ican Petroleum Institute (API) performance classification CE or CF for engines used in continuous and prime power generation
applications with load factor greater than or equal to 80 percent. High quality SAE 15W40 heavy duty diesel engine oil which
meets or exceeds API performance classification CF4 is recommended for engines used in standby or light load factor (less
than 80 percent) power generation applications.
For proper engine performance and durability, the lubricating oil must be compatible with the fuel used by the engine. The Total
Base Number (TBN) of the lubricating oil must be chosen to match the current sulfur content of the fuel.
Use the following formula for determining the required lubricating oil TBN:
Required TBN = 15 X % sulfur in fuel
Example: Fuel sulfur content= 1.5% Required TBN = 15 X (1.5) = 23
Minimum required TBN (regardless of fuel sulfur content) = 15
NOTE: If API performance classification CE, CF or CF4 oils do not offer the required TBN, oils meeting API performance classi-
fication CD may be used but the recommended oil drain interval should be reduced by one half.
Lubricating oils protect the engine as long as the oil's additive package is functioning properly. The required oil and filter change
interval is determined by the rate of depletion of these essential oil additives due to contamination. Progressive contamination of
the oil between oil and filter change intervals is normal. The amount of contamination will vary depending on the engines' duty
cycle, oil consumption, fuel type, fuel quality, oil capacity, and oil quantity.
Oil Analysis
Cummins Inc., recommends using an oil analysis program administered by a reputable laboratory to assist in determining the
appropriate oil and filter change interval for a specific engine and application. During the first years operation, Cummins recom-
mends the oil be sampled and analyzed every 250 operating hours. Beyond the first year of operation, the sampling interval
may increase to every 500 operating hours.
At a minimum, the lubricating oil sample analysis should test the following parameters:
• Total Acid Number (TAN) (ASTM D664)
• Total Base Number (TBN) (ASTM D664)
• Soot (ASTM D4055)
• Sulfur
• Viscosity at 100°C (ASTM D445)
• Wear metals content
Use the following guidelines for collecting the oil samples:
• Take the sample from the engine immediately after shutdown and while the engine is at operating temperature.
• Make certain the sampling containers are clean and free of contaminants.
• Remove a crankcase access cover and draw the sample from the middle level of the oil contained in the sump. Do not
draw the sample from the bottom or top of the oil.
• Draw at least the minimum volume of oil required by the sampling laboratory.
NOTE: Do not disassemble an engine for repair based only on the results of an oil analysis. Contact a Cummins Authorized
Repair Facility to have the oil filters inspected for evidence of internal engine damage.
QSV27 and QSV36 Coolant Recommendations and Specifications
Coolant Recommendations and Specifications

Cummins Inc., recommends the use of a 60/40 ratio mixture composed of 60 percent high quality de-ionized water and 40 per-
cent low silicate antifreeze concentrate that meets ASTM D4985 specifications (less than 0.10 percent silicate expressed as
Na2SIO3).
In addition, Cummins recommends the use of supplemental coolant additives (SCA) at a concentration of 1.5 units per 3.8 liters
[1.0 U.S. gallons] of coolant. Supplemental coolant additives are used to prevent cylinder liner pitting, corrosion, solder bloom-
ing, and scale deposits in the cooling system.
Water Quality:
Hardness (as CaCO3 + MgCo3) ........................................................................................................................................ 170 ppm
Chloride (as CI) ................................................................................................................................................................... 40 ppm
Sulfur (as SO4) .................................................................................................................................................................. 100 ppm
Premixed, ready-to-use, fully formulated heavy duty engine coolant containing a pre-charge of SCA's (such as Fleetgaurd®
Compleat) simplifies cooling system maintenance. The use of high quality, 60/40 ratio, fully formulated heavy duty coolant is an
approved alternative.
NOTE: Do not use sealing additives or soluble oils in the cooling system. Damage to the engine and cooling system compo-
nents will occur.
Coolant Recommendations and Specifications QSV27 and QSV36
Supplemental Coolant Additive (SCA)

Fully formulated products contain SCA's and are required to
protect the cooling system from fouling, solder blooming, and
general corrosion.
CAUTION
Insufficient concentration of the coolant additives will
result in cylinder liner pitting, corrosion, solder blooming,
and scale deposits which could lead to engine failure.
The SCA concentration must not fall below 1.2 units or exceed
3 units per gallon of cooling system capacity.
Testing SCA Concentration Level CC-2602 Test Kit

Carefully follow the instructions to test the coolant and take the appropriate action recommended by the kit.
• The coolant sample to be tested must be between 10° and 54°C [50° and 130°F]. If the sample is too cold or too hot, you
will get incorrect results.
• To get the best color match results, compare test strip pads to the color chart in daylight or under cool white fluorescent
lighting. If unsure about a specific color match when a test does fall between two colors on the color chart, choose the
lower numbered block. It is safer to underestimate your results than to overestimate.
• The test strips do have a limited shelf life and are sensitive to humidity and extreme heat. Proper handling and storage is
necessary to protect the life of the strips.
• Keep the cap tightly sealed on the test strip bottle except when removing a strip. Store away from direct sunlight and in an
area where the temperature will generally stay below 32°C [90°F].
• Do not use the test strips after the expiration date stamped on the bottle.
• Discard the kit if any of the pads on the unused strips have turned light brown or pink.
• Use one strip at a time and take care not to touch any of the pads on the strip. Doing so will contaminate the pads and
affect the test results.
• If the strip container is left uncapped for 24 hours, moisture in the air will render the strips useless, although no discolora-
tion will be evident.
• Only use the color chart supplied with the kit.
• Clean and dry the sample cup and syringe after each use. This will prevent contaminating future samples.
• Following the correct test times is very important. Use a clock or stopwatch.
Coolant Recommendations and Specifications QSV27 and QSV36
Test Intervals
Testing is recommended if the operator is not sure of his cool-
ing system condition due to leaks, uncontrolled topping off of
the system, or major coolant loss.
Testing is also recommended twice a year to monitor the SCA
level. If the SCA level is above 3 units, test at subsequent oil
drain intervals until the concentration is back under 3 units.
NOTE: Do not utilize the test kit to maintain minimum SCA con-
centration levels (i.e., 1.2 units).
NOTE: In some instances the A or B reading can be high. How-
ever, it is the combined reading that is important. Therefore,
always follow the chart.
CC2602 Coolant Test Kit – Works with any SCA formulation (Call 1-800-521-4005 if you have this test kit and
the color chart does not show the number of units of SCA per gallon of coolant.)
Probablizer:
3318169S Plug – Installs on the engine for easy coolant sampling
3318168S Cap – Use with Monitor C bottle to sample coolant
CC2700 Monitor C – Lab analysis of coolant samples
To get answers to any questions you may have about cooling system maintenance, contact your Local Cummins
Authorized Repair Location.
Coolant Replacement Requirements

