QSKV 45/60 : Introduction

CONTENTS

1. INTRODUCTION

2. BLOCK

3. CYLINDER HEAD

4. ENDS

5. AIR SYSTEM

6. LUBRICATION SYSTEM

7. COOLING SYSTEM

8. FUEL SYSTEM

9. CONTROL SYSTEM

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 QSKV 45/60 : Introduction
INTRODUCTION - Objectives
The overall goal of this course is to assist the student in gaining the knowledge and skills necessary to properly service the
new QSK 45 and 60 Engines from Cummins.

At the conclusion of this course, the student will be prepared to:

 Describe the features of the QSK 45 and 60 Engines

 Describe the features and operation of the fuel system
 Trace the flow through the lubrication, cooling, air and fuel systems
 Describe and perform unique service and troubleshooting procedures
 Enter the qualification phase of QSK 45 and 60 Engine training

INTRODUCTION – Product Overview

SCENE AUDIO
This program introduces the newest members of the Cummins high horsepower family – the QSK 45 and the QSK 60 engines.
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The QSK 45 and 60 engines build on the success of Cummins’ K38 and K50 engines. However, the QSK 45 and 60 engines have internal and
external hardware improvements over their predecessors.
In addition to the other changes, the QUANTUM engine control system is used on QSK 45 and 60 engines. This electronic control system is
designed to optimize engine control and reduce exhaust emissions.
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This system has the flexibility to provide precise control in a variety of off-highway equipment applications.
With the previous K Series engines, many parts were interchangeable between the vee and inline configurations.
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However, the QSK 45 and 60 engines have fewer interchangeable parts with their companion six cylinder inline engine, the QSK19.
Both the QSK 45 and the QSK 60 engines have a 159 mm bore and a stroke of 190 mm. The stroke of each of these engines has been increased
10300 over the K38 and K50 engines, to produce added horsepower. The QSK 45 engine is a turbocharged, vee 12 cylinder design and has 45 liters of
displacement. The QSK 60 engine is a turbocharged, vee 16 cylinder design and has 60 liters of displacement.
The QSK 45 utilizes two turbochargers, mounted near the center of the engine, to supply the intake air. The intake air from each of the
turbochargers supplies air flow to the two aftercoolers on one bank of the engine.

Some QSK 60 engines utilize four turbochargers to supply the intake air to the engine. The intake air from each of the turbochargers supplies air
flow to the aftercooler at one of the engine quadrants.
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However, some of the higher horsepower QSK 60 engines utilize a two-stage turbocharger system. For these engines, four low pressure
turbochargers supply intake air flow through intercoolers and then to the high pressure turbochargers. Passing the intake air through two
turbochargers increases boost to provide increased horsepower.

We will look at the turbocharger arrangement in detail in the air system portion of this program.
At introduction the QSK 45 has horsepower ranges from 1500 to 2000, at 1900 RPM.

10600 The single stage QSK 60 has horsepower ranges from 1600 to 2500 at 1900 RPM.

The two-stage QSK 60 has horse power ratings of 2500 and 2700, both at 1900 RPM.
POWER GENERATOR RATINGS
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At introduction, genset ratings for the QSK 45 will be available up to 1250 kilowatts. For the QSK 60 engine, genset ratings will be available up
to 2000 kilowatts.
The external dimensions of the QSK 45 and 60 engines allow them to be installed in an engine compartment designed for a KV engine. However,
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if the two-stage QSK 60 engine is used, it is taller due to the addition of the front and rear intercoolers and other two stage hardware.
The capscrews used on the QSK 45 and 60 engines have a tapered flanged head design. This taper helps to hold the capscrews in position without
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the use of lockwashers.
FIRST TIME AT THE SCENE:
The following segment briefly describes the components of the QSK 60 engine and compares them with the components used on KV engines.
Although the cylinder block contains four less cylinders and therefore is shorter, most of the individual components used on the QSK 45 are the
10800 same. Please click on the available button to continue.
UPON RETURNING TO THIS SCENE WHEN IN THE STRUCTURED MODE:
Now that you have viewed a step by step build of the entire QSK 60 engine, you may either view the step by step build again, view the build
continuously with no audio, or you may continue the course by clicking on the previous menu button.
Let’s begin by taking a look at the major components of the QSK 45 and 60 engines. The overall engine blocks are 6.2 mm longer than the K38
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and K50 engines. All threaded ports are designed for metric straight thread o-ring fittings.
The QSK 45 and 60 cylinder liner is a top counterbore lower press fit design utilizing a brass sealing ring, two D-ring seals and a lower crevice
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seal.
11100 The block contains seven main bearing saddles for the QSK 45 or nine saddles for the QSK 60.
INTRODUCTION – Product Overview
SCENE AUDIO
The crankshaft incorporates a larger crankshaft nose that is the same diameter as the flywheel flange.
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The crankshaft utilizes a wider crankshaft gear.

