Cummins QSK45, QSK60 Engine Service Repair Manual

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 Windows software format  Instant download

Covers: Cummins QSK45 and QSK60 Engine Service
Format: software download
Compatibility: Windows XP/Vista/7/8/10 only

This Service Repair Manual  is intended to aid in determining the cause of Cummins QSK45, QSK60 engine related problems and to provide recommended repair procedures. This software runs on Windows operating systems only (no installation required) and is a convenient way to view the Cummins QSK45, QSK60 Engine Service Repair Manual in digital format.

Topics covered in the Cummins QSK45 QSK60 Service Repair Manual:

Introduction

Engine and System Identification
Engine Diagrams
Service Engine Model Product Identification

Familiarization
Complete Engine – Overview
Engine Block – Overview
Cylinder Head – Overview
Rocker Levers – Overview
Cam Followers/Tappets – Overview
Fuel System – Overview
Flow Diagram, Fuel System
Injectors and Fuel Lines – Overview
Lubricating Oil System – Overview
Flow Diagram, Lubricating Oil System
Cooling System – Overview
Flow Diagram, Cooling System
Drive Units – Overview
Air Intake System – Overview
Flow Diagram, Air Intake System
Exhaust System – Overview
Flow Diagram, Exhaust System – Overview
Compressed Air System – Overview
Flow Diagram, Compressed Air System
Electrical Equipment – Overview
Engine Testing – Overview
Mounting Adaptations – Overview

Troubleshooting Procedures and Techniques
Troubleshooting Symptoms Charts
Air Compressor Air Pressure Rises Slowly
Air Compressor Noise is Excessive
Air Compressor Pumping Excess Lubricating Oil into the Air System
Air Compressor will Not Maintain Adequate Air Pressure (Not Pumping Continuously
Air Compressor Will Not Pump Air
Air Compressor Will Not Stop Pumping
Alternator Not Charging or Insufficient Charging
Alternator Overcharging
Coolant Loss – External
Coolant Loss – Internal
Coolant Pressure Low
Coolant Temperature Above Normal – Gradual Overheat
Coolant Temperature Above Normal – Sudden Overheat
Coolant Temperature is Below Normal
Crankcase Gases (Blowby Excessive
Engine Noise Excessive
Engine Noise Excessive – Combustion Knocks
Engine Noise Excessive – Connecting Rod
Engine Noise Excessive – Main Bearing
Engine Noise Excessive – Piston
Engine Noise Excessive – Turbocharger
Engine Will Not Crank or Cranks Slowly (Air Starter
Engine Will Not Crank or Cranks Slowly (Electric Starter
Engine Will Not Shut Off
Fuel Consumption Excessive
Fuel Temperature Above Normal Operating Range
Fuel in Coolant
Fuel in the Lubricating Oil
Fuel Leak – External
Intake Manifold Air Temperature Above Specification
Intake Manifold Air Temperature Is High (Rapid Rise
Intake Manifold Pressure is High
Lubricating Oil Consumption Excessive
Lubricating Oil Pressure High
Lubricating Oil Pressure Low
Lubricating Oil Sludge in the Crankcase Excessive
Lubricating Oil Temperature Above Specifications
Lubricating or Transmission Oil in the Coolant
Turbocharger Leaks Engine Oil or Fuel
Troubleshooting Overview