Drain and flush the cooling system after 6,000 hours, or 2 years
of service. Refill with either new fully formulated coolant or a
60/40 mixture of good quality water and fully formulated anti-
freeze.
NOTE: If the coolant is not going to be reused, dispose of used
coolant/antifreeze in accordance with federal, state, and local
laws and regulations.
Engine Component Torque Values QSV27 and QSV36
Engine Component Torque Values

Torque Table
Engine Component Torque Values
Component Torque Value

N•m [ft-lb]
Oil Drain Plug 135 100
Oil filter housing drain plug 100 75
Oil filter housing cover plug 100 75
Crosshead Adjusting Screw Locknut 40 30
Valve Adjusting Screw Locknut 60 45
Centrifugal filter rotor top nut 10 8
Centrifugal filter cover top nut 20 15
Fuel filter housing cover nuts 100 75
Mounting feet to block capscrews 350 260
QSV27 and QSV36 Capscrew Markings and Torque Values
Capscrew Markings and Torque Values

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 QSV27 and QSV36
Capscrew Markings and Torque Values - Metric
Commercial Steel Class

8.8 10.9 12.9
Capscrew Head Markings
Body
Size Torque Torque Torque
Diam. Cast Iron Aluminium Cast Iron Aluminium Cast Iron Aluminium
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 12 9 7 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
8 25 18 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 60 45 30 25 70 50 30 25
12 80 60 55 40 105 75 55 40 125 95 55 40
14 125 90 90 65 165 122 90 65 195 145 90 65
16 180 130 140 100 240 175 140 100 290 210 140 100
18 230 170 180 135 320 240 180 135 400 290 180 135
QSV27 and QSV36 QSV27/36 Torque Tightening of Threaded Fasteners
QSV27/36 Torque Tightening of Threaded Fasteners

Refer to table 5 for exceptions and critical fasteners
Unless otherwise stated it is assumed that:
All external fasteners will be lubricated with clean engine oil (SAE30/40) on threads and under fastener heads.
All external exhaust system fasteners including turbocharger turbine casing fasteners will be lubricated with
Rocol J166.
All internal fasteners will be installed with Loctite 243 on threads and clean engine oil under heads.
Table 1
Standard torque values for 8.8 grade fasteners in steel or cast iron
Thread Stud install torque Nut on stud torque Screw torque Nut on bolt torque
size N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb
M5 2 20 in-lb 5 44 in-lb 5 44 in-lb 5 44 in-lb
M8 8 70 in-lb 22 16 22 16 22 16
M10 11 95 in-lb 44 32 44 32 44 32
M12 22 16 76 56 76 56 76 56
M14 44 32 121 90 121 90 121 90
M16 64 47 189 140 189 140 189 140
M18 76 56 261 190 261 190 261 190
M20 121 90 370 270 370 270 370 270
M24 189 140 637 470 637 470 637 470
Table 2
M8 8 70 in-lb 32 25 32 25 32 25
M10 11 95 in-lb 64 50 64 50 64 50
M12 22 16 111 82 111 82 111 82
M14 44 32 178 130 178 130 178 130
M16 64 47 278 205 278 205 278 205
M18 76 56 384 285 384 285 384 285
M20 121 90 544 400 544 400 544 400
M24 189 140 936 690 936 690 936 690
QSV27/36 Torque Tightening of Threaded Fasteners QSV27 and QSV36
Table 3
M6 3 25 in-lb 16 12 16 12 16 12
M8 8 70 in-lb 38 28 38 28 38 28
M10 11 95 in-lb 75 56 75 56 75 56
M12 22 16 130 95 130 95 130 95
M14 44 32 209 155 209 155 209 155
M16 64 47 325 240 325 240 325 240
M18 76 56 449 330 449 330 449 330
M20 121 90 637 470 637 470 637 470
M24 189 140 1095 810 1095 810 1095 810
Table 4
Standard torque values for 8.8, 10.9 and 12.9 grade fasteners in aluminum or brass
Thread Stud install Nut on stud Screw torque Nut on bolt Nut on bolt Nut on bolt
size torque torque torque 8.8 torque 10.9 torque 12.9
grade grade grade
N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb
M5 1 9 in-lb 4 35 in-lb 4 35 in-lb 5 44 in-lb 8 70 in-lb 9 80 in-lb
M6 2 20 in-lb 7 60 in-lb 7 60 in-lb 9 80 in-lb 13 115 in-lb 16 12
M8 4 35 in-lb 18 13 18 13 22 16 32 25 38 28
M10 8 70 in-lb 35 25 35 25 44 32 64 50 75 56
M12 13 10 61 45 61 45 76 56 111 82 130 95
M14 22 16 97 70 97 70 121 90 178 130 209 155
M16 44 32 151 110 151 110 189 140 278 205 325 240
M18 61 45 209 155 209 155 261 190 384 285 449 330
M20 64 47 296 220 296 220 370 270 544 400 637 470
M24 121 90 510 375 510 375 637 470 936 690 1095 810
For steel and cast iron parent material

