Cummins Power Generation QSX15, QSK23, QSK45, QSK60, QSK78, QST30 Troubelshooting and Repair Specification

Troubleshooting and Repair Manual
QSK60, QSK78 and QST30 Series Engines Volume 1

Power Generation Control Systems, QSX15, QSK23, QSK45,
Cummins Inc.
Box 3005
Columbus, Indiana, U.S.A., 47202 Power Generation Control Systems, QSX15, QSK23,
Registered Office QSK45, QSK60, QSK78 and QST30 Series Engines
Cummins Engine Company, Ltd.
Unit 1-B Uniongate, Ridgeway Trading Estate,
Volume 1
Iver,
Buckinghamshire SL0 9HX,
England
Registration 573951 England
Copyright© 2005
Cummins Inc.
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Bulletin 4021419
Printed in U.S.A. 16-SEPTEMBER-2005 p147
Power Generation Control Systems, QSX15, QSK23,
QSK45, QSK60, QSK78 and QST30 Series Engines
Volume 1
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Copyright© 2005 Bulletin 4021419

Cummins Inc. Printed 16-SEPTEMBER-2005
All rights reserved
Foreword
This manual provides instructions for troubleshooting and repairing this engine in the chassis. Component and
assembly rebuild procedures are provided in the engine shop manual. Refer to Section i - Introduction for instructions
on how to use this manual.
Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i
- Introduction.
The manual is organized to guide a service technician through the logical steps of identifying and correcting problems
related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment
manufacturer for repair procedures.
A series of specific service manuals (for example: Shop, Specifications, and Alternative Repair) are available and can
be ordered by Contacting your local area Cummins Regional office. A Cummins Regional listing is located in Service
Literature (Section L).
The repair procedures used in this manual are recommended by Cummins Inc. Some service procedures require the
V1 use of special service tools. Use the correct tools as described.
Cummins Inc. encourages the user of this manual to report errors, omissions, and recommendations for improvement.
V2 Please use the postage paid, pre-addressed Literature Survey Form in the back of this manual for communicating V
your comments.
V3 The specifications and rebuild information in this manual is based on the information in effect at the time of printing.
Cummins Inc. reserves the right to make any changes at any time without obligation. If differences are found between
your engine and the information in this manual, contact a Cummins Authorized Repair Location or call 1-800-DIESELS
V4 (1-800-343-7357) toll free in the U.S. and Canada.
The latest technology and the highest quality components are used to manufacture Cummins engines. When
V5 replacement parts are needed, we recommend using only genuine Cummins or ReCon® exchange parts. These parts
can be identified by the following trademarks:
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V8
Table of Contents
Section
Introduction 204 ....................................................................................................................................... i
Engine and System Identification ............................................................................................................ E
Familiarization .......................................................................................................................................... F
Troubleshooting Symptoms ..................................................................................................................... TS
Electronic Engine Controls - Group 19 .................................................................................................... 19

V1 Service Literature ..................................................................................................................................... L
V2 Specifications ........................................................................................................................................... V V
V3
V4
V5
V6
V7
V8
QSX15, QSK23, QSK45, QSK60, an [...]
Section V - Specifications Page V-a
Section V - Specifications
Section Contents
Page
Capscrew Markings and Torque Values .........................................................................................................V-38
Capscrew Markings and Torque Values - Metric..............................................................................................V-38
Capscrew Markings and Torque Values - U.S. Customary...............................................................................V-38
General Information........................................................................................................................................V-38
Drive Belt Tension ..........................................................................................................................................V-37
Tension Chart.................................................................................................................................................V-37
Electronic Engine Controls - Group 19 - Torque Values .................................................................................V-1
V1 Barometric Air Pressure Sensor.................................................................................................................................V-1
Burn Valve Solenoid, Centinel™ Oil...........................................................................................................................V-6
V2 Coolant Pressure Sensor...........................................................................................................................................V-1
V
Deutsch HD10 Connector Series...............................................................................................................................V-6
Deutsch HDP20 and HD30 Connector Series............................................................................................................V-6
V3 Electronic Control Module (ECM)...............................................................................................................................V-1
Engine Coolant Temperature Sensor.........................................................................................................................V-1
Engine Fuel Temperature Sensor..............................................................................................................................V-5
V4
Engine Oil Pressure Sensor.......................................................................................................................................V-4
Engine Position Sensor (EPS)...................................................................................................................................V-1
V5 Engine Speed Sensor (ESS)......................................................................................................................................V-1
Engine Wiring Harness...............................................................................................................................................V-2
Fuel Pump Actuator....................................................................................................................................................V-5
V6 Fuel Pump Pressure Sensor......................................................................................................................................V-5
Fuel Shutoff Valve......................................................................................................................................................V-3
Fuel Supply Pump Pressure Sensor..........................................................................................................................V-7
V7 Fuel Supply Pump Temperature Sensor....................................................................................................................V-7
Fuel Timing Pressure Sensor.....................................................................................................................................V-4
Fueling Actuator.........................................................................................................................................................V-4
V8 Intake Manifold Air Temperature Sensor....................................................................................................................V-3
Intake Manifold Pressure Sensor...............................................................................................................................V-4
Intake Manifold Pressure/Temperature Sensor..........................................................................................................V-5
Lubricating Oil Level Sensor......................................................................................................................................V-3
Oil Pressure/Temperature Sensor..............................................................................................................................V-5
Rail Fuel Pressure Sensor.........................................................................................................................................V-5
Rail Pressure Sensor.................................................................................................................................................V-6
Timing Actuator..........................................................................................................................................................V-4
Timing Pressure Sensor.............................................................................................................................................V-6
Fraction, Decimal, Millimeter Conversions ....................................................................................................V-40
Conversion Chart............................................................................................................................................V-40
Newton-Meter to Foot-Pound Conversions ....................................................................................................V-41
Pipe Plug Torque Values ................................................................................................................................V-42
Torque Table..................................................................................................................................................V-42
Specifications ...................................................................................................................................................V-8
Electrical Specifications....................................................................................................................................V-8
General Information..........................................................................................................................................V-8
Sensor Specifications.......................................................................................................................................V-8
QSX15, QSK23, QSK45, QSK60, an [...]
Page V-b Section V - Specifications
Electronic Components.....................................................................................................................................V-8
V1 General Information..........................................................................................................................................V-8
V2 Electrical Specifications....................................................................................................................................V-8 V
V3
V4 General Information..........................................................................................................................................V-8
V5 Electrical Specifications....................................................................................................................................V-8
V6 Specifications ...................................................................................................................................................V-8
V7
V8 Electrical Specifications....................................................................................................................................V-8
QSK45 and QSK60........................................................................................................................................V-8
QSK78 Engines...........................................................................................................................................V-33
Tap-Drill Chart - U.S. Customary and Metric .................................................................................................V-43
General Information........................................................................................................................................V-43
Weights and Measures - Conversion Factors ................................................................................................V-44
QSX15, QSK23, QSK45, QSK60, an [...] Electronic Engine Controls - Group 19 - Torque Values
Section V - Specifications Page V-1
Ref.No./
Component or Assembly (Procedure) Metric U.S.
Steps
.
Electronic Engine Controls - Group 19 - Torque Values

Barometric Air Pressure Sensor (019-004)
Fuel Timing Pressure Sensor Qsx15 14 N•m [ 124 in-lb ]
Fuel Timing Pressure Sensor Qst30 23 N•m [ 204 in-lb ]
Fuel Timing Pressure Sensor Qsk45/60 28 N•m [ 248 in-lb ]
Coolant Pressure Sensor (019-016)

V1 Coolant Pressure Sensor 14 N•m [ 124 in-lb ]
V2 V
V3
V4 Engine Coolant Temperature Sensor (019-019)

Coolant Temperature Sensor 14 N•m [ 124 in-lb ]
V5
V6
V7 Electronic Control Module (ECM) (019-031)

Ecm Mounting Capscrews 20 N•m [ 15 ft-lb ]
V8
Generator Control And Extension Harness 3 N•m [ 27 in-lb ]

Connectors
Engine Position Sensor (EPS) (019-038)

Engine Position Sensor 25 N•m [ 18 ft-lb ]
Engine Speed Sensor (ESS) (019-042)

Engine Speed Sensor Locknut 34 to 47 [ 25 to 35
N•m ft-lb ]
Electronic Engine Controls - Group 19 QSX15, QSK23, QSK45, QSK60, an [...]
Page V-2 Section V - Specifications
Ref.No./
Steps
.
Engine Wiring Harness (019-043)
Shutoff Valve Terminal Nut 3 N•m [ 27 in-lb ]
Engine Harness Ecm Connector 3 N•m [ 27 in-lb ]
V1
V2 V
V3 4 Mm [5/32 In] Hex Head Capscrew 3 N•m [ 27 in-lb ]
V4
V5
Qst30 Upgrade Engine Block Ground 20 N•m [ 177 in-lb ]

V6
Fastener
V7
V8
Fuel Shutoff Terminal Nut 3 N•m [ 27 in-lb ]
Engine Harness Cable Fastener 3 N•m [ 27 in-lb ]
Engine Harness Support Bracket 45 N•m [ 33 ft-lb ]

Capscrews
QSX15, QSK23, QSK45, QSK60, an [...] Electronic Engine Controls - Group 19
Ref.No./
Steps
.
Breather Box Mounting Capscerws 45 N•m [ 33 ft-lb ]
Datalink Connector Capscrews 1 N•m [ 9 in ]
V1
V2 V
Fuel Shutoff Valve Nuts 3 N•m [ 27 in-lb ]

V3
V4
V5
Fuel Shutoff Valve (019-050)

Fuel Shutoff Valve Solenoid 8 N•m [ 72 in-lb ]
V6
V7
V8
Fuel Shutoff Valve Electrical Connection 3 N•m [ 27 in-lb ]
Lubricating Oil Level Sensor (019-056)

Lubricating Oil Level Sensor 14 N•m [ 124 in-lb ]
Intake Manifold Air Temperature Sensor (019-059)

Intake Manifold Air Temperature Sensor 14 N•m [ 124 in-lb ]
Ref.No./
Steps
.
Intake Manifold Pressure Sensor (019-061)
Intake Manifold Pressure Sensor 14 N•m [ 124 in-lb ]
Engine Oil Pressure Sensor (019-066)