Engine Performance Troubleshooting Tree
Vibration Excessive

Service Tools
Lubricating Oil System
Lubricating Oil Filter (Spin-On
Cooling System
Lubricating Oil Filter Head
Eliminator™ Filter
Lubricating Oil Pan
Lubricating Oil Pan Adapter Cover Plate
Lubricating Oil Pan Adapter
Lubricating Oil Pressure Regulator (Piston Cooling
Coolant Filter
Coolant Filter Head
Fuel Filter (Spin-On Type
Fuel Filter Head
Fuel Supply Lines
Fuel Pump
Air Compressor
Belt Tensioner, Automatic (Alternator
Alternator
Starting Motor
Pre-Lubricating Oil Pump
Drive Belt, Cooling Fan
Fan, Cooling
Fan Drive Idler Arm Assembly
Fan Hub, Belt Driven
Vibration Damper, Viscous
Crankshaft Adapter
Crankshaft Seal, Front
Engine Wiring Harness
Electronic Control Module (ECM
Fuel Control Valve Body Assembly
Crankcase Breather (External
Aftercooler Assembly
Intercooler Assembly
Turbocharger, Low Pressure
Frame, Two-Stage Turbocharger
Turbocharger, High Pressure
Fuel Drain Lines
Fuel Connection Block (Manifold-Mounted
Fuel Manifold (Supply
Coolant Thermostat Housing Support
Water Pump
Low-Temperature Aftercooler (LTA Water Pump
Accessory Drive Pulley
Accessory Drive Seal
Accessory Drive
Alternator Drive Pulley
Water Pump Drive
Hydraulic Pump Drive
Exhaust Manifold, Dry
Lubricating Oil Cooler Cover
Lubricating Oil Cooler Element
Rocker Lever Cover
Rocker Lever Assembly
Push Rods or Tubes
Crosshead
Rocker Lever Housing
Cam Follower Cover
Cam Follower Assembly
Injector
Cylinder Head
Engine Support Bracket, Front
Gear Cover, Front
Idler Gear, Camshaft (Left Bank
Idler Gear, Camshaft (Right Bank
Idler Gear, Hydraulic Pump
Idler Gear, Water Pump
Camshaft
Gear Housing, Front
Camshaft Bushings
Lubricating Oil Dipstick Tube
Lubricating Oil Suction Tube (Block-Mounted
Lubricating Oil Fill Tube
Hand Hole Cover
Lubricating Oil Transfer Tube
Lubricating Oil Pump
Block Stiffener Plate
Piston Cooling Nozzle
Piston and Connecting Rod Assembly
Piston and Cylinder Liner
Piston Rings
Flywheel
Crankshaft Seal, Rear
Flywheel Housing
Cylinder Liner
Crankshaft

Service Tools
Crankshaft
Flywheel Housing
Crankshaft Seal, Rear
Flywheel
Piston and Connecting Rod Assembly
Piston and Cylinder Liner
Piston Rings
Piston Cooling Nozzle
Block Stiffener Plate
Lubricating Oil Pump
Lubricating Oil Transfer Tube
Hand Hole Cover
Lubricating Oil Fill Tube
Lubricating Oil Suction Tube (Block-Mounted
Lubricating Oil Dipstick Tube
Gear Housing, Front
Camshaft Bushings
Camshaft
Idler Gear, Water Pump
Idler Gear, Hydraulic Pump
Idler Gear, Camshaft (Right Bank
Idler Gear, Camshaft (Left Bank
Gear Cover, Front
Engine Support Bracket, Front
Cylinder Head
Injector
Cam Follower Assembly
Crosshead
Rocker Lever Housing
Cam Follower Cover
Push Rods and Tubes
Rocker Lever Assembly
Overhead Set (OBC
Static Injection Timing
Rocker Lever Cover
Lubricating Oil Cooler Element
Lubricating Oil Cooler Cover
Exhaust Manifold, Dry
Hydraulic Pump Drive
Water Pump Drive
Alternator Drive Pulley
Accessory Drive
Accessory Drive Seal
Accessory Drive Pulley
Low-Temperature Aftercooler (LTA Water Pump
Water Pump
Coolant Thermostat Housing Support
Fuel Manifold (Supply
Fuel Connection Block (Manifold-Mounted
Fuel Drain Lines
Turbocharger, High Pressure
Frame, Two-Stage Turbocharger
Turbocharger, Low Pressure
Intercooler Assembly
Aftercooler Assembly
Crankcase Breather (External
Right Bank Number 8 Coolant Loop
Fuel Control Valve Body Assembly
Electronic Control Module (ECM
Engine Wiring Harness
Crankshaft Seal, Front
Crankshaft Adapter
Vibration Damper, Viscous
Fan Hub, Belt Driven
Fan Drive Idler Arm Assembly
Fan, Cooling
Drive Belt, Cooling Fan
Pre-Lubricating Oil Pump
Starting Motor
Alternator
Belt Tensioner, Automatic (Alternator
Air Compressor
Fuel Pump
Fuel Filter Head
Fuel Supply Lines
Fuel Filter (Spin-On Type
Coolant Filter Head
Coolant Filter
Lubricating Oil Pan Adapter
Lubricating Oil Pan Adapter Cover Plate
Lubricating Oil Pan
Lubricating Oil Pressure Regulator (Piston Cooling
Lubricating Oil Filter Head
Eliminator™ Filter
Cooling System
Lubricating Oil Filter (Spin-On
Lubricating Oil System