Torque values for screws and nuts are based on 75% yield stress of the screw stud or bolt.
Ref NF E 25-030 Aug 94 Precision class B.
Stud installation torques are based on 25 to 35% torque value of an 8.8 grade fastener.
For aluminum and brass parent material

Torque values for screws and nuts on studs are based on 60% yield stress of an 8.8 grade fastener.
Torque values for nuts and bolts are based on 75% yield stress for the respective grade fastener.
Ref NF E 25-030 Aug 94 Precision class B.
Stud installation torques are based on 15 to 25% torque value of an 8.8 grade fastener.
Table 5a
Exceptions to the Standard Torque Values
Cylinder Block, Crankshaft, Connecting Rods and Flywheels
Module Fastener Part Number Application Torque Value Torque Value Lubricant -
Detail N•m ft-lb Loctite
Cylinder block M12 screw 3420865 Piston cooling 44 32 Loctite 243
oil jet to cylin-
der block
Cylinder block M30 studs 3420611 Main bearing 100 75 Rocol J166
stud
Cylinder block M30 studs 3420612 Cylinder head 100 75 Rocol J166
stud
Main bearing
cap
Crankshaft bal- M20 screw 3420550 Balance weight 400 +/- 40 then 295 +/- 30 then SAE 30/40 on
ance weight to crankshaft check tight at check tight at threads and
400 +/- 40 295 +/- 30 under screw
head
Connecting rod
Flywheel M16 screw 3421324 “Ringfinder”
assy taper cou-
pling
Flywheel M20 screw 3425265 “Clarke Suwe”
assy taper cou-
pling
Flywheel M20 screw 3421132 Flywheel to 540 in 2 398 in 2 Loctite 243 on
taper coupling stages. First stages. First threads and
76, second 76, second SAE 30/40
540, then 398, then under screw
check tight to check tight to head.
540. 395.
Table 5b
Cylinder Heads and Exhaust System
Cylinder head M10 nut 3420629 Crosshead 40 30 SAE 30-/40
adjusting screw
Cylinder head M12 nut 3420625 Valve lever 60 45 SAE 30-/40
adjusting screw
Cylinder head M14 screw 3428119 Valve lever Two stage, Two stage, SAE 30-/40 on
12.9 grade support to cyl- tighten to 50, tighten to 37, threads and
inder head then 90 deg then 90 deg under screw
+/- 5 +/- 5 head
Cylinder head M12 screw 3425204 Valve lever 120 89 SAE 30-/40 on
12.9 grade support to cyl- threads and
inder head under screw
head
Cylinder head M10 screw Cylinder head 22 16 none
cover screw
Exhaust M10 screw 3421094 Exhaust collec- 130 95 SAE 30-/40
system 12.9 grade tor supports to
cylinder block
Exhaust M12 nut on 3421908 Exhaust collec- 111 82 Rocol J166
system 10.9 stud 3421907 tor support to
exhaust mani-
fold
Exhaust M10 screw 3421898 Exhaust sys- 50 35 Rocol J166
system 10.9 tem general
Exhaust M12 nut on 3421908 Exhaust sys- 111 82 Rocol J166
system 10.9 stud 3241907 tem outlet
housing sup-
port to exhaust
collector
Exhaust M10 nut on 3421906 Multiduct to cyl- 64 47 Rocol J166
system 10.9 stud 3421905 inder block
Multiduct M12 screw 3422903 Multiduct to 30 22 SAE 30-/40
block mounting
Multiduct M10 screw Multiduct to cyl- 64 47 Rocol J166
10.9 grade inder head
Table 5c
Multiducts and Camshafts
Multiduct M12 screw Multiduct to cyl- Two stages, Two stages, SAE 30-/40
12.9 grade inder block first to 44, then first to 32, then
to 130 to 96
Camshafts M12 studs 3420624 Installation into 9 80 in-lb Loctite 270
3426011 camshafts,
4010806 camshaft end
pieces and
camshaft
extensions
Camshafts M12 nut 12.0 3422900 Nut on stud Two stages, Two stages, SAE 30-/40
grade 18AF first to 22, then first to 16, then
to 110* to 81*
Camshafts M20 x 1.5 3420528 Cam drive Two stages, Two stages, SAE 30-/40 on
screw 3425256 intermediate first to 76, then first to 56, then threads and
3425724 gear to 650 to 480 under screw
head
* Complete the assembly within 15 minutes of stud fitting, before Loctite is fully cured.
Table 5d
Free End Drives
Lube oil pump M6 screw with 3423283 Lube oil pump SAE 30-/40 on
drive Ringfinder assy drive gear threads and
Ringfinder under screw
head and on
Ringfinder assy
Water pump M8 screw with 3421117 Water pump SAE 30-/40 on
drive Ringfinder assy drive gear threads and
Ringfinder under screw
head and on
Ringfinder assy
Damper M18 *8.8 nut Flange, crank- Two stages, Two stages, Loctite 243 on
and bolt shaft to crank- first 76, then to first 56, then to threads, SAE
shaft 261 192 30-/40 under
bolt head
Damper M16 *10.9 Damper to Two stages, Two stages, Loctite 243 on
screw crankshaft first 76, then to first 56, then to threads, SAE
544 400 30-/40 under
bolt head
Gear mounting M16 *10.9 Gear, crank- Two stages, Two stages, Loctite 243 on
screw shaft free end first 76, then to first 56, then to threads, SAE
to flange, 278 205 30-/40 under
crankshaft bolt head
Table 5e
Miscellaneous
Lifting bracket nut to cylinder head stud 500 369 Dry
Oil sump M8 x 20 SHC DIN 912 Oil strainer 22 16 Loctite 243
8.8 grade assembly
Check valve Pin, guide Assembly 16 12 Loctite 270
shaft 3425521 3422328
Capscrew Markings and Torque Values - U.S.