Lubricating Oil Pressure Sensor 14 N•m [ 124 in-lb ]
V1
V2 V
V3
Fueling Actuator (019-110)
V4
Qsx15 Fueling Rail Actuator 5.4 N•m [ 48 in-lb ]
V5
V6
Qsk23/45/60/78 Fueling Rail Actuator 25 N•m [ 221 in-lb ]

V7
V8
Timing Actuator (019-111)

Qsx15 Timing Rail Actuator 5.4 N•m [ 48 in-lb ]
Qsk23, Qsk45, Qsk60, And Qsk78 Timing 25 N•m [ 18 ft-lb ]

Rail Actuator
Fuel Timing Pressure Sensor (019-113)

Fuel Timing Pressure Sensor 14 N•m [ 124 in-lb ]
Ref.No./
Steps
.
Rail Fuel Pressure Sensor (019-115)
Qsx15 Fuel Rail Pressure Sensor 14 N•m [ 124 in-lb ]
Qsk23, Qsk45, Qsk60, And Qsk78 Fuel Rail 14 N•m [ 124 in-lb ]
Pressure Sensor
V1
V2 V
V3 Fuel Pump Actuator (019-117)

Fuel Pump Actuator 24 N•m [ 212 in-lb ]
V4
V5
V6
Fuel Pump Pressure Sensor (019-118)
Fuel Pump Pressure Sensor 14 N•m [ 124 in-lb ]
V7
V8
Engine Fuel Temperature Sensor (019-119)

Fuel Temperature Sensor 14 N•m [ 124 in-lb ]
Oil Pressure/Temperature Sensor (019-155)

Oil Pressure/Temperature Sensor 14 N•m [ 124 in-lb ]
Intake Manifold Pressure/Temperature Sensor (019-159)

Intake Manifold Pressure/Temperature 14 N•m [ 124 in-lb ]
Sensor
Ref.No./
Steps
.
Burn Valve Solenoid, Centinel™ Oil (019-173)
Solenoid Nut 5 N•m [ 44 in-lb ]
3/8 O-Ring Fitting 13.5 N•m [ 120 in-lb ]
V1
V2 V
V3 Timing Pressure Sensor (019-191)

14 N•m [ 124 in-lb ]
V4
V5
V6
Deutsch HD10 Connector Series (019-207)
1 N•m [ 9 in-lb ]
V7
V8
Deutsch HDP20 and HD30 Connector Series (019-208)

Clamp Capscrews 1 N•m [ 9 in-lb ]
Clamp Capscrews 1 N•m [ 9 in-lb ]
Rail Pressure Sensor (019-338)

Rail Pressure Sensor 14 N•m [ 124 in-lb ]
Ref.No./
Steps
.
Fuel Supply Pump Pressure Sensor (019-398)
Fuel Supply Pump Pressure Sensor 14 N•m [ 124 in-lb ]
Fuel Supply Pump Temperature Sensor (019-399)

Fuel Supply Pump Temperature Sensor 14 N•m [ 124 in-lb ]
V1
V2 V
V3
V4
V5
V6
V7
V8
Specifications QSX15, QSK23, QSK45, QSK60, an [...]
Specifications
General Information
WARNING
This diagram is provided as a diagnostic tool for trained, experienced technicians only. Improper
troubleshooting or repair can result in severe personal injury, death, or property damage. See important
instructions in service manual.
Electrical Specifications
Datalink
• Transmit wire to receive wire (loaded)
- 5.0 to 15.0 VDC
V1 • Transmit wire to receive wire (unloaded)
- OK if < 25.0 VDC.
V2 V
All Continuity Checks
• OK (no open circuit) if < 10 Ohms.
V3
All Shorts to Ground
• OK (no short circuit) if > 10 MOhms.
V4
Short Circuit to External Voltage
• OK if < 1.5 VDC.
V5
5-VDC Power at ECM
• 4.75 to 5.25 VDC.
V6
ECM Connector
V7
• Retaining capscrew torque = 3 N•m [27 in-lb].
Solenoids
V8 • Fuel shutoff valve coil resistance
- 7 to 8 Ohms
• Fueling and timing actuator resistance
- 0.5 to 1.3 Ohms after subtracting the multimeter resistance
• Fueling actuator temperature resistance
- 0.54 to 1.07 Ohms = negative (-) 17°C [0°F] to 54°C [130°F]
- 0.67 to 1.20 Ohms = 38°C [100°F] to 93°C [200°F]
• Timing actuator temperature resistance
- 0.87 to 1.73 Ohms = negative (-)17°C [0°F] to 54°C [130°F]
- 1.10 to 1.97 Ohms = 38°C [100°F] to 93°C [200°F].
Sensor Specifications
Oil Pressure Sensor Torque = 14 N•m [124 in-lb]
Pressure (kPa) Pressure [psia] Voltage (VDC)
0 0 0.25 to 0.75
172 25 1.25 to 1.75
345 50 2.25 to 2.75
517 75 3.25 to 3.75
689 100 4.25 to 4.75
All Temperature Sensors Torque = 15 N•m [133 in-lb]

Temperature (°C) Temperature [°F] Resistance (Ohms)
0 32 30k to 36k
25 77 9k to 11k
50 122 3k to 4k
75 167 1350 to 1500
QSX15, QSK23, QSK45, QSK60, an [...] Specifications

100 212 600 to 675
Fuel Pressure Sensor Torque = 14 N•m [124 in-lb]

0 0 0.25 to 0.75
517 75 1.11 to 1.61
1034 150 1.97 to 2.47
1551 225 2.62 to 3.32
2068 300 3.68 to 4.18
V1
Intake Manifold Pressure Sensor Torque = 14 N•m [124 in-lb]

V2 V
Pressure (mmHg) Pressure [inHg] Pressure [psia] Voltage (VDC)
0 0 0 0.75 to 1.20
V3
646.48 25.45 12.5 1.60 to 2.10
1292.88 50.90 25 2.40 to 3.00
V4
1939.36 76.35 37.5 3.25 to 3.85
2585.76 101.80 50 4.10 to 4.70
V5
Barometric Air Pressure Sensor Torque = 15 N•m [133 in-lb]
V6
Altitude (m) Altitude [ft] Pressure [psia] Voltage (VDC)
0 (sea level) 0 14.7 3.40 to 4.50
915 3000 13.2 2.80 to 3.80
V7
1830 6000 11.8 2.20 to 3.25
2744 9000 10.5 1.70 to 2.70
V8
3659 12,000 9.35 1.20 to 2.20
Engine Position Sensor (Crankshaft & Camshaft) Torque = 25 N•m [221 in-lb]
On metal = 3.5 to 5 VDC
Off metal = 0.0 to 2.2 VDC
Specifications
General Information
WARNING
Datalink
- 5.0 to 15.0 VDC
- OK if < 25.0 VDC.
V2 V
V3
V4
• OK if < 1.5 VDC.
V5
5 VDC Power Supply at ECM
• 4.75 to 5.25 VDC.
V6
ECM Connector
V7
• Retaining capscrew torque = 3 N•m [27 in-lb]
Solenoids
V8 • Fuel shutoff valve coil resistance
- 7 to 8 Ohms
• Fueling and timing actuators resistance
- 0.5 to 1.3 Ohms after subtracting the multimeter resistance
• Fueling actuator temperature resistance
- 0.67 to 1.20 Ohms = 38°C [100°F] to 93°C [200°F]
• Timing actuator temperature resistance
- 1.10 to 1.97 Ohms = 38°C [100°F] to 93°C [200°F].
0 0 0.25 to 0.75
172 25 1.25 to 1.75
345 50 2.25 to 2.75
517 75 3.25 to 3.75
689 100 4.25 to 4.75

0 32 30k to 36k
25 77 9k to 11k
50 122 3k to 4k
75 167 1350 to 1500

100 212 600 to 675
Fuel Pressure Sensor Torque = 14 N•m [124 in-lb]

0 0 0.25 to 0.75
517 75 1.11 to 1.61
1034 150 1.97 to 2.47
1551 225 2.62 to 3.32
2068 300 3.68 to 4.18
V1
Intake Manifold Pressure Sensor Torque = 14 N•m [124 in-lb]

V2 V
0 0 0 0.75 to 1.20
V3
646.48 25.45 12.5 1.60 to 2.10
1292.88 50.90 25 2.40 to 3.00
V4
1939.36 76.35 37.5 3.25 to 3.85
2585.76 101.80 50 4.10 to 4.70
V5
Barometric Air Pressure Sensor Torque = 15 N•m [133 in-lb]
V6
0 (sea level) 0 14.7 3.40 to 4.50
915 3000 13.2 2.80 to 3.80
V7
1830 6000 11.8 2.20 to 3.25
2744 9000 10.5 1.70 to 2.70
V8
3659 12,000 9.35 1.20 to 2.20
Engine Position Sensor (Crankshaft and Camshaft) Torque = 25 N•m [221 in-lb]
Off metal = 0.0 to 2.2 VDC
Specifications
General Information
WARNING
This diagram is provided as a diagnostic tool for trained, experienced technicians only. Troubleshooting
presents the risk of equipment damage, personal injury, or death. Troubleshooting must be performed by
trained, experienced technicians. See important instructions in the service manual.
Datalink
- 5.0 to 15.0 VDC
- OK if < 25.0 VDC.
V2 V
V3
V4
• OK if < 1.5 VDC.
V5
5 VDC Power Supply (Sensor and Switch)
• 4.75 to 5.25 VDC.
V6
ECM Connector
V7
Solenoids
V8 • Fuel shutoff valve
- Coil resistance = 7 to 8 Ohms
• Fueling and timing actuators
- Resistance = 0.5 to 1.3 Ohms after subtracting the multimeter resistance
• Fueling actuator temperature resistance =
- 0.67 to 1.20 Ohms = 38°C [100°F] to 93°C [200°F]
• Timing actuator temperature resistance =
- 1.10 to 1.97 Ohms = 38°C [100°F] to 93°C [200°F].
Oil Pressure Sensor
Pressure (kPa) Pressure [psia] Pressure [inHg] Voltage (VDC)
0 0 0 0.22 to 0.80
103 15 30.54 1.00 to 1.20
172 25 50.90 1.33 to 1.68
345 50 101.80 2.17 to 2.83
517 75 152.70 3.09 to 3.91
689 100 203.60 4.10 to 4.92
Intake Manifold Pressure Sensor