Service Tools
Engine Removal
Engine Installation
Engine Storage – Long Term

Service Tools
Alternator Drive Seal
Accessory Drive Seal
Bearings, Connecting Rod
Bearings, Main
Bearings, Thrust
Camshaft
Camshaft Bushings
Camshaft Gear (Camshaft Installed
Camshaft Gear (Camshaft Removed
Connecting Rod
Crankshaft
Crankshaft Adapter
Crankshaft Gear, Front (Crankshaft Removed
Crankshaft Pulley
Crankshaft Seal, Front
Crankshaft Seal, Rear
Cylinder Block
Cylinder Block and Liner Seats
Cylinder Liner
Gear Cover Trunion Sleeve
Gear Cover, Front
Gear Housing, Front
Hand Hole Cover
Idler Gear, Camshaft (Left Bank
Idler Gear, Camshaft (Right Bank
Idler Gear, Hydraulic Pump
Idler Gear, Water Pump
Piston
Piston and Cylinder Liner
Piston Cooling Nozzle
Piston Rings
Vibration Damper, Viscous
Piston and Connecting Rod Assembly
Gear Train Backlash, Front
Camshaft Thrust Bearing
Cylinder Liner Protrusion
Block Stiffener Plate

Service Tools
Crosshead
Cylinder Head
Cylinder Head Gasket

Service Tools
Crankcase Breather (External
Overhead Set (OBC
Rocker Lever Assembly
Rocker Lever Cover
Rocker Lever Housing

Cam Follower Assembly
Cam Follower Cover
Push Rods or Tubes

Service Tools
Fuel Consumption
Fuel Pump
Fuel Pump Gear Pump
Fuel Shutoff Valve
Fuel Lift Pump
Fuel Pump Pressurizing Assembly

Service Tools
Air in Fuel
Fuel Check Valve
Fuel Connection Block (Manifold-Mounted
Fuel Drain Line Restriction
Fuel Drain Lines
Fuel Filter (Spin-On Type
Fuel Filter Head
Fuel Inlet Restriction
Fuel Manifold (Drain
Fuel Manifold (Supply
Fuel Supply Lines
Static Injection Timing
Injector
Fuel Control Valve Body Assembly
Injector Supply Lines (High Pressure
Fuel Pressure Relief Valve
Fuel Cooler
Delta Pressure Indicator
Fuel Filter (Stage 1
Fuel Filter (Stage 2

Service Tools
Lubricating Oil Cooler Element
Lubricating Oil Dipstick
Lubricating Oil Dipstick Tube
Lubricating Oil Filter (Spin-On
Lubricating Oil Filter Head
Lubricating Oil Filter Head Adapter
Lubricating Oil High Pressure Relief Valve
Lubricating Oil Leaks
Lubricating Oil Pan
Lubricating Oil Pan Adapter Cover Plate
Lubricating Oil Pan Adapter
Lubricating Oil Pressure Gauge
Lubricating Oil Pressure Regulator (Main Rifle
Lubricating Oil Pressure Regulator (Piston Cooling
Lubricating Oil Pump
Lubricating Oil Suction Tube (Block-Mounted
Lubricating Oil System
Lubricating Oil Temperature Gauge
Lubricating Oil Transfer Tube
Lubricating Oil Contamination
Lubricating Oil Cooler Cover
Cylinder Smokes (Blue Smoke
Oil Transfer Connection
Pre-Lubricating Oil Pump
Lubricating Oil Fill Tube
Eliminator™ Filter
Fleetguard® Centrifuge