Customary
As shown in the illustration, SAE Grade 5 capscrews (1) are
identified with three lines radiating from the center of the cap-
screw head. SAE Grade 8 capscrews (2) are identified with six
lines radiating from the capscrew head.
SAE Grade Number 5 8
Capscrew Torque - Grade 5 Capscrew Capscrew Torque - Grade 8 Capscrew
Capscrew Body Size Cast Iron Aluminium Cast Iron Aluminium

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
- 28 12 9 9 7 18 13 9 7
5/16 - 18 20 15 16 12 30 22 16 12
- 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
- 24 40 30 35 25 60 45 35 25
7/16 - 14 60 45 45 35 90 65 45 35
- 20 65 50 55 40 95 70 55 40
1/2 - 13 95 70 75 55 130 95 75 55
- 20 100 75 80 60 150 110 80 60
9/16 - 12 135 100 110 80 190 140 110 80
- 18 150 110 115 85 210 155 115 85
5/8 - 11 180 135 150 110 255 190 150 110
- 18 210 155 160 120 290 215 160 120
3/4 - 10 325 240 255 190 460 340 255 190
- 16 365 270 285 210 515 380 285 210
7/8 - 9 490 360 380 280 745 550 380 280
- 14 530 390 420 310 825 610 420 310
1-8 720 530 570 420 1100 820 570 420
- 14 800 590 650 480 1200 890 650 480
NOTES
QSV27 and QSV36 Index
Page X-1
About the Manual .......................................................................... i-3 Install ..................................................................................... 1-30
Additional Service Literature ...................................................... L-3 Remove ................................................................................. 1-29
Air Cleaner Element ................................................................... 10-6 Camshaft Cover Plate................................................................ 1-31
Assemble ............................................................................... 10-7 Clean ..................................................................................... 1-31
Clean ...................................................................................... 10-7 Inspect for Reuse................................................................... 1-32
Disassemble........................................................................... 10-6 Install ..................................................................................... 1-32
Remove.................................................................................. 10-6 Remove ................................................................................. 1-31
Inspect.................................................................................... 10-7 Camshaft Gear ........................................................................... 1-32
Install ...................................................................................... 10-7 Clean ..................................................................................... 1-34
Air in Fuel...................................................................................... 6-7 Inspect for Reuse................................................................... 1-34
Test........................................................................................... 6-7 Install ..................................................................................... 1-35
Venting Fuel Filter .......................................................... 6-8 Remove ................................................................................. 1-32
Venting Injection Pump .................................................. 6-9 Camshaft Gear Bushings.......................................................... 1-76
Air Intake Restriction ............................................................... 10-16 Clean ..................................................................................... 1-76
Measure ............................................................................... 10-16 Inspect for Reuse................................................................... 1-77
Air Intake System ....................................................................... 10-4 Install ..................................................................................... 1-77
General Information ............................................................... 10-4 Remove ................................................................................. 1-77
Air Leaks, Air Intake and Exhaust ............................................ 10-5 Camshaft Intermediate Gear..................................................... 1-77
Initial Check............................................................................ 10-5 Clean ..................................................................................... 1-80
Air or Combustion Gas Test...................................................... 8-27 Inspect for Reuse................................................................... 1-81
Leak Test - Air in Cooling System .......................................... 8-27 Remove ................................................................................. 1-77
Air Starting Motor....................................................................... 12-5 Capscrew Markings and Torque Values ................................. V-19
Inspect for Reuse ................................................................... 12-5 Capscrew Markings and Torque Values - Metric................... V-20
Install ...................................................................................... 12-5 Capscrew Markings and Torque Values - U.S. Customary ... V-27
Remove.................................................................................. 12-5 Charge Air Cooler (CAC)........................................................... 10-8
Anode .......................................................................................... 8-38 Assemble ..............................................................................10-11
Inspect for Reuse ................................................................... 8-38 Clean ................................................................................... 10-10
Install ...................................................................................... 8-38 Disassemble ........................................................................ 10-10
Remove.................................................................................. 8-38 Fill Cooling System .............................................................. 10-14
Application of Sealants and Lubricants.................................... V-3 Inspect ..................................................................................10-11
Helerine o-ring lubricant .......................................................... V-5 Install ................................................................................... 10-12
Loctite 243 - Blue - Stud/Screw locking................................... V-4 Leak Test ............................................................................. 10-12
Loctite 515 - Purple - Normal temperature standard sealant .. V-3 Preparatory ............................................................................ 10-8
Loctite 5699 Ultra Grey - high temp, large gap fill sealant ...... V-3 Pressure Differential Test..................................................... 10-16
Loctite 577 - Yellow - Medium strength thread sealant ........... V-4 Remove ................................................................................. 10-8
Loctite 641 - Yellow - Sealant.................................................. V-4 Temperature Differential Test ............................................... 10-15
Loctite 620 - Green - High temperature high strength sealant V-4 Complete Engine - General Information .................................... 0-3
Mobilplex 47 - brown multipurpose grease.............................. V-5 Compressed Air System - General Information...................... 12-3
Molykote 111 - clear - Silicone based lubricant ....................... V-5 Connecting Rod ......................................................................... 1-37
Oraseal - Zero clearance sealant ............................................ V-5 Assemble ............................................................................... 1-41
Rocol J166 - Copper based high temp antiseize compound... V-5 Clean ..................................................................................... 1-39
Bearings, Connecting Rod .......................................................... 1-8 Disassemble .......................................................................... 1-38
Clean ........................................................................................ 1-9 General Information ............................................................... 1-37
Inspect for Reuse ..................................................................... 1-9 Inspect for Reuse................................................................... 1-39
Install ........................................................................................ 1-9 Install ..................................................................................... 1-42
Remove.................................................................................... 1-8 Measure ................................................................................. 1-40
Bearings, Thrust......................................................................... 1-18 Remove ................................................................................. 1-38
Clean and Inspect .................................................................. 1-19 Coolant Hoses............................................................................ 8-28
Initial Check............................................................................ 1-18 Inspect for Reuse................................................................... 8-28
Install ...................................................................................... 1-20 Coolant Recommendations ........................................................ 8-9
Measure ................................................................................. 1-20 Antifreeze................................................................................. 8-9
Remove.................................................................................. 1-18 Coolant Additives ................................................................... 8-10
Cam Followers.............................................................................. 4-3 Fully Formulated Coolant......................................................... 8-9
Assemble ................................................................................. 4-5 Sealing Additives ................................................................... 8-10
Clean ........................................................................................ 4-4 Soluble Oils............................................................................ 8-10
Disassemble............................................................................. 4-3 Supplemental Coolant Additive (SCA)................................... 8-10
General Information ................................................................. 4-3 Coolant Recommendations and Specifications .................... V-13
Inspect for Reuse ..................................................................... 4-4 Coolant Replacement Requirements .................................... V-17
Install ........................................................................................ 4-6 Supplemental Coolant Additive (SCA).................................. V-14
Remove.................................................................................... 4-3 Test Intervals......................................................................... V-16
Camshaft..................................................................................... 1-21 Testing SCA Concentration Level CC-2602 Test Kit............. V-15
Clean ...................................................................................... 1-24 Coolant Temperature Gauge......................................................8-11
Inspect for Reuse ................................................................... 1-25 Maintenance Check ................................................................8-11
Install ...................................................................................... 1-26 Coolant Thermostat....................................................................8-11
Preparatory ............................................................................ 1-21 Assemble ............................................................................... 8-15
Remove.................................................................................. 1-23 Clean ..................................................................................... 8-13
Camshaft Bushings ................................................................... 1-29 Disassemble .......................................................................... 8-13
Inspect.................................................................................... 1-30 Inspect for Reuse................................................................... 8-14
Index QSV27 and QSV36
Page X-2
Install ...................................................................................... 8-15 Remove.................................................................................... 9-4