0 0 0 0.75 to 1.20
86.18 12.50 25.45 1.06 to 2.10
103 15 30.54 1.97 to 2.47

172.37 25 50.90 2.40 to 3.00
258.55 37.50 76.35 3.25 to 3.85
344.74 50 101.80 4.10 to 4.70
All Temperature Sensors

0 32 30k to 36k
25 77 9k to 11k
50 122 3k to 4k
V1
75 167 1350 to 1500
100 212 600 to 675
V2 V
Fuel Rail Pressure Sensor

V3
Pressure (kPa) Pressure [psia] Pressire [inHg] Voltage (VDC)
0 0 0 0.25 to 0.75
V4
517.11 75 152.70 1.11 to 1.61
1034.21 150 305.40 1.97 to 2.47
V5 1551.32 225 458.10 2.62 to 3.32
2068.43 300 610.81 3.68 to 4.18
V6
Barometric (Ambient) Air Pressure Sensor
V7
64.47 9.35 19.04 1.20 to 2.20
72.39 10.50 21.38 1.70 to 2.70
V8
81.36 11.80 24.03 2.20 to 3.25
91.01 13.20 26.88 2.80 to 3.80
101.35 14.70 29.93 3.40 to 4.50
Engine Position Sensor

Off metal = 0 to 2.2 VDC
Specifications
General Information
WARNING
This diagram is provided as a diagnostic tool for trained, experienced technicians only. Troubleshooting
presents the risk of equipment damage, personal injury, or death. Troubleshooting must be performed by
trained, experienced technicians. See important instructions in the service manual.
Datalink
- 5.0 to 15.0 VDC
- OK if < 25.0 VDC.
V2 V
V3
V4
• OK if < 1.5 VDC.
V5
5 VDC Power Supply (Sensor and Switch)
• 4.75 to 5.25 VDC.
V6
ECM Connector
V7
Solenoids
V8 • Fuel shutoff valve
- Coil resistance = 7 to 8 Ohms
• Fueling and timing actuators
- Resistance = 0.5 to 1.3 Ohms after subtracting the multimeter resistance
• Fueling actuator temperature resistance =
- 0.67 to 1.20 Ohms = 38°C [100°F] to 93°C [200°F]
• Timing actuator temperature resistance =
- 1.10 to 1.97 Ohms = 38°C [100°F] to 93°C [200°F].
Oil Pressure Sensor
0 0 0 0.22 to 0.80
103 15 30.54 1.00 to 1.20
172 25 50.90 1.33 to 1.68
345 50 101.80 2.17 to 2.83
517 75 152.70 3.09 to 3.91
689 100 203.60 4.10 to 4.92

0 0 0 0.75 to 1.20
86.18 12.50 25.45 1.06 to 2.10
103 15 30.54 1.97 to 2.47

172.37 25 50.90 2.40 to 3.00
258.55 37.50 76.35 3.25 to 3.85
344.74 50 101.80 4.10 to 4.70

0 32 30k to 36k
25 77 9k to 11k
50 122 3k to 4k
V1
75 167 1350 to 1500
100 212 600 to 675
V2 V

V3
Pressure (kPa) Pressure [psia] Pressire [inHg] Voltage (VDC)
0 0 0 0.25 to 0.75
V4
517.11 75 152.70 1.11 to 1.61
1034.21 150 305.40 1.97 to 2.47
V5 1551.32 225 458.10 2.62 to 3.32
2068.43 300 610.81 3.68 to 4.18
V6
V7
64.47 9.35 19.04 1.20 to 2.20
72.39 10.50 21.38 1.70 to 2.70
V8
81.36 11.80 24.03 2.20 to 3.25
91.01 13.20 26.88 2.80 to 3.80
101.35 14.70 29.93 3.40 to 4.50
Engine Position Sensor

Off metal = 0 to 2.2 VDC
Specifications
Electronic Components
WARNING
troubleshooting or repair can result in severe personal injury or death or property damage. See important
DATALINK
• Positive wire to chassis ground: 2.5 to 5.0 VDC
• Negative wire to chassis ground: 0.0 to 2.5 VDC
ALL CONTINUITY CHECKS

V1
• OK (no open circuit) if less than 10 Ohms
V2 SHORT CIRCUIT TO EXTERNAL VOLTAGE V

• OK if less than 1.5 VDC
V3 ALL SHORTS TO GROUND
• ESS circuits: OK (no short circuit) if more than 10M Ohms
• All other circuits: OK (no short circuit) if more than 100k Ohms
V4
V5
Oil Pressure Sensor
V6
0 0 0 0.22 to 0.80
103 15 30.54 1.00 to 1.20
V7
172 25 50.90 1.33 to 1.68
345 50 101.80 2.17 to 2.83
V8
517 75 152.70 3.09 to 3.91
689 100 203.60 4.10 to 4.92
Coolant or Intake Manifold Pressure Sensor

0 0 0 0.22 to 0.80
103 15 30.54 1.23 to 1.40
207 30 61.08 1.97 to 2.27
310 45 91.62 2.71 to 3.16
414 60 122.16 3.45 to 4.04
517 75 152.70 4.20 to 4.92

Temperature (C) Temperature [F] Resistance (Ohms)
0 32 30K to 36K
25 77 9K to 11K
50 122 3K to 4K
75 167 1350 to 1500
100 212 600 to 675
Engine Speed Sensor

Torque = 34 to 47 N•m [25 to 35 ft-lb]
First Coil Resistance = 750 to 1100 Ohms
Second Coil Resistance = 1100 to 1500 Ohms
Barometric (Ambient Air) Pressure Sensor

0 0 0 0.32 to 0.69
34.47 5 10.18 1.58 to 2.09
68.95 10 20.36 2.89 to 3.45
103.42 15 30.54 4.12 to 4.85
Fuel Pump or Timing Rail Pressure Sensor

0 0 0 0.48 to 0.53
103.42 15 30.54 0.63 to 0.67
V1
345 50 101.80 0.98 to 1.13
1034 150 305.40 1.98 to 2.33
V2 V
1724 250 509.00 2.97 to 3.55
2585 375 763.50 4.18 to 4.92
V3

V4
103 15 30.54 0.48 to 0.52
V5 345 50 101.80 1.03 to 1.17
689 100 203.60 1.81 to 2.09
V6 1034 150 305.40 2.59 to 3.00
1379 200 407.20 3.38 to 3.93
V7 1724 250 509.00 4.17 to 4.84
V8
Specifications
General Information
WARNING
Datalink
- 5.0 to 15.0 VDC
- OK of less than 25.0 VDC.
V2 V
• OK (no open circuit) if less than 10 Ohms.
V3
5-VDC Power Supply at ECM
• 4.75 to 5.25 VDC.
V4
ECM Connector
V5
• OK if less than 1.5 VDC.
V6
V7
• ESS circuits
- OK (no short circuit) if more than 10M Ohms
• All other circuits
V8 - OK (no short circuit) if more than 100k Ohms.
Coolant Temperature Sensor Torque = 15 N•m [133 in-lb]
0 32 30k to 36k
25 77 9k to 11k
50 122 3k to 4k
75 167 1350 to 1500
100 212 600 to 675

0 0 0.42 to 0.58
172 25 1.42 to 1.58
344 50 2.42 to 2.58
517 75 3.42 to 3.58
689 100 4.42 to 4.58
Engine Speed Sensor

First coil resistance = 750 to 1100 Ohms
Second coil resistance 1100 to 1500 Ohms
Fuel Shutoff
Resistance = 28 to 32 Ohms
Rack Actuator
Coil resistance = 0.5 to 1.5 Ohms
Rack Position Sensor

Resistance Value = 17 to 32 Ohms (between pins for rack position measure signal and common signal and between
pins rack position reference signal and common signal)
V1
V2 V
V3
V4
V5
V6
V7
V8
Specifications
General Information
WARNING
instructions in the service manual.
Datalink
- 5.0 to 15.0 VDC
- OK if less than 25.0 VDC.
V2 V
• ESS circuits
V3 - OK (no short circuit) if greater than 10MOhms
- OK (no short circuit) if greater than 100kOhms.
V4
V5
• 4.75 to 5.25 VDC.
V6
ECM Connector
V7
• Retaining capscrew torque
- 1 N•m [9 in-lb].
V8 Short Circuit to External Voltage

Oil Pressure Sensor
0 0 0 0.22 to 0.80
103 15 30.54 1.00 to 1.20
172 25 50.90 1.33 to 1.68
345 50 101.80 2.17 to 2.83
517 75 152.70 3.09 to 3.91
689 100 203.60 4.10 to 4.92

0 0 0 0.22 to 0.80
103 15 30.54 1.23 to 1.40
207 30 61.08 1.97 to 2.27
310 45 91.62 2.71 to 3.16
414 60 122.16 3.45 to 4.04
517 75 152.70 4.20 to 4.92

Temperature (°C) Temperature [°F] Resistance (ohms)
0 32 30k to 36k
25 77 9k to 11k
50 122 3k to 4k
75 167 1350 to 1500
100 212 600 to 675
Engine Speed Sensor

First coil resistance = 750 to 1100 ohms
V1
Second coil resistance = 1100 to 1500 ohms
V2 V
V3
0 0 0 0.32 to 0.69
34.47 5 10.18 1.58 to 2.09
V4
68.95 10 20.36 2.89 to 3.45
103.42 15 30.54 4.12 to 4.85
V5
V6
0 0 0 0.48 to 0.53
103.42 15 30.54 0.63 to 0.67
V7
345 50 101.80 0.98 to 1.13
1034 150 305.40 1.98 to 2.33
V8
1724 250 509 2.97 to 3.55
2585 375 763.5 4.18 to 4.92