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 QSKV 45/60 : Introduction
The crankshaft counterweights bolt on the crankshaft. These counterweights are attached in pairs for the companion cylinders. For a QSK 60,
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companion cylinders are 1 and 8; 2 and 7; 3 and 6; and 4 and 5.
The thrust bearings on the QSK 60 install on the number 8 main bearing cap. For the QSK 45, the thrust bearings install on the number 6 main
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bearing cap.
The main caps are positioned in the block by dowel rings. The caps attach to the engine block using two capscrews through the cap and then into
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the block and also by two capscrews that come through the side of the block and into the cap.
The articulated pistons consist of a steel crown and an aluminum skirt. The piston pin bore diameter has increased. The connecting rod is a split
angle design to improve accessibility. The piston pin is now hollow for reduced weight.
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Two connecting rods, one from each bank, install on each crankshaft journal.
The split angle rods and the connecting rod caps have serrations on the mating face to provide a larger clamping surface. Dowel rings locate the
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rod caps that are held in place with four capscrews. The rod journal size has also increased.
11800 QSK 45 and 60 engines utilize two targeted piston cooling nozzles per cylinder.
11900 A block stiffener plate mounts to the bottom of the block. This plate improves the overall strength of the block and reduces engine noise.
The oil pump contains the pressure relief valve as part of the pump assembly. The pump mounts to the bottom of the block and is driven directly
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off the bottom side of the crankshaft gear.
The oil transfer tube connects the oil pump to the cylinder block drillings that feed the oil filter head mounted on that same side of the block.
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Selection of one of the two transfer tube options depends on whether the oil filter head mounts on the right or left side of the engine.
The length and configuration of the oil suction tube depends on the location and type of oil sump used. There are three options for the QSK 45
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engine and 4 options for the QSK 60 engine.
12300 The oil pan adapter capacity has increased over the KV engines and mounts on the pan rail.
Options for the oil sump provide versatility in oil system capacity. The mounting location for the sump can vary depending on the needs of the
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specific application.
12500 The front gear housing is deeper to accommodate the wider front gear train.
12600 The camshaft bushings install into the bores in the cylinder block. The camshaft journals are over 105 mm in diameter.
12700 The camshaft for each bank is larger to withstand the increased injection pressure for QSK 45 and 60 engines.
The camshaft thrust plates install on the nose of the camshafts. These directional thrust plates must be installed with the thin side toward the
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outside of the engine block.
The timing key installed in the nose of the camshaft adjusts the position of the camshaft relative to the camshaft gear. This key is used to precisely
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set the engine static timing.
13000 The camshaft gears, along with rest of the gear train, feature spur gears.
13100 The water pump idler gear mounts using three bolts.
13200 The right bank camshaft idler gear mounts using 4 bolts
Both the left bank camshaft idler gear and the accessory drive idler gear also mount using 4 bolts. Both of these gears are compound gears to
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provide the necessary modification to the gear ratio. The small gear on each of these compound gears installs toward the engine block.
13400 The gear cover is located using dowel pins in the lower corners.
The camfollower assembly for each cylinder consists of an intake, exhaust and injector camfollower installed on a common shaft. Both the
13500 injector camfollower roller and the camshaft lobe are wider than on previous engines. This assembly mounts on the side of the engine block and
is located on two dowel rings.
13600 Each camfollower cover installs over two sets of camfollowers.
A variety of hand hole covers are used to seal the round opening in the side of the block by each cylinder. These covers provide the desired
13700 dipstick locations, oil fill tubes, and mounting for the oil breather tubes. Other locations use blank covers. Each of the covers is sealed using an o-
ring.
13800 The crankcase breathers are a new design and attach a drainback hose to the hand hole cover. The current QSK 60 utilizes three breathers.
13900 The taller oil cooler elements install into the water cavity in the vee of the block.
The water header covers mount over the oil cooler elements and seal off the coolant passages in the center of the engine. On two stage engines,
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brackets attached to the water header covers help support the turbocharger assembly frame.
Individual head gaskets for each cylinder are a steel plate design utilizing edge molded seals around the oil passages, coolant passages, and the
capscrew holes.
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Both the QSK 45 and 60 engines utilize edge molded gaskets for the cylinder head and in various other locations for improved sealing.
The new cylinder heads are taller to accommodate the QUANTUM fuel system. These heads mount using a seven bolt pattern to improve load
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clamping and cylinder head durability.
Replaceable valve guides and valve seats install in the cylinder head.
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Four valves per cylinder install into each head.
14400 Valve stem seals control the flow of oil past the valve stems.