Remove .................................................................................. 8-11 Engine Component Torque Values.......................................... V-18
Test ......................................................................................... 8-14 Torque Table ......................................................................... V-18
Coolant Thermostat Housing .................................................... 8-16 Engine Diagrams ......................................................................... E-4
Clean ...................................................................................... 8-18 Engine Views ........................................................................... E-4
Inspect for Reuse ...................................................................8-19 Engine Identification.................................................................... E-3
Install ...................................................................................... 8-19 Engine Dataplate ..................................................................... E-3
Remove .................................................................................. 8-16 Fuel Pump Dataplate ............................................................... E-3
Cooling System ............................................................................ 8-4 General Information ................................................................. E-3
Flow Diagram, Cooling System ................................................8-5 Engine Installation ....................................................................... 0-6
General Information.................................................................. 8-4 General Information ................................................................. 0-6
QSV36 Heat Exchanger Assembly, With Fuel Cooler .............. 8-7 Engine Removal ........................................................................... 0-3
QSV36 Heat Exchanger Assembly, Without Fuel Cooler ......... 8-6 General Information ................................................................. 0-3
Specifications ........................................................................... 8-8 Erosion Plugs............................................................................. 5-19
Cooling System .......................................................................... 8-21 General Information ............................................................... 5-19
Clean ...................................................................................... 8-21 Inspect ................................................................................... 5-19
Drain ....................................................................................... 8-21 Install...................................................................................... 5-20
Fill ........................................................................................... 8-22 Remove.................................................................................. 5-19
Pressure Test ......................................................................... 8-24 Exhaust Manifold ........................................................................11-4
Crankcase Blowby, Measure ..................................................... 14-8 Clean.......................................................................................11-5
Measure ................................................................................. 14-8 Inspect for Reuse ....................................................................11-5
Crankcase Breather (External)....................................................3-4 Install.......................................................................................11-6
Clean ........................................................................................ 3-4 Remove...................................................................................11-4
Install ........................................................................................ 3-5 Exhaust Restriction ....................................................................11-7
Remove .................................................................................... 3-4 Measure ..................................................................................11-7
Crankshaft Gear, Front (Crankshaft Installed).........................1-43 Exhaust Shielding.......................................................................11-4
Clean ...................................................................................... 1-43 Install.......................................................................................11-4
Inspect for Reuse ...................................................................1-44 Remove...................................................................................11-4
Install ...................................................................................... 1-44 Exhaust System ..........................................................................11-4
Remove .................................................................................. 1-43 General Information ................................................................11-4
Crankshaft Seal, Rear ................................................................ 1-45 Engine Testing - General Information ...................................... 14-3
Clean and Inspect .................................................................. 1-46 In-Service Run-in ................................................................... 14-3
Finishing ................................................................................. 1-47 Engine Testing (In Chassis) ...................................................... 14-8
Install ...................................................................................... 1-46 Test ........................................................................................ 14-8
Preparatory............................................................................. 1-45 Flow Diagram, Lubricating Oil System ...................................... 7-3
Remove .................................................................................. 1-45 Fuel Control Linkage ................................................................. 5-21
Crosshead..................................................................................... 2-5 Adjust ..................................................................................... 5-21
Clean ........................................................................................ 2-5 Check ..................................................................................... 5-26
Inspect for Reuse .....................................................................2-6 Governor Actuator Arm .......................................................... 5-24
Install ........................................................................................ 2-6 Initial Check ........................................................................... 5-21
Remove .................................................................................... 2-5 Varification.............................................................................. 5-24
Cylinder Block ............................................................................ 1-47 Fuel Drain Line ........................................................................... 6-22
Inspect for Reuse ...................................................................1-47 Clean...................................................................................... 6-22
Cylinder Block and Liner Seats ................................................1-48 Inspect for Reuse ................................................................... 6-23
Leak Test ................................................................................ 1-48 Install...................................................................................... 6-23
Cylinder Head ............................................................................... 2-7 Remove.................................................................................. 6-22
Assemble................................................................................ 2-15 Fuel Drain Line Restriction ....................................................... 6-21
Clean and Inspect .................................................................. 2-11 Measure ................................................................................. 6-21
Disassemble ........................................................................... 2-11 Fuel Filter (Canister Type)........................................................... 6-9
Inspect .................................................................................... 2-12 Maintenance Check ................................................................. 6-9
Install ...................................................................................... 2-18 Priming ....................................................................................6-11
Measure ................................................................................. 2-13 Fuel Injection Pump Control Shaft Assembly ......................... 5-29
Pressure Test ......................................................................... 2-14 Clean...................................................................................... 5-30
Remove .................................................................................... 2-7 Inspect for Reuse ................................................................... 5-31
Cylinder Liner ............................................................................. 1-49 Install...................................................................................... 5-31
Clean ...................................................................................... 1-53 Remove.................................................................................. 5-29
Disassemble ........................................................................... 1-52 Fuel Inlet Restriction ................................................................. 6-12
Finishing ................................................................................. 1-60 General Information ................................................................. 6-5
General Information................................................................ 1-49 Fuel Leakage Indicator Switch ................................................. 19-3
Inspect for Reuse ...................................................................1-53 Install...................................................................................... 19-4
Install ...................................................................................... 1-56 Remove.................................................................................. 19-3
Preparatory............................................................................. 1-49 Fuel Lift Pump ............................................................................ 5-20
Remove .................................................................................. 1-49 Inspect for Reuse ................................................................... 5-20
Drive Units - General Information ............................................... 9-3 Install...................................................................................... 5-21
Engine Barring Device ................................................................. 9-4 Remove.................................................................................. 5-20
Assemble.................................................................................. 9-5 Testing.................................................................................... 5-20
Clean and Inspect for Reuse ....................................................9-4 Fuel Pressure Regulating Valve ............................................... 6-25
Install ........................................................................................ 9-5 Clean and Inspect .................................................................. 6-26
Page X-3
General Information ............................................................... 6-25 Install ..................................................................................... 5-15
Install ...................................................................................... 6-26 Remove ................................................................................. 5-12
Remove.................................................................................. 6-25 Injector........................................................................................ 6-16
Fuel Priming Pump .................................................................... 5-33 Clean and Inspect .................................................................. 6-17
Inspect for Reuse ................................................................... 5-33 Install ..................................................................................... 6-19