103 15 30.54 0.48 to 0.52
345 50 101.80 1.03 to 1.17
689 100 203.60 1.81 to 2.09
1034 150 305.40 2.59 to 3.00
1379 200 407.20 3.38 to 3.93
1724 250 509 4.17 to 4.84
Specifications
General Information
WARNING
Datalink
• Positive wire to chassis ground
- 2.5 to 5.0 VDC
V1 • Negative wire to chassis ground
- 0.0 to 2.5 VDC.
V2 V
V3
V4
• ESS circuits
V5
- OK (no short circuit) if more than 10M Ohms
- OK (no short circuit) if more than 100k Ohms.
V6
V7
V8 Pressure (kPa) Pressure [psig] Pressure [inHg] Voltage (VDC)
0 0 0 0.22 to 0.80
103 15 30.54 1.00 to 1.20
172 25 50.90 1.33 to 1.68
345 50 101.80 2.17 to 2.83
517 75 152.70 3.09 to 3.91
689 100 203.60 4.10 to 4.92
Coolant or Intake Manifold Pressure Sensor Torque = 14 N•m [124 in-lb]

0 0 0 0.22 to 0.80
103 15 30.54 1.23 to 1.40
207 30 61.08 1.97 to 2.27
310 45 91.62 2.71 to 3.16
414 60 122.16 3.45 to 4.04
517 75 152.70 4.20 to 4.92

0 32 30k to 36k
25 77 9k to 11k
50 122 3k to 4k
75 167 1350 to 1500
100 212 600 to 675
Engine Speed Sensor

Barometric (Ambient Air) Pressure Sensor Torque = 23 N•m [204 in-lb]

0 0 0 0.32 to 0.69
34.47 5 10.18 1.58 to 2.09
68.95 10 20.36 2.89 to 3.45
103.42 15 30.54 4.12 to 4.85
V1
Fuel Pump or Timing Rail Pressure Sensor Torque = 14 N•m [124 in-lb]
V2 V
0 0 0 0.48 to 0.53
V3
103.42 15 30.54 0.63 to 0.67
345 50 101.8 0.98 to 1.13
V4
1034 150 305.4 1.98 to 2.33
1724 250 509 2.97 to 3.55
V5 2585 375 763.5 4.18 to 4.92
V6
Fuel Rail Pressure Sensor Torque = 14 N•m [124 in-lb]
103 15 30.54 0.48 to 0.52
V7
345 50 101.80 1.03 to 1.17
689 100 203.6 1.81 to 2.09
V8
1034 150 305.4 2.59 to 3.00
1379 200 407.2 3.38 to 3.93
1724 250 509 4.17 to 4.84
Specifications
General Information
WARNING
Datalink
- 5.0 to 15.0 VDC
V2 V
• ESS circuits
V4
V5
• 4.75 to 5.25 VDC.
V6
ECM Connector
V7
- 1 N•m [9 in-lb].

Oil Pressure Sensor
0 0 0 0.22 to 0.80
103 15 30.54 1.00 to 1.20
172 25 50.90 1.33 to 1.68
345 50 101.80 2.17 to 2.83
517 75 152.70 3.09 to 3.91
689 100 203.60 4.10 to 4.92

0 0 0 0.22 to 0.80
103 15 30.54 1.23 to 1.40
207 30 61.08 1.97 to 2.27
310 45 91.62 2.71 to 3.16
414 60 122.16 3.45 to 4.04
517 75 152.70 4.20 to 4.92

0 32 30k to 36k
25 77 9k to 11k
50 122 3k to 4k
75 167 1350 to 1500
100 212 600 to 675
Engine Speed Sensor

V1
V2 V
V3
0 0 0 0.32 to 0.69
34.47 5 10.18 1.58 to 2.09
V4
68.95 10 20.36 2.89 to 3.45
103.42 15 30.54 4.12 to 4.85
V5
V6
0 0 0 0.48 to 0.53
103.42 15 30.54 0.63 to 0.67
V7
345 50 101.80 0.98 to 1.13
1034 150 305.40 1.98 to 2.33
V8
1724 250 509 2.97 to 3.55
2585 375 763.50 4.18 to 4.92

103 15 30.54 0.48 to 0.52
345 50 101.80 1.03 to 1.17
689 100 203.60 1.81 to 2.09
1034 150 305.40 2.59 to 3.00
1379 200 407.20 3.38 to 3.93
1724 250 509 4.17 to 4.84
Specifications
General Information
WARNING
Datalink
- 5.0 to 15.0 VDC
V2 V
• ESS circuits
V4
V5
• 4.75 to 5.25 VDC.
V6
ECM Connector
V7
- 1 N•m [9 in-lb].

Oil Pressure Sensor
0 0 0 0.22 to 0.80
103 15 30.54 1.00 to 1.20
172 25 50.90 1.33 to 1.68
345 50 101.80 2.17 to 2.83
517 75 152.70 3.09 to 3.91
689 100 203.60 4.10 to 4.92

0 0 0 0.22 to 0.80
103 15 30.54 1.23 to 1.40
207 30 61.08 1.97 to 2.27
310 45 91.62 2.71 to 3.16
414 60 122.16 3.45 to 4.04
517 75 152.70 4.20 to 4.92

0 32 30k to 36k
25 77 9k to 11k
50 122 3k to 4k
75 167 1350 to 1500
100 212 600 to 675
Engine Speed Sensor

V1
V2 V
V3
0 0 0 0.32 to 0.69
34.47 5 10.18 1.58 to 2.09
V4
68.95 10 20.36 2.89 to 3.45
103.42 15 30.54 4.12 to 4.85
V5
V6
0 0 0 0.48 to 0.53
103.42 15 30.54 0.63 to 0.67
V7
345 50 101.80 0.98 to 1.13
1034 150 305.40 1.98 to 2.33
V8
1724 250 509 2.97 to 3.55
2585 375 763.50 4.18 to 4.92

103 15 30.54 0.48 to 0.52
345 50 101.8 1.03 to 1.17
689 100 203.6 1.81 to 2.09
1034 150 305.4 2.59 to 3.00
1379 200 407.2 3.38 to 3.93
1724 250 509 4.17 to 4.84
Specifications
General Information
WARNING
Datalink
- 5.0 to 15.0 VDC
V2 V
• ESS circuits
V4
V5
• 4.75 to 5.25 VDC.
V6
ECM Connector
V7
- 1 N•m [9 in-lb].

Oil Pressure Sensor
0 0 0 0.22 to 0.80
103 15 30.54 1.00 to 1.20
172 25 50.90 1.33 to 1.68
345 50 101.80 2.17 to 2.83
517 75 152.70 3.09 to 3.91
689 100 203.60 4.10 to 4.92

0 0 0 0.22 to 0.80
103 15 30.54 1.23 to 1.40
207 30 61.08 1.97 to 2.27
310 45 91.62 2.71 to 3.16
414 60 122.16 3.45 to 4.04
517 75 152.70 4.20 to 4.92

0 32 30k to 36k
25 77 9k to 11k
50 122 3k to 4k
75 167 1350 to 1500
100 212 600 to 675
Engine Speed Sensor

V1
V2 V
V3
0 0 0 0.32 to 0.69
34.47 5 10.18 1.58 to 2.09
V4
68.95 10 20.36 2.89 to 3.45
103.42 15 30.54 4.12 to 4.85
V5
V6
0 0 0 0.48 to 0.53
103.42 15 30.54 0.63 to 0.67
V7
345 50 101.80 0.98 to 1.13
1034 150 305.40 1.98 to 2.33
V8
1724 250 509 2.97 to 3.55
2585 375 763.50 4.18 to 4.92

103 15 30.54 0.48 to 0.52
345 50 101.8 1.03 to 1.17
689 100 203.60 1.81 to 2.09
1034 150 305.40 2.59 to 3.00
1379 200 407.20 3.38 to 3.93
1724 250 509 4.17 to 4.84
Specifications
General Information
WARNING
Datalink
- 5.0 to 15.0 VDC
V2 V
• ESS circuits
V4
V5
• 4.75 to 5.25 VDC.
V6
ECM Connector
V7
- 1 N•m [9 in-lb].

Oil Pressure Sensor
0 0 0 0.22 to 0.80
103 15 30.54 1.00 to 1.20
172 25 50.90 1.33 to 1.68
345 50 101.80 2.17 to 2.83
517 75 152.70 3.09 to 3.91
689 100 203.60 4.10 to 4.92

0 0 0 0.22 to 0.80
103 15 30.54 1.23 to 1.40
207 30 61.08 1.97 to 2.27
310 45 91.62 2.71 to 3.16
414 60 122.16 3.45 to 4.04
517 75 152.70 4.20 to 4.92

0 32 30k to 36k
25 77 9k to 11k
50 122 3k to 4k
75 167 1350 to 1500
100 212 600 to 675
Engine Speed Sensor

V1
V2 V
V3
0 0 0 0.32 to 0.69
34.47 5 10.18 1.58 to 2.09
V4
68.95 10 20.36 2.89 to 3.45
103.42 15 30.54 4.12 to 4.85
V5
V6
0 0 0 0.48 to 0.53
103.42 15 30.54 0.63 to 0.67
V7
345 50 101.80 0.98 to 1.13
1034 150 305.40 1.98 to 2.33
V8
1724 250 509 2.97 to 3.55
2585 375 763.50 4.18 to 4.92

103 15 30.54 0.48 to 0.52
345 50 101.80 1.03 to 1.17
689 100 203.60 1.81 to 2.09
1034 150 305.40 2.59 to 3.00
1379 200 407.20 3.38 to 3.93
1724 250 509 4.17 to 4.84
Specifications
General Information
WARNING
DATALINK
• Positive wire to chassis ground 2.5 to 5.0 VDC
• Negative wire to chassis ground 0.0 to 2.5 VDC
V1
ALL CONTINUITY CHECKS
V2
• OK (no open circuit) if less than 10 Ohms
V
ALL SHORTS TO GROUND
V3 • ESS circuits OK (no short circuit) if more than 100M Ohms
• All other circuits OK (no short circuit) if more than 100k Ohms
V4 SHORT CIRCUIT TO EXTERNAL VOLTAGE
• OK if less than 1.5 VDC
V5
QSK45 and QSK60
V6
OIL PRESSURE SENSOR
Pressure (kPa) Pressure [psi] Pressure [inHg] Voltage (VDC)
V7
0 0 0 0.22 to 0.80
103 15 30.54 1.00 to 1.20
V8
172 25 50.90 1.33 to 1.68
345 50 101.80 2.17 to 2.83
517 75 152.70 3.09 to 3.91
689 100 203.60 4.10 to 4.92
COOLANT OR INTAKE MANIFOLD PRESSURE SENSORS