Service Tools
Drive Belt, Cooling Fan
Coolant Temperature Gauge
Coolant Filter
Coolant Filter Head
Coolant Thermostat
Coolant Thermostat Housing Support
Coolant Thermostat Seal
Coolant Vent Lines
Cooling System
Cooling System – Air or Combustion Gas Test
Cooling System Diagnostics
Cooling System Service Requirements
Fan Drive Idler Arm Assembly
Fan Drive Idler Pulley Assembly
Fan Hub Bracket
Fan Hub, Belt Driven
Fan Shroud Assembly
Fan, Cooling
Marine Gear Oil Cooler
Radiator
Radiator Hoses
Radiator Pressure Cap
Radiator Top Tank
Expansion Tank
Heat Exchanger
Sea Water Pump
Supplemental Coolant Additive (SCA
Water Manifold
Water Pump
Low-Temperature Aftercooler (LTA Water Pump
Right Bank Number 8 Coolant Loop
ECM Cooling Plate
ECM Cooling Plate Lines

Service Tools
Accessory Drive
Accessory Drive Pulley
Alternator Drive Pulley
Fuel Pump Drive
Hydraulic Pump Drive
Hydraulic Pump Drive Gear and Shaft
Water Pump Drive
Engine Barring Device
Accessory Drive Cover

Service Tools
Aftercooler Assembly
Aftercooler Coolant Tube
Aftercooler Element
Air Cleaner Assembly (Engine-Mounted
Air Leaks, Air Intake and Exhaust Systems
Air Intake Restriction
Turbocharger
Turbocharger, High Pressure
Turbocharger, Low Pressure
Turbocharger Coolant Hoses
Turbocharger Oil Drain Line
Turbocharger Oil Supply Line
Turbocharger Heat Shield
Frame, Two-Stage Turbocharger
Intercooler Assembly
Intercooler Element
Aftercooler Heat Shield
Turbocharger Inlet Connections
Air Shutoff Valve

Service Tools
Exhaust Connection Pipe
Exhaust Connection Pipe (Turbocharger to Turbocharger
Exhaust Manifold, Dry
Exhaust Restriction
Exhaust Manifold Heat Shield

Service Tools
Air Compressor Carbon Buildup
Air Compressor Pin Bore Wear
Air Compressor Unloader and Valve Assembly
Air Compressor
Air Governor (Air Compressor Will Not Pump
Air Governor (Air Compressor Pumps Continuously
Air Leaks, Compressed Air System
Air Compressor (Oil Carryover
Air Starting Motor

Service Tools
Alternator
Alternator, Bracket
Drive Belt, Alternator
Alternator Pulley
Batteries
Battery Cables and Connections
Started Magnetic Switch
Starter Switch
Starter Solenoid
Starter Motor
Belt Tensioner, Automatic (Alternator

Service Tools
Dynamometer Worksheet
Engine Testing (Chassis Dynamometer
Engine Run-in (Without Dynamometer
Engine Testing (Engine Dynamometer
Engine Run-in (Engine Dynamometer
Engine Testing (In Chassis
Engine Compression

Service Tools
Engine Lifting Brackets
Engine Support Bracket, Front
Flexplate
Flywheel
Flywheel Housing
Flywheel Ring Gear
Engine Mounts

Capscrew
Cup Plug
Flexible Hose
Pipe Plug
Straight Thread Plug

Specifications

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