Install ...................................................................................... 5-33 Preparatory ............................................................................ 6-16
Remove.................................................................................. 5-33 Remove ................................................................................. 6-17
Fuel Recommendations and Specifications........................... V-11 Test ........................................................................................ 6-18
Fuel Supply Lines ...................................................................... 6-23 Injector/Injection Pump Drain Line .......................................... 6-30
Clean ...................................................................................... 6-24 Clean ..................................................................................... 6-30
Inspect for Reuse ................................................................... 6-24 Inspect for Reuse................................................................... 6-30
Install ...................................................................................... 6-25 Install ..................................................................................... 6-31
Preparatory ............................................................................ 6-23 Remove ................................................................................. 6-30
Remove.................................................................................. 6-24 Injectors and Fuel Lines.............................................................. 6-5
Fuel System .................................................................................. 5-4 General Information ................................................................. 6-5
General Information ................................................................. 5-4 Installation Recommendations............................................ 5-8, 6-7
Fuel System Pre-Filter ............................................................... 5-27 Overhead Tank Installation Requirements........................ 5-8. 6-7
Clean ...................................................................................... 5-27 Lubricating Oil Analysis............................................................ 7-41
Install ...................................................................................... 5-28 Maintenance Check ............................................................... 7-41
Remove.................................................................................. 5-27 Lubricating Oil and Filters .......................................................... 7-7
Gear Housing, Front .................................................................. 1-61 Drain ........................................................................................ 7-7
Clean ...................................................................................... 1-62 Inspect ..................................................................................... 7-9
Finishing ................................................................................. 1-65 Install ..................................................................................... 7-10
Inspect for Reuse ................................................................... 1-63 Remove ................................................................................... 7-8
Install ...................................................................................... 1-63 Engine Running ............................................................. 7-8
Preparatory ............................................................................ 1-61 Engine Stopped ............................................................. 7-9
Remove.................................................................................. 1-61 Lubricating Oil Cooler ................................................................7-11
Gear Train Backlash................................................................... 1-76 Assemble ............................................................................... 7-15
Measure ................................................................................. 1-76 Clean ..................................................................................... 7-14
General Cleaning Instructions ..................................................... i-8 Disassemble .......................................................................... 7-13
Glass or Plastic Bead Cleaning................................................. i-8 Install ..................................................................................... 7-16
Solvent and Acid Cleaning ........................................................ i-8 Pressure Test ......................................................................... 7-16
Steam Cleaning......................................................................... i-8 Remove ..................................................................................7-11
General Repair Instructions ......................................................... i-7 Lubricating Oil Dipstick ............................................................ 7-18
General Safety Instructions ......................................................... i-6 Calibrate ................................................................................ 7-18
Important Safety Notice............................................................. i-6 Lubricating Oil Filter (Canister-Type) ...................................... 7-20
Generator Coupling ................................................................... 16-3 Inspect ................................................................................... 7-20
Clean ...................................................................................... 16-3 Lubricating Oil Filter (Centrifugal) ........................................... 7-42
General Information ............................................................... 16-3 Assemble ............................................................................... 7-45
Inspect for Reuse ................................................................... 16-4 Clean ..................................................................................... 7-43
Install ...................................................................................... 16-4 Disassemble .......................................................................... 7-43
Remove.................................................................................. 16-3 General Information ............................................................... 7-42
Heat Exchanger Cooling Plates ................................................ 8-29 Inspect for Reuse................................................................... 7-44
Clean ...................................................................................... 8-30 Install ..................................................................................... 7-46
Inspect for Reuse ................................................................... 8-31 Remove ................................................................................. 7-42
Install ...................................................................................... 8-31 Lubricating Oil Filter Bypass Valve.......................................... 7-20
Remove.................................................................................. 8-29 Assemble ............................................................................... 7-23
Heat Exchanger Support Housing............................................ 8-32 Clean and Inspect .................................................................. 7-22
Clean ...................................................................................... 8-33 Disassemble .......................................................................... 7-21
Inspect for Reuse ................................................................... 8-34 Test ........................................................................................ 7-25
Install ...................................................................................... 8-34 Install ..................................................................................... 7-25
Remove.................................................................................. 8-32 Remove ................................................................................. 7-20
High Pressure Fuel Tube ........................................................... 6-26 Lubricating Oil Pressure Regulating Valve ............................. 7-26
Clean ...................................................................................... 6-27 Adjust..................................................................................... 7-26
Inspect for Reuse ................................................................... 6-28 Lubricating Oil Leaks ................................................................ 7-27
Install ...................................................................................... 6-28 Maintenance Check ............................................................... 7-27
Preparatory ............................................................................ 6-26 Lubricating Oil Pan.................................................................... 7-29
Remove.................................................................................. 6-27 Clean ..................................................................................... 7-30
High Pressure Tube Drain Line................................................. 6-31 Fill .......................................................................................... 7-33
Install ...................................................................................... 6-32 Remove ................................................................................. 7-29
Remove.................................................................................. 6-31 Lubricating Oil Pressure Gauge............................................... 7-33
How to Use the Manual................................................................. i-3 Test ........................................................................................ 7-33
Illustrations.................................................................................... i-5 Lubricating Oil Pump ................................................................ 7-34
Injection Pump ........................................................................... 5-12 Clean ..................................................................................... 7-35
Index QSV27 and QSV36
Page X-4
Preparatory............................................................................. 7-34 Sea Water Pump......................................................................... 8-35
Remove .................................................................................. 7-34 Clean...................................................................................... 8-36
Lubricating Oil Recommendations and Specifications .. 7-4, V-12 Inspect for Reuse ................................................................... 8-36
General Specifications ............................................................. 7-4 Install...................................................................................... 8-37
Lubricating Oil System ................................................................ 7-6 Remove.................................................................................. 8-35
General Specifications ............................................................. 7-4 Sea Water Strainer ..................................................................... 8-48
Centrifugal Bypass Filter ................................................7-6 Clean...................................................................................... 8-48
Lubricating Oil Pump...................................................... 7-6 Service Tools............................ 1-5, 2-3, 3-3, 5-3, 6-3, 7-5, 8-3, 14-6
Oil Module ...................................................................... 7-6 Cooling System ........................................................................ 8-3
Oil Pan ........................................................................... 7-6 Cylinder Block .......................................................................... 1-5
Lubricating Oil Thermostat ....................................................... 7-39 Cylinder Head .......................................................................... 2-3
Inspect for Reuse ...................................................................7-40 Engine Testing ....................................................................... 14-6
Install ...................................................................................... 7-40 Fuel System ............................................................................. 5-3
Remove .................................................................................. 7-39 Injectors and Fuel Lines ........................................................... 6-3