Pressure (kPa) Pressure (psia) Pressure [inHg] Voltage (VDC)
0 0 0 0.22 to 0.80
103 15 30.54 1.23 to 1.40
207 30 61.08 1.97 to 2.27
310 45 91.62 2.71 to 3.16
414 60 122.16 3.45 to 4.04
517 75 152.70 4.20 to 4.92
ALL TEMPERATURE SENSORS

Temperature (C°) Temperature [F°] Resistance (Ohms)
0 32 30k to 36k
25 77 9k to 11k
50 122 3k to 4k
75 167 1350 to 1500
100 212 600 to 675
BAROMETRIC (AMBIENT) AIR PRESSURE SENSOR

0 0 0 0.32 to 0.69
34.47 5 10.18 1.58 to 2.09
68.95 10 20.36 2.89 to 3.45
103.42 15 30.54 4.12 to 4.85
FUEL PUMP OR TIMING RAIL PRESSURE SENSOR

0 0 0 0.48 to 0.53
103.42 15 30.54 0.63 to 0.67
V1
345 50 101.8 0.98 to 1.13
1034 150 305.4 1.98 to 2.33
V2 V
1724 250 509 2.97 to 3.55
2585 375 763.5 4.18 to 4.92
V3
FUEL RAIL PRESSURE SENSOR

V4
Pressure (kpa) Pressure (psia) Pressure [inHg] Voltage (VDC)
103 15 30.54 0.48 to 0.52
V5 345 50 101.80 1.03 to 1.17
689 100 203.60 1.81 to 2.09
V6 1034 150 305.4 2.59 to 3.00
1379 200 407.2 3.38 to 3.93
V7 1724 250 509 4.17 to 4.84
ENGINE SPEED SENSOR

V8
QSK78 Engines
OIL PRESSURE SENSOR
0 0 0 0.21 to 0.79
103 15 30.54 0.90 to 1.10
172 25 50.90 1.17 to 1.52
345 50 101.80 1.83 to 2.50
517 75 152.70 2.59 to 3.41
689 100 203.60 3.43 to 4.25
827 120 244 4.09 to 4.91
COOLANT OR INTAKE MANIFOLD PRESSURE SENSORS

0 0 0 0.22 to 0.80
103 15 30.54 1.23 to 1.40
207 30 61.08 1.97 to 2.27
310 45 91.62 2.71 to 3.16
414 60 122.16 3.45 to 4.04
517 75 152.70 4.20 to 4.92
ALL TEMPERATURE SENSORS

Temperature (C°) Temperature [F°] Resistance (Ohms)
0 32 30k to 36k
25 77 9k to 11k
50 122 3k to 4k
75 167 1350 to 1500
100 212 600 to 675
ENGINE SPEED SENSOR

V1
BAROMETRIC (AMBIENT) AIR PRESSURE SENSOR

V2 V
44.82 6.50 13.23 0.32 to 0.69
V3
68.95 10 20.36 1.72 to 2.23
89.63 13 26.47 2.96 to 3.52
V4
103.42 15 30.54 3.72 to 4.45
110.30 16 32.58 4.14 to 4.87
V5
TIMING RAIL PRESSURE SENSOR
V6
0 0 0 0.48 to 0.53
103.42 15 30.54 0.63 to 0.67
V7
345 50 101.80 0.98 to 1.13
1034 150 305.40 1.98 to 2.33
V8
1724 250 509 2.97 to 3.55
2585 375 763.50 4.18 to 4.92
FUEL RAIL PRESSURE SENSOR

103 15 30.54 0.48 to 0.52
345 50 101.80 1.03 to 1.17
689 100 203.60 1.81 to 2.09
1034 150 305.40 2.59 to 3.00
1379 200 407.20 3.38 to 3.93
1724 250 509 4.17 to 4.84
FUEL PUMP PRESSURE SENSOR

0 0 0 0.48 to 0.53
103.42 15 30.54 0.63 to 0.67
689 100 203.60 1.43 to 1.58
1379 200 407.20 2.28 to 2.63
2068 300 610.80 3.21 to 3.79
2758 400 814.40 4.18 to 4.87
Specifications
General Information
WARNING
Datalink
- 5.0 to 15.0 VDC
V2 V
• ESS circuits
V4
V5
• 4.75 to 5.25 VDC.
V6
ECM Connector
V7
- 1 N•m [9 in-lb].

Oil Pressure Sensor
0 0 0 0.21 to 0.79
103 15 30.54 0.90 to 1.10
172 25 50.90 1.17 to 1.52
345 50 101.80 1.83 to 2.50
517 75 152.70 2.59 to 3.41
689 100 203.60 3.43 to 4.25
827 120 244 4.09 to 4.91

0 0 0 0.22 to 0.80
103 15 30.54 1.23 to 1.40
207 30 61.08 1.97 to 2.27
310 45 91.62 2.71 to 3.16
414 60 122.16 3.45 to 4.04
517 75 152.70 4.20 to 4.92

0 32 30k to 36k
25 77 9k to 11k
50 122 3k to 4k
75 167 1350 to 1500
100 212 600 to 675
Engine Speed Sensor

V1
V2 V
V3
44.82 6.5 13.23 0.32 to 0.69
68.95 10 20.36 1.72 to 2.23
V4
89.63 13 26.47 2.96 to 3.52
103.42 15 30.54 3.72 to 4.87
V5 110.30 16 32.58 4.14 to 4.87
V6
Timing Rail Pressure Sensor
0 0 0 0.48 to 0.53
V7
103.42 15 30.54 0.63 to 0.67
345 50 101.80 0.98 to 1.13
V8
1034 150 305.40 1.98 to 2.33
1724 250 509 2.97 to 3.55
2585 375 763.50 4.18 to 4.92

103 15 30.54 0.48 to 0.52
345 50 101.80 1.03 to 1.17
689 100 203.60 1.81 to 2.09
1034 150 305.40 2.59 to 3.00
1379 200 407.20 3.38 to 3.93
1724 250 509 4.17 to 4.84
Fuel Pump Pressure Sensor

0 0 0 0.48 to 0.53
103.42 15 30.54 0.63 to 0.67
689 100 203.60 1.43 to 1.58
1379 200 407.20 2.28 to 2.63
2068 300 610.80 3.21 to 3.79
2758 400 814.40 4.18 to 4.87
QSX15, QSK23, QSK45, QSK60, an [...] Drive Belt Tension
Drive Belt Tension

Tension Chart
SAE Belt Size Belt Tension Gauge Part No. Belt Tension New Belt Tension Range Used*
Click-type Burroughs N lbf N lbf
0.380 in 3822524 620 140 270 to 490 60 to 110
0.440 in 3822524 620 140 270 to 490 60 to 110
1/2 in 3822524 ST-1138 620 140 270 to 490 60 to 110
11/16 in 3822524 ST-1138 620 140 270 to 490 60 to 110
3/4 in 3822524 ST-1138 620 140 270 to 490 60 to 110
V1 7/8 in 3822524 ST-1138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 110
V2 5 rib 3822524 ST-1138 670 150 270 to 530 60 to 120 V
6 rib 3822525 ST-1293 710 160 290 to 580 65 to 130
V3 8 rib 3822525 ST-1293 890 200 360 to 710 80 to 160
10 rib 3822525 3823138 1110 250 440 to 890 100 to 200
V4 12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240
12 rib K section 3822525 3823138 1330 300 890 to 1070 200 to 240
V5 NOTE: This chart does not apply to automatic belt tensioners.
* A belt is considered used if it has been in service for ten minutes or longer.
V6 * If used belt tension is less than the minimum value, tighten the belt to the maximum used belt value.
V7
V8
Capscrew Markings and Torque Values QSX15, QSK23, QSK45, QSK60, an [...]
Capscrew Markings and Torque Values

General Information
CAUTION
When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew
being replaced. Using the wrong capscrews can result in engine damage.
Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface
of the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew.
The following examples indicate how capscrews are identified:
V1
V2 V
V3
NOTES:
V4
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.
V5 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
V6 wrench. Example: 6 ft-lb equals 72 in-lb.
Capscrew Markings and Torque Values - Metric

V7
V8
Body Size Torque Torque Torque

Diameter Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
mm N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb
6 9 5 7 4 13 10 7 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
8 23 17 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 65 50 30 25 70 50 30 25
12 80 60 55 40 115 85 55 40 125 95 55 40
14 125 90 90 65 180 133 90 65 195 145 90 65
16 195 140 140 100 280 200 140 100 290 210 140 100
18 280 200 180 135 390 285 180 135 400 290 180 135
20 400 290 — — 550 400 — — — — — —
Capscrew Markings and Torque Values - U.S. Customary

QSX15, QSK23, QSK45, QSK60, an [...] Capscrew Markings and Torque Values
Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum

N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb
1/4 - 20 9 7 8 6 15 11 8 6
1/4 - 28 12 9 9 7 18 13 9 7
5/16 - 18 20 15 16 12 30 22 16 12
V1 5/16 - 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
V2
3/8 - 24 40 30 35 25 60 45 35 25
V
7/16 - 14 60 45 45 35 90 65 45 35
V3 7/16 - 20 65 50 55 40 95 70 55 40
1/2 - 13 95 70 75 55 130 95 75 55
V4
1/2 - 20 100 75 80 60 150 110 80 60
9/16 - 12 135 100 110 80 190 140 110 80
9/16 - 18 150 110 115 85 210 155 115 85
V5
5/8 - 11 180 135 150 110 255 190 150 110
5/8 - 18 210 155 160 120 290 215 160 120
V6 3/4 - 10 325 240 255 190 460 340 255 190
3/4 - 16 365 270 285 210 515 380 285 210
V7 7/8 - 9 490 360 380 280 745 550 380 280
7/8 - 14 530 390 420 310 825 610 420 310
V8 1-8 720 530 570 420 1100 820 570 420
1 - 14 800 590 650 480 1200 890 650 480
Fraction, Decimal, Millimeter Conversions QSX15, QSK23, QSK45, QSK60, an [...]
Fraction, Decimal, Millimeter Conversions