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 QSKV 45/60 : Introduction
INTRODUCTION – Product Overview
SCENE AUDIO
14500 Valve rotators install under each of the valve springs. The springs are then held in place using spring retainers and collets.
14600 The fuel injectors are a QUANTUM style open nozzle design. Each injector is held in place by a holddown clamp.
14700 Cast passages in the rocker housings installed over each cylinder are connected together with water tubes to form the water manifold
14800 Stemless crossheads install over each pair of intake and exhaust valves.
14900 The push rods used on QSK 45 and 60 engines are longer to allow for the increase in height of the cylinder head.
Rocker levers for each cylinder mount on a common shaft. The intake and exhaust rocker levers are equipped with a pivot pad featuring a ball
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and socket joint to improve durability.
The aerodynamically designed exhaust manifolds mount toward the vee of the engine using towers and capscrews. The sections of the exhaust
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manifold connect together using stainless steel bellows to allow for thermal expansion of the manifold.
15200 The cast iron valve covers contain a diagnostic port for use with the single cylinder cutout procedure.
15300 The fuel pump/air compressor drive mounts on the back side of the front gear housing.
15400 If the engine is equipped with an air compressor, it installs on the fuel pump/air compressor drive.
The gear pump design fuel pump provides approximately three times the fuel flow as the pump used on KV engines. The pump installs on the
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rear of the air compressor or directly to the fuel pump/air compressor drive.
The fuel filter head typically mounts to the pan rail and contains a provision for a fuel warmer.
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Three fuel filter canisters install onto the filter head.
The Fuel Connection Block mounts on the engine block head deck between cylinders 3 and 4 on QSK 45 engines and between cylinders 4 and 5
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on QSK 60 engines. This block transfers fuel from the internal drillings in the block to the fuel manifold.
A fuel manifold, containing larger passages than KV engines, attaches to the side of the cylinder heads on each bank and runs the length of the
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engine.
The Electronic Fuel Control Valve Assembly, or ECVA, attaches to the side of the engine block. This assembly contains fuel passages, sensors, a
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shutoff valve, and actuators to control the flow of timing and metering fuel to the engine.
16000 Fuel lines connect the fuel pump to the ECVA.
16200 A fuel equalizer line connects the two fuel manifolds. This line provides consistent pressure to the fuel timing rail on each bank.
16300 The fuel drain line connects to the fuel manifolds.
16350 An aftercooler housing, core, and cover installs on each quadrant of the engine.
The reversible flywheel housing gasket directs the flow of oil from the oil filter assembly to the oil manifold cavity in the mounting face of the
flywheel housing.
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The QSK 45 and 60 flywheel housing is shorter due to the elimination of the rear gear train.
A piston cooling regulator installs on each side of the flywheel housing. These regulators control the flow of oil from the oil manifold to the
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piston cooling nozzle rifles.
16800 A crankshaft seal retainer on the rear of the engine holds the unitized crankshaft seal in position.
The flywheel, or flexplate, installed on the rear of the crankshaft has valve set marks on the inboard side. These marks are visible through the
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access port in the flywheel housing for both left and right bank starter mounting.
The new optional Eliminator automatic, self-cleaning oil filter can be installed on the side of the engine. Eliminator provides the maximum
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filtration, the least amount of filter maintenance, and the lowest cost of operation of all of the oil filter options.
The oil filter head can be installed on the left or right side of the engine. However, a left side mount must be remote due to interference with the
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engine ECM and ECVA.
When the oil filter head is used, QSK 45 and 60 engines utilize Venturi combo filters for improved oil flow through the bypass portion of the
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filter. QSK 45 engines use 3 filters and QSK 60 engines use 4 filters.
Optional additional bypass filtration may be achieved by utilizing the Fleetguard ConeStaC centrifuge bypass filter. The centrifugal bypass oil
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filter housing can be installed on the left bank, right bank, or at a remote location.
17400 An optional hydraulic pump can be mounted on the front or rear of the gear housing on the left side of the engine.
The water pump drive and gear driven primary engine water pump install on the rear of the gear cover on the right bank. QSK 45 and 60 pumps
17500 have increased capacity as compared to the pumps used on KV engines to increase the coolant flow rate. This is necessary due to the increase in
horsepower for QSK 45 and 60 engines.
17600 The water inlet connection supplies coolant to the water pump from the bypass connection or the engine radiator.
17700 A secondary gear driven water pump, mounted on the front of the gear cover, provides flow to the aftercoolers for LTA cooling systems.
17800 The unitized front crankshaft seal mounts to the gear cover.
17900 If the engine is not equipped with a water pump pulley or an accessory drive pulley, a steel cap installs over the shaft.
18000 If pulleys are used on the water pump and accessory drive, drive seals install in place of the steel cap.
18100 A one piece front engine support attaches around the gear cover trunion for the crankshaft.
18200 If the engine is equipped with a front PTO option, it attaches to the nose of the crankshaft.
The crankshaft adapter installs on the front face of the crankshaft. This adapter is located in the proper position by the dowel pin installed in the
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crankshaft.
18400 QSK 45 and 60 engines use a pulley and double vibration damper.
A timing pointer installs on the gear cover. This pointer aligns with marks on the vibration damper to position the engine correctly for engine
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timing or valve set procedures.
18600 The thermostat support installs onto the top of the engine block at the front of the engine.