Test ......................................................................................... 7-40 Lubricating Oil System ............................................................. 7-5
Lubricating Oil Temperature Gauge ......................................... 7-38 Rocker Levers .......................................................................... 3-3
Test ......................................................................................... 7-38 Specifications .................................. 5-9, 10-3, 11-3, 12-4, 14-5, V-7
Main Bearings............................................................................. 1-10 Air Intake System ..........................................................10-3, V-10
Clean ...................................................................................... 1-13 Compressed Air System ...............................................12-4, V-10
Inspect for Reuse ...................................................................1-13 Cooling System ........................................................................ V-9
Install ...................................................................................... 1-14 Engine Testing ....................................................................... 14-5
Preparatory............................................................................. 1-10 Exhaust System ............................................................ 11-3, V-10
Remove .................................................................................. 1-11 Fuel Recommendations ......................................................... 5-10
Multiduct ...................................................................................10-34 Fuel System ......................................................................5-9, V-9
Clean ....................................................................................10-35 General Specifications ............................................................. V-7
Inspect ..................................................................................10-36 Cylinder Numbering Sequence...................................... V-8
Install ....................................................................................10-36 Intake and Exhaust Valve Locations.............................. V-8
Preparatory...........................................................................10-34 Lubricating Oil System ............................................................. V-9
Remove ................................................................................10-35 Static Injection Timing............................................................... 6-13
Overhead Set ................................................................................ 3-5 Adjust ..................................................................................... 6-15
Adjust ....................................................................................... 3-6 General Information ............................................................... 6-13
Crossheads .................................................................... 3-7 Initial Check ........................................................................... 6-13
Valves............................................................................. 3-8 Preparatory ............................................................................ 6-13
General Information.................................................................. 3-5 Symbols ......................................................................................... i-4
Piston ..........................................................................................1-66 To the Owner and Operator.......................................................... i-3
Clean ...................................................................................... 1-66 Transfer Housing ....................................................................... 8-39
General Information................................................................ 1-66 Clean...................................................................................... 8-40
Install ...................................................................................... 1-70 Inspect for Reuse ................................................................... 8-40
Preparatory............................................................................. 1-66 Install...................................................................................... 8-41
Piston Cooling Nozzle................................................................ 1-70 Remove.................................................................................. 8-39
Clean ...................................................................................... 1-71 Troubleshooting Procedures and Techniques........................TS-3
Inspect for Reuse ...................................................................1-72 Troubleshooting Symptoms Charts .........................................TS-3
Install ...................................................................................... 1-72 Coolant Temperature is Below Normal ..................................TS-4
Remove .................................................................................. 1-70 Coolant Temperature Above Normal......................................TS-5
Pressure Cap .............................................................................. 8-28 Engine Difficult to Start or Will Not Start (Exhaust Smoke)....TS-6
Inspect for Reuse ...................................................................8-28 Engine Difficult to Start or Will Not Start (No Exst Smoke) ....TS-7
Install ...................................................................................... 8-29 Engine Power Output Low .....................................................TS-8
Remove .................................................................................. 8-28 Engine Starts But Will Not Keep Running ............................TS-10
Test ......................................................................................... 8-28 Engine Will Not Crank or Cranks Slowly (Air Starter) .......... TS-11
Push Tubes ................................................................................... 4-6 Engine Will Not Reach Rated Speed (RPM)........................TS-12
Clean ........................................................................................ 4-7 Engine Will Not Shut Off ......................................................TS-13
Finishing ................................................................................... 4-8 Lubricating Oil Pressure Low ...............................................TS-14
Inspect for Reuse .....................................................................4-7 Smoke, Black — Excessive .................................................TS-15
Install ........................................................................................ 4-8 Smoke, White — Excessive .................................................TS-16
Preparatory............................................................................... 4-6 Turbocharger............................................................................ 10-18
Remove .................................................................................... 4-6 Clean.................................................................................... 10-19
QSV27/36 Torque Tightening of Threaded Fasteners ........... V-21 Inspect for Reuse ................................................................. 10-19
Rocker Lever Assembly............................................................... 3-9 Install.................................................................................... 10-21
Assemble................................................................................ 3-11 Remove................................................................................ 10-18
Clean and Inspect .................................................................. 3-10 Turbocharger Axial Clearance ................................................ 10-22
Disassemble ............................................................................. 3-9 Measure ............................................................................... 10-22
Install ...................................................................................... 3-12 Turbocharger Bearing ............................................................. 10-30
Remove .................................................................................... 3-9 Assemble ............................................................................. 10-32
Rocker Lever Cover ...................................................................3-13 Clean.................................................................................... 10-32
Clean ...................................................................................... 3-13 Disassemble ........................................................................ 10-30
Inspect .................................................................................... 3-14 Finishing............................................................................... 10-34
Install ...................................................................................... 3-14 Inspect ................................................................................. 10-31
Remove .................................................................................. 3-13 Inspect for Reuse ................................................................. 10-32
Page X-5
Preparatory .......................................................................... 10-30
Turbocharger Blade Damage .................................................. 10-23
Inspect for Reuse ................................................................. 10-23
Turbocharger Compressor Seal Leaks .................................. 10-24
Leak Test .............................................................................. 10-24
Turbocharger Oil Drain Line.................................................... 10-24
Clean .................................................................................... 10-25
Initial Check.......................................................................... 10-24
Inspect for Reuse ................................................................. 10-25
Install .................................................................................... 10-26
Remove................................................................................ 10-25
Turbocharger Radial Bearing Clearance................................ 10-26
Measure ............................................................................... 10-26
Turbocharger Turbine Seal Leaks .......................................... 10-27
Leak Test .............................................................................. 10-27
Turbocharger Wastegate Valve ............................................... 10-28
Clean .................................................................................... 10-29
Inspect.................................................................................. 10-29
Install .................................................................................... 10-30
Remove................................................................................ 10-28
Test....................................................................................... 10-29
Water Pump ................................................................................ 8-42
Assembly................................................................................ 8-45
Clean ...................................................................................... 8-44
Disassemble........................................................................... 8-44
Inspect for Reuse ................................................................... 8-45
Install ...................................................................................... 8-47
Remove.................................................................................. 8-42
Valve Seats ................................................................................. 2-24
Inspect.................................................................................... 2-24
Valves .......................................................................................... 2-24
Inspect.................................................................................... 2-24
Vibration Damper ....................................................................... 1-73
Clean ...................................................................................... 1-73
Eccentricity ............................................................................. 1-75
General Information ............................................................... 1-73
Inspect for Reuse ................................................................... 1-74
Install ...................................................................................... 1-75
Preparatory ............................................................................ 1-73
Remove.................................................................................. 1-73
Wobble Check ........................................................................ 1-76