Conversion Chart
Fraction inch mm Fraction inch mm
1/64 0.0156 0.397 33/64 0.5156 13.097
1/32 0.0313 0.794 17/32 0.5313 13.494
3/64 0.0469 1.191 35/64 0.5469 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.0781 1.984 37/64 0.5781 14.684
3/32 0.0938 2.381 19/32 0.5938 15.081
V1 7/64 0.1094 2.778 39/64 0.6094 15.478
1/8 0.1250 3.175 5/8 0.6250 15.875
V2 9/64 0.1406 3.572 41/64 0.6406 16.272 V
5/32 0.1563 3.969 21/32 0.6563 16.669
V3 11/64 0.1719 4.366 43/64 0.6719 17.066
3/16 0.1875 4.763 11/16 0.6875 17.463
V4 13/64 0.2031 5.159 45/64 0.7031 17.859
7/32 0.2188 5.556 23/32 0.7188 18.256
V5
15/64 0.2344 5.953 47/64 0.7344 18.653
1/4 0.2500 6.350 3/4 0.7500 19.050
17/64 0.2656 6.747 49/64 0.7656 19.447
V6
9/32 0.2813 7.144 25/32 0.7813 19.844
19/64 0.2969 7.541 51/64 0.7969 20.241
V7
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.3281 8.334 53/64 0.8281 21.034
V8 11/32 0.3438 8.731 27/32 0.8438 21.431
23/64 0.3594 9.128 55/64 0.8594 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.3906 9.922 57/64 0.8906 22.622
13/32 0.4063 10.319 29/32 0.9063 23.019
27/64 0.4219 10.716 59/64 0.9219 23.416
7/16 0.4375 11.113 15/16 0.9375 23.813
29/64 0.4531 11.509 61/64 0.9531 24.209
15/32 0.4688 11.906 31/32 0.9688 24.606
31/64 0.4844 12.303 63/64 0.9844 25.003
1/2 0.5000 12.700 1 1.0000 25.400
Conversion Factor: 1 inch = 25.4 mm

QSX15, QSK23, QSK45, QSK60, an [...] Newton-Meter to Foot-Pound Conversions
Newton-Meter to Foot-Pound Conversions

Conversion Chart
N•m ft-lb N•m ft-lb N•m ft-lb
1 9 in-lb 55 41 155 114
5 44 in-lb 60 44 160 118
6 53 in-lb 65 48 165 122
7 62 in-lb 70 52 170 125
8 71 in-lb 75 55 175 129
9 80 in-lb 80 59 180 133
V1 10 89 in-lb 85 63 185 136
11 97 in-lb 90 66 190 140
V2 12 106 in-lb 95 70 195 144 V
14 124 in-lb 100 74 200 148
V3 15 133 in-lb 105 77 205 151
16 142 in-lb 110 81 210 155
V4 18 159 in-lb 115 85 215 159
20 15 ft-lb 120 89 220 162
V5
25 18 125 92 225 165
30 22 130 96 230 170
35 26 135 100 235 173
V6
40 30 140 103 240 177
45 33 145 107 245 180
V7
50 37 150 111 250 184
NOTE: To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803.
V8
Pipe Plug Torque Values QSX15, QSK23, QSK45, QSK60, an [...]
Pipe Plug Torque Values

Torque Table
Size Torque Torque
Thread Actual Thread O.D. In Aluminum Components In Cast Iron or
Steel Components
in in N•m ft-lb N•m ft-lb
1/16 0.32 5 45 in-lb 15 10
1/8 0.41 15 10 20 15
1/4 0.54 20 15 25 20
V1
3/8 0.68 25 20 35 25
1/2 0.85 35 25 55 40
V2
3/4 1.05 45 35 75 55
V
1 1.32 60 45 95 70
V3 1-1/4 1.66 75 55 115 85
1-1/2 1.90 85 65 135 100
V4
V5
V6
V7
V8
QSX15, QSK23, QSK45, QSK60, an [...] Tap-Drill Chart - U.S. Customary and Metric
Tap-Drill Chart - U.S. Customary and Metric

General Information
NOTE ON SELECTING TAP-DRILL SIZES: The tap drill sizes shown on this card give the theoretical tap drill size for
approximately 60% and 75% of full thread depth. Generally, it is recommended that drill sizes be selected in the 60%
range as these sizes will provide about 90% of the potential holding power. Drill sizes in the 75% range are
recommended for shallow hole tapping (less than 1 1/2 times the hole diameter) in soft metals and mild steel.
V1
V2 V
V3
V4
V5
V6
V7
V8
Weights and Measures - Conversion Factors QSX15, QSK23, QSK45, QSK60, an [...]
Weights and Measures - Conversion Factors

Conversion Chart
From U.S. From Metric
Customary To U.S.
Quantity U.S. Customary Metric
To Metric Customary
Multiply By Multiply By
Unit Name Abbreviation Unit Name Abbreviation
sq. inch in2 sq. millimeters mm2 645.16 0.001550
Area sq. centimeters cm2 6.452 0.155
sq. foot ft2 sq. meter m2 0.0929 10.764
V1
Fuel pounds per lb/hp-hr grams per kilowatt g/kW-hr 608.277 0.001645
Consumption horsepower hour hour
V2 V
Fuel miles per gallon mpg kilometers per liter km/l 0.4251 2.352
Performance gallons per mile gpm liters per kilometer l/km 2.352 0.4251
V3
Force pounds force lbf Newton N 4.4482 0.224809
inch in millimeters mm 25.40 0.039370
V4 Length
foot ft millimeters mm 304.801 0.00328
Power horsepower hp kilowatt kW 0.746 1.341
V5 pounds force per psi kilopascal kPa 6.8948 0.145037
sq. inch
inches of mercury in Hg kilopascal kPa 3.3769 0.29613
V6
inches of water in H2O kilopascal kPa 0.2488 4.019299
inches of mercury in Hg millimeters of mm Hg 25.40 0.039370
V7
Pressure mercury
inches of water in H2O millimeters of mm H2O 25.40 0.039370
V8 water
bars bars kilopascals kPa 100.001 0.00999
bars bars millimeters of mm Hg 750.06 0.001333
mercury
Temperature fahrenheit °F centigrade °C (°F-32) ÷1.8 (1.8 x °C) +32
pound force per ft-lb Newton-meter N•m 1.35582 0.737562
foot
Torque
pound force per in-lb Newton-meter N•m 0.113 8.850756
inch
Velocity miles/hour mph kilometers/hour kph 1.6093 0.6214
gallon (U.S.) gal. liter l 3.7853 0.264179
Volume: gallon (Imp*) gal. liter l 4.546 0.219976
liquid
displacement
cubic inch in3 liter l 0.01639 61.02545
cubic inch in3 cubic centimeter cm3 16.387 0.06102
Weight (mass) pounds (avoir.) lb kilograms kg 0.4536 2.204623
British Thermal BTU joules J 1054.5 0.000948
Unit
Work British Thermal BTU kilowatt-hour kW-hr 0.000293 3414
Unit
horsepower hours hp-hr kilowatt-hour kW-hr 0.746 1.341
Index
Page X-1
About the Manual ..........................................................................................i-1 Deutsch DTM and DTP Connector Series ..............................................19-138
General Information.....................................................................................i-1 Connector Replacement........................................................................19-138
AC Harness .............................................................................................19-190 Pin Replacement...................................................................................19-138
General Information...............................................................................19-190 Deutsch HD10 Connector Series ...........................................................19-140
Install....................................................................................................19-191 Connector Replacement........................................................................19-142
Remove................................................................................................19-190 Pin Replacement...................................................................................19-140
Acronyms and Abbreviations ......................................................................i-12 Deutsch HDP20 and HD30 Connector Series ........................................19-144
General Information...................................................................................i-12 Connector Replacement........................................................................19-146
Additional Service Literature .......................................................................L-1 Pin Replacement...................................................................................19-144
General Information....................................................................................L-1 Diagnostic Test Mode Switch ..................................................................19-15
AMP Connector Series ...........................................................................19-126 Check for Short Circuit to Ground...........................................................19-16
Connector Replacement........................................................................19-128 General Information................................................................................19-15
Pin Replacement...................................................................................19-126 Resistance Check...................................................................................19-16
AMP VP44 Connector Series ..................................................................19-150 Diagnostic Test Mode Switch Circuit .......................................................19-17
Connector Replacement........................................................................19-150 Check for Short Circuit from Pin to Pin....................................................19-18
Pin Replacement...................................................................................19-150 Check for Short Circuit to Ground...........................................................19-17
Barometric Air Pressure Sensor ................................................................19-6 Resistance Check...................................................................................19-17
Initial Check..............................................................................................19-6 Drive Belt Tension .....................................................................................V-37
Install........................................................................................................19-6 Tension Chart...........................................................................................V-37
V1 Remove....................................................................................................19-6 ECM Calibration Code ..............................................................................19-20
Battery Ground Circuit ...............................................................................19-6 General Information................................................................................19-20
Voltage Check..........................................................................................19-6 ECM Circuit Board ..................................................................................19-202
Blowby Pressure Sensor ............................................................................19-7 General Information...............................................................................19-202
V2 Install........................................................................................................19-8 Install....................................................................................................19-203 V
Remove....................................................................................................19-7 Remove................................................................................................19-202
Bosch® Actuator and Sensor Connector Series ....................................19-160 Electronic Control Module (ECM) .............................................................19-19
Connector Replacement........................................................................19-161 Initial Check............................................................................................19-19
V3 Pin Replacement...................................................................................19-160 Install......................................................................................................19-20
Bosch® ECM Actuator and Sensor Connector Series ...........................19-168 Remove..................................................................................................19-19
Connector Replacement........................................................................19-171 Electronic Controlled Fuel System ..............................................................F-1
Pin Replacement...................................................................................19-168 Calibration and Adjustment.......................................................................F-32
V4 Bosch® ECM Injector Driver Connector Series ......................................19-162 Modifying Setup/Adjust Submenus........................................................F-32
Connector Replacement........................................................................19-165 Calibration Procedure...........................................................................F-42
Pin Replacement...................................................................................19-162 Control Panel............................................................................................F-22
Bosch® ECM OEM Connector Series ......................................................19-173 Operator Interface Panel.......................................................................F-22
V5 Connector Replacement........................................................................19-177 Switch Panel.........................................................................................F-23
Pin Replacement...................................................................................19-173 Diagnostic Fault Codes...............................................................................F-7
Burn Valve Solenoid, Centinel™ Oil .......................................................19-103 ECM.........................................................................................................F-43
Install....................................................................................................19-104 Controls Box.........................................................................................F-43
V6 Remove................................................................................................19-103 Board Description.................................................................................F-43
BUS PT Module .......................................................................................19-198 Engine Protection System...........................................................................F-7
Install....................................................................................................19-198 Flow Diagram.............................................................................................F-9
Remove................................................................................................19-198 QSX15....................................................................................................F-9
V7 Capscrew Markings and Torque Values ....................................................V-38 QST30....................................................................................................F-9
Capscrew Markings and Torque Values - Metric........................................V-38 QST30....................................................................................................F-9
Capscrew Markings and Torque Values - U.S. Customary.........................V-38 QSK23, QSK45, QSK60, and QSK78....................................................F-10
General Information..................................................................................V-38 General Information....................................................................................F-1
V8 Power Generation...................................................................................F-1
Communication Error - Electronic Service Tool or Control Device.............TS-3
Component Connector and Pin Inspection ............................................19-216 INPOWER Description..............................................................................F-21
General Information...............................................................................19-216 INPOWER™ Adjust Mode..........................................................................F-21
Inspect for Reuse..................................................................................19-216 INPOWER™ Monitor Mode........................................................................F-21
Moisture in Connector.......................................................................19-216 INPOWER™ PRO Description....................................................................F-21
Bent or Expanded Pins......................................................................19-217 INPOWER™ Test Mode.............................................................................F-21
Corroded Pins...................................................................................19-217 Menus......................................................................................................F-25
Pushed Back Pins.............................................................................19-217 Programmable Features.............................................................................F-1
Connector, Butt Splice ...........................................................................19-117 QSK23, QSK45, QSK60, and QSK78 System Components.......................F-18
General Information...............................................................................19-117 ECM Inputs...........................................................................................F-19
Control Panel Assembly .........................................................................19-188 ECM Outputs........................................................................................F-21
General Information...............................................................................19-188 QST30 System Components.....................................................................F-13
Install....................................................................................................19-189 ECM Inputs...........................................................................................F-14
Remove................................................................................................19-188 ECM Outputs........................................................................................F-16
Coolant Pressure Sensor ...........................................................................19-9 QST30 System Components.....................................................................F-16
Install......................................................................................................19-10 ECM Inputs...........................................................................................F-16
Remove....................................................................................................19-9 ECM Outputs........................................................................................F-18
Test..........................................................................................................19-9 QSX15 System Components.....................................................................F-11
Cummins Customized Parts Catalog ...........................................................L-3 ECM Inputs...........................................................................................F-11
General Information....................................................................................L-3 ECM Outputs........................................................................................F-13
Ordering the Customized Parts Catalog......................................................L-3 Engine Coolant Level Sensor ...................................................................19-11
Ordering by Telephone...........................................................................L-3 Install......................................................................................................19-11
Ordering On-Line....................................................................................L-3 Remove..................................................................................................19-11
D-Sub Miniature Connector Series .........................................................19-155 Engine Coolant Temperature Sensor .......................................................19-12
Pin Replacement...................................................................................19-155 Install......................................................................................................19-13
Danfoss (Circular DIN Series) Connector ..............................................19-183 Remove..................................................................................................19-13
Connector Replacement........................................................................19-186 Engine Decelerates Slowly.......................................................................TS-5
Pin Replacement...................................................................................19-183 Engine Diagrams ..........................................................................................E-2
Data Link Circuit, Public ..........................................................................19-14 Engine Views............................................................................................E-10
Check for Short Circuit from Pin to Pin....................................................19-15 Generator Views.........................................................................................E-2
Check for Short Circuit to Ground...........................................................19-15 Engine Difficult to Start or Will Not Start (Exhaust Smoke)........................TS-8
General Information................................................................................19-14 Engine Difficult to Start or Will Not Start (No Exhaust Smoke).................TS-14
Resistance Check...................................................................................19-14 Engine Fuel Temperature Sensor ..........................................................19-100
Deutsch DRC Connector Series .............................................................19-129 Install....................................................................................................19-101
Connector Replacement........................................................................19-132 Remove................................................................................................19-100
Pin Replacement...................................................................................19-129 Engine Identification ....................................................................................E-1
Deutsch DT Connector Series ................................................................19-134 ECM Dataplate...........................................................................................E-1
Connector Replacement........................................................................19-136 Engine Oil Pressure Sensor .....................................................................19-79
Index
Page X-2
Remove..................................................................................................19-79 Fuel Supply Pump Temperature Sensor ................................................19-222