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 QSKV 45/60 : Introduction
INTRODUCTION – Product Overview
SCENE AUDIO
The four engine thermostats install in the outboard openings in the thermostat housing.
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The two center thermostats control the coolant flow in the LTA cooling circuit. All of the thermostats install with the heat sensing bulb facing
down.
The water filter head installs on the left side of the thermostat housing assembly. The two water filters help to maintain the engine cooling system
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with the proper amount of cooling system additives.
18900 Both the engine cooling system and the LTA system have water inlet and outlet connections on top of the thermostat housing.
19000 The water pump bypass line connects the outlet of the thermostat housing directly to the water pump.
19100 The secondary water pump also has inlet and bypass connections leading to the LTA cooling system thermostats and radiator.
19200 Options for the fan hub include a manual hub and a Rockford fan clutch.
19300 The fan belt idler adjusts to apply pressure on the belt to maintain proper belt tension.
19400 The fan belt idler adjusts using a turnbuckle assembly.
19500 The optional alternator bracket and alternator assembly install on the gear housing.
19600 The drive belts for the fan, alternator, or optional freon compressor are located on the front of the engine.
19700 The ECM mounts on top of the Electronic Fuel Control Valve Assembly.
19800 The majority of the Quantum sensors are found on the left side of the engine.
19900 The engine and OEM wiring harnesses connect the ECM to each of the sensors and to the output devices.
The engine barring device installs on the front side of the flywheel housing on the side opposite the starter.
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An access hole cover, seals off the opening used to locate the timing marks on the inboard side of the flywheel.
20100 The standard lifting arrangement requires the use of four lifting hooks located between the cylinder heads and mounted to the engine block.
QSK 45 engines use two turbochargers, one installed on each of the exhaust manifolds for one bank of the engine.
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The four QSK 60 high pressure two stage turbochargers or the single stage turbochargers install onto the exhaust manifolds. These turbochargers
install in this location regardless of whether the engine is equipped as a single stage or two stage turbocharger arrangement.
If the engine utilizes a two stage air system, the turbocharger frame support brackets attach to the sides of the cylinder heads and support the
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frame assembly for the two stage turbochargers.
20400 The bellows connections attach to the exhaust outlet of each of the turbochargers.
20500 The two transfer connections install onto the turbocharger frame and connect to the bellows.
20600 The four, two stage low pressure turbochargers install onto the transfer connections.
20700 Bellows connections attach the low pressure turbochargers to the two exhaust outlet connections.
An intercooler installs at both the front and rear of the engine.
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The air inlet and outlet pipes connect the intercoolers to the low pressure and high pressure turbochargers.
20900 The air crossover connections direct the flow of air from the high pressure turbochargers to the aftercoolers.
All of the turbochargers are cooled and lubricated using engine oil. The turbocharger oil supply lines deliver oil to the turbochargers from the oil
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manifold. The oil drain lines return oil from the turbochargers to the engine block.
The four, two-stage high pressure and single stage turbochargers also have water cooled bearing housings. Coolant is supplied from the water
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manifold and returned from the turbochargers to the bypass portion of the thermostat housing.
21200 Coolant lines supply coolant to the intercoolers from the vee of the engine through one of the water header plates.
21300 Coolant lines attach the aftercoolers to the LTA cooling circuit.
55000 This completes our overview of the Cummins QSK 60 engine.
CONTINUOUS BUILD
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(NO AUDIO)
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