QSV27-36 Troubleshooting and Repair - 4021310

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QSV27-36 Troubleshooting and Repair - 4021310

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Troubleshooting and Repair Manual

QSV27 and QSV36 Series Engines

Copyright 2001 Bulletin No. 4021310

THIS PAGE LEFT INTENTIONALLY BLANK.

To the Owner and Operator

About the Manual

How to Use the Manual

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step.

CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque.

PERFORM an electrical MEASUREMENT.

The illustrations are intended to show repair or replacement

General Repair Instructions

Air Compressor Flywheel Mounting Capscrews

• Follow all safety instructions noted in the procedures

General Cleaning Instructions

Glass or Plastic Bead Cleaning

Section E - Engine Identification

THIS PAGE LEFT INTENTIONALLY BLANK.

Fuel Pump Dataplate

1. Rocker Lever Cover 12. Flywheel Housing

1. Oil Filter Selector Lever 9. Oil Drain Plug

1. HT LT Thermostat (Coolant) 7. Oil Sump

1. Turbocharger 6. Oil Drain Plug

Section 0 - Complete Engine - Group 00

THIS PAGE LEFT INTENTIONALLY BLANK.

Complete Engine - General Informa-

Engine Removal (000-001)

Disconnect the exhaust pipe.

NOTE: If the rear engine mounts are attached to the transmis-

Remove and use all remaining accessories and brackets with

Engine Installation (000-002)

NOTE: If the rear engine mounts are attached to the transmis-

Total Oil Capacity

Fill the cooling system with 50-percent water, 50-percent ethyl-

Total Coolant Capacity (engine only)

NOTE: Refer to the equipment manufacturer’s specifications for

Make a final inspection to make sure all hoses, wires, linkages,

Operate the engine for 8 to 10 minutes to check for correct

Section 1 - Cylinder Block - Group 01

Crankshaft Gear, Front (Crankshaft Installed)..................................................................................................................... 1-43

Vibration Damper ................................................................................................................................................................... 1-73

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Tool No. Tool Description Tool Illustration

Hydraulic Set Tightening Tool

Main Bearing Roll-out Tool

Cylinder Liner and Piston Lifting Assembly

Camshaft Bushing Extractor

Camshaft Bushing Positioning Rod

Tool No. Tool Description Tool Illustration

Dial Bore Gauge

Piston Ring Expander

Piston Ring Compressor

Crack Detection Kit

Tool No. Tool Description Tool Illustration

Camshaft Bushing Installation Tool

Bearings, Connecting Rod (001-005)

Bar crankshaft to position the rod cap for removal.

Install a 11x175x140 mm capscrew into service tool 3162284.