Test........................................................................................................19-79 Install....................................................................................................19-223
Engine Position Sensor (EPS) ..................................................................19-21 Remove................................................................................................19-222
Inspect for Reuse....................................................................................19-22 Fuel Timing Pressure Sensor ...................................................................19-93
Install......................................................................................................19-22 Initial Check............................................................................................19-93
Remove..................................................................................................19-21 Install......................................................................................................19-95
Engine Power Output Low......................................................................TS-19 Remove..................................................................................................19-93
Engine Power Output Low — Performance Measurement.......................TS-27 Test........................................................................................................19-94
Engine Runs Rough or Misfires..............................................................TS-28 Fueling Actuator .......................................................................................19-88
Engine Shuts Off Unexpectedly or Dies During Deceleration...................TS-35 General Information................................................................................19-88
Engine Speed Sensor (ESS) .....................................................................19-22 Install......................................................................................................19-90
Check for Short Circuit from Pin to Pin....................................................19-25 QSX15................................................................................................19-90
Check for Short Circuit to Ground...........................................................19-24 QSK23, QSK45, QSK60, and QSK78...................................................19-90
Inspect for Reuse....................................................................................19-23 Remove..................................................................................................19-89
Install......................................................................................................19-23 QSX15................................................................................................19-89
Remove..................................................................................................19-22 QSK23, QSK45, QSK60, and QSK78...................................................19-90
Resistance Check...................................................................................19-24 Test........................................................................................................19-89
Engine Speed Sensor Circuit ...................................................................19-82 Fuse Holder ..............................................................................................19-73
Check for Short Circuit from Pin to Pin....................................................19-85 Install......................................................................................................19-73
V1 Check for Short Circuit to Ground...........................................................19-83 Remove..................................................................................................19-73
Resistance Check...................................................................................19-82 Fuse, Harness In-Line ............................................................................19-117
Engine Speed Surges at Low or High Idle...............................................TS-39 Inspect..................................................................................................19-117
Engine Speed Surges Under Load or in Operating Range.......................TS-44 General Cleaning Instructions ......................................................................i-8
V2 Engine Starts But Will Not Keep Running...............................................TS-48 Abrasive Pads and Abrasive Paper..............................................................i-8 V
Engine Transient Response Poor............................................................TS-50 Definition of Clean.......................................................................................i-8
Engine Will Not Reach Rated Speed (RPM)............................................TS-57 Gasket Surfaces..........................................................................................i-9
Engine Will Not Shut Off.........................................................................TS-62 Plastic Bead Cleaning................................................................................i-10
V3 Engine Wiring Harness .............................................................................19-25 Solvent and Acid Cleaning...........................................................................i-9
General Information................................................................................19-25 Steam Cleaning.........................................................................................i-10
QST30................................................................................................19-25 General Repair Instructions ..........................................................................i-7
Install......................................................................................................19-44 General Information.....................................................................................i-7
V4 QSX15................................................................................................19-44 Welding on a Vehicle with an Electronic Controlled Fuel System..................i-7
QSK23 Engines..................................................................................19-48 General Safety Instructions ..........................................................................i-5
QST30................................................................................................19-50 Important Safety Notice................................................................................i-5
QST30 Upgrade..................................................................................19-56 Generator Control Harness ....................................................................19-107
V5 QSK45, QSK60, and QSK78...............................................................19-58 General Information...............................................................................19-107
Remove..................................................................................................19-26 Install....................................................................................................19-111
QSX15................................................................................................19-26 Remove................................................................................................19-108
QSK23 Engines..................................................................................19-29 How to Use the Manual .................................................................................i-2
V6 QST30................................................................................................19-32 General Information.....................................................................................i-2
QST30 Upgrade..................................................................................19-37 Illustrations ....................................................................................................i-4
QSK45, QSK60, and QSK78...............................................................19-40 General Information.....................................................................................i-4
Extension Wiring Harness ......................................................................19-105 Inactive or Intermittent Fault Code ........................................................19-217
V7 General Information...............................................................................19-105 General Information...............................................................................19-217
Install....................................................................................................19-106 Initial Check..........................................................................................19-218
Remove................................................................................................19-105 Harness Shake Test..........................................................................19-218
Fault Code Warning Lamps Do Not Illuminate.........................................TS-65 Ground Circuit Check........................................................................19-219
V8 Fault Code Warning Lamps Stay On (No Apparent Reason)....................TS-64 Clean the Connectors........................................................................19-220
Fault Lamp ................................................................................................19-63 INPOWER™ Service Tool ............................................................................F-47
General Information................................................................................19-63 General Information..................................................................................F-47
Voltage Check.........................................................................................19-64 INPOWER™ Adjust Mode..........................................................................F-47
Fault Lamp Circuit ....................................................................................19-64 INPOWER™ Monitor Mode........................................................................F-47
General Information................................................................................19-64 INPOWER™ PRO Description....................................................................F-47
Resistance Check...................................................................................19-64 INPOWER™ Test Mode.............................................................................F-48
Voltage Check.........................................................................................19-65 Intake Manifold Air Temperature Sensor .................................................19-75
Ford™ Connector Series .........................................................................19-154 Check for Short Circuit to Ground...........................................................19-76
Connector Replacement........................................................................19-154 Install......................................................................................................19-75
Fraction, Decimal, Millimeter Conversions ...............................................V-40 Remove..................................................................................................19-75
Conversion Chart......................................................................................V-40 Resistance Check...................................................................................19-75
Framatome Connector Series ................................................................19-179 Intake Manifold Pressure Sensor .............................................................19-76
Fuel Consumption Excessive..................................................................TS-67 Remove..................................................................................................19-77
Fuel in Coolant.......................................................................................TS-74 Test........................................................................................................19-77
Fuel in the Lubricating Oil.......................................................................TS-75 Intake Manifold Pressure/Temperature Sensor .....................................19-102
Fuel Pump Actuator .................................................................................19-98 Install....................................................................................................19-103
Install......................................................................................................19-98 Remove................................................................................................19-102
Remove..................................................................................................19-98 ITT Cannon Connector Series ................................................................19-148
Fuel Pump Pressure Sensor ....................................................................19-99 Connector Replacement........................................................................19-149
Install....................................................................................................19-100 Pin Replacement...................................................................................19-148
Remove..................................................................................................19-99 Lubricating Oil Level Sensor ...................................................................19-74
Test........................................................................................................19-99 Install......................................................................................................19-74
Fuel Shutoff Valve ....................................................................................19-69 Remove..................................................................................................19-74
Inspect for Reuse....................................................................................19-71 Metripack Connector Series ...................................................................19-124
Install......................................................................................................19-72 Connector Replacement........................................................................19-125
Remove..................................................................................................19-70 Pin Replacement...................................................................................19-124
Resistance Check...................................................................................19-69 Multimeter Usage ....................................................................................19-205
Voltage Check.........................................................................................19-69 General Information...............................................................................19-205
Fuel Shutoff Valve Circuit ........................................................................19-65 How to Use a Multimeter...................................................................19-205
Check for Short Circuit from Pin to Pin....................................................19-67 Use of Special Test Leads.................................................................19-206
Check for Short Circuit to External Voltage Source..................................19-68 How to Measure Amperage...............................................................19-206
Check for Short Circuit to Ground...........................................................19-67 How to Measure Voltage...................................................................19-206
Initial Check............................................................................................19-65 How to Measure Resistance..............................................................19-206
Resistance Check...................................................................................19-66 How to Find the Internal Resistance of the Meter...............................19-207
Fuel Supply Pump Pressure Sensor ......................................................19-221 How to Test for Continuity.................................................................19-207
Install....................................................................................................19-221 Short Circuit to Ground - Check.........................................................19-207
Remove................................................................................................19-221 Short Circuit from Pin to Pin - Check.................................................19-208
Index
Page X-3
Voltage Checking..............................................................................19-209 Specifications ..............................................................................................V-8

Polarity Check...................................................................................19-210 Electrical Specifications..............................................................................V-8
Continuity Check...............................................................................19-210 General Information....................................................................................V-8
Resistance Check - Coil....................................................................19-211 Sensor Specifications.................................................................................V-8
Newton-Meter to Foot-Pound Conversions ...............................................V-41 Specifications ..............................................................................................V-8
Conversion Chart......................................................................................V-41 Electrical Specifications..............................................................................V-8
Oil Pressure/Temperature Sensor ..........................................................19-102 General Information....................................................................................V-8
Install....................................................................................................19-102 Sensor Specifications.................................................................................V-8
Remove................................................................................................19-102 Specifications ..............................................................................................V-8
Packard Relay Connector .......................................................................19-152 Electrical Specifications..............................................................................V-8
Connector Replacement........................................................................19-152 General Information....................................................................................V-8
Pin Replacement...................................................................................19-152 Sensor Specifications.................................................................................V-8
Paralleling Harness .................................................................................19-193 Specifications ..............................................................................................V-8
General Information...............................................................................19-193 Electrical Specifications..............................................................................V-8
Install....................................................................................................19-194 General Information....................................................................................V-8
Remove................................................................................................19-193 Sensor Specifications.................................................................................V-8
Pipe Plug Torque Values ...........................................................................V-42 QSK45 and QSK60.................................................................................V-8
Torque Table............................................................................................V-42 QSK78 Engines....................................................................................V-33
PT/CT Board ...........................................................................................19-197 Specifications ..............................................................................................V-8
V1 Install....................................................................................................19-197 Electrical Specifications..............................................................................V-8
Remove................................................................................................19-197 General Information....................................................................................V-8
Rail Fuel Pressure Sensor ........................................................................19-95 Sensor Specifications.................................................................................V-8
General Information................................................................................19-95 Symbols .........................................................................................................i-3
V2 QSX15................................................................................................19-95 General Information.....................................................................................i-3 V
QSK23, QSK45, QSK60, and QSK78...................................................19-95 Tap-Drill Chart - U.S. Customary and Metric ............................................V-43
Install......................................................................................................19-97 General Information..................................................................................V-43
QSX15................................................................................................19-97 Terminal Block - General ........................................................................19-198
V3 QSK23, QSK45, QSK60, and QSK78...................................................19-98 General Information...............................................................................19-198
Remove..................................................................................................19-95 Install....................................................................................................19-199
QSX15................................................................................................19-95 Remove................................................................................................19-199
QSK23, QSK45, QSK60, and QSK78...................................................19-96 Terminal Block - TB3 ..............................................................................19-200
V4 Test........................................................................................................19-96 General Information...............................................................................19-200
QSX15................................................................................................19-96 Install....................................................................................................19-201
QSK23, QSK45, QSK60, and QSK78...................................................19-97 Remove................................................................................................19-200
Rail Pressure Sensor ..............................................................................19-204 Timing Actuator ........................................................................................19-91
V5 Initial Check..........................................................................................19-204 General Information................................................................................19-91
Install....................................................................................................19-205 QSX15................................................................................................19-91
Remove................................................................................................19-204 QSK23, QSK45, QSK60, and QSK78...................................................19-91
Resistance Measurement Using a Multimeter and a Wiring Diagram ...19-212 Install......................................................................................................19-92
V6 Check for Short Circuit from Pin to Pin..................................................19-214 QSX15................................................................................................19-92
Check for Short Circuit to Ground..........................................................19-215 QSK23, QSK45, QSK60, and QSK78...................................................19-93
Continuity Check...................................................................................19-213 Remove..................................................................................................19-91
General Information...............................................................................19-212 QSX15................................................................................................19-91
V7 Resistance Check.................................................................................19-213 QSK23, QSK45, QSK60, and QSK78...................................................19-92
Ring Terminal .........................................................................................19-116 Test........................................................................................................19-91
Connector Replacement........................................................................19-116 Timing Pressure Sensor .........................................................................19-114
Service Literature Ordering Location ..........................................................L-2 Initial Check..........................................................................................19-114
V8
Contact Information....................................................................................L-2 Install....................................................................................................19-115
Service Tools ..............................................................................................19-1 Remove................................................................................................19-114
Electronic Engine Controls........................................................................19-1 Troubleshooting Procedures and Techniques ..........................................TS-1
Smoke, Black — Excessive....................................................................TS-78 General Information..................................................................................TS-1
Smoke, White — Excessive....................................................................TS-84 Troubleshooting Symptoms Charts ..........................................................TS-2
Specifications ..............................................................................................V-8 General Information..................................................................................TS-2
Electrical Specifications..............................................................................V-8 Unswitched Battery Supply Circuit ..........................................................19-80
General Information....................................................................................V-8 General Information................................................................................19-80
Sensor Specifications.................................................................................V-8 Initial Check............................................................................................19-81
Specifications ..............................................................................................V-8 Resistance Check...................................................................................19-81
Electrical Specifications..............................................................................V-8 Voltage Regulator ...................................................................................19-196
General Information....................................................................................V-8 Install....................................................................................................19-196
Sensor Specifications.................................................................................V-8 Remove................................................................................................19-196
Specifications ..............................................................................................V-8 Weather Pak Connector Series ..............................................................19-118
Electrical Specifications..............................................................................V-8 Connector Replacement........................................................................19-122
General Information....................................................................................V-8 Pin Replacement...................................................................................19-118
Sensor Specifications.................................................................................V-8 Weights and Measures - Conversion Factors ...........................................V-44
Specifications ..............................................................................................V-8 Conversion Chart......................................................................................V-44
Electrical Specifications..............................................................................V-8 Wiring Harness Repair Kit ..........................................................................19-4
General Information....................................................................................V-8 General Information..................................................................................19-4
Sensor Specifications.................................................................................V-8
Specifications ..............................................................................................V-8
Electronic Components...............................................................................V-8
Electrical Specifications..............................................................................V-8
General Information....................................................................................V-8
QSK60, QSK78, and QST30 Series Engines Volume 1
Power Generation Control Systems, QXS15, QSK23, QSK45,
Cummins Inc.
Box 3005
Columbus, Indiana, U.S.A., 47202 Power Generation Control Systems, QXS15, QSK23,
Registered Office QSK45, QSK60, QSK78, and QST30 Series Engines
Cummins Engine Company, Ltd.
Unit 1-B Uniongate, Ridgeway Trading Estate,
Volume 1
Iver,
Buckinghamshire SL0 9HX,
England
Registration 573951 England
Copyright© 2005
Cummins Inc.
V1
V2 V
V3
V4
V5
V6
V7
V8
Bulletin 4021419
Printed in U.S.A. 16-SEPTEMBER-2005 p147

Cummins Power Generation QSX15, QSK23, QSK45, QSK60, QSK78, QST30 Troubelshooting and Repair Specification

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Cummins Power Generation QSX15, QSK23, QSK45, QSK60, QSK78, QST30 Troubelshooting and Repair Specification

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Troubleshooting and Repair Manual

QSK60, QSK78 and QST30 Series Engines Volume 1

Copyright© 2005 Bulletin 4021419

Introduction 204 ....................................................................................................................................... i

Engine and System Identification ............................................................................................................ E

Troubleshooting Symptoms ..................................................................................................................... TS

Electronic Engine Controls - Group 19 .................................................................................................... 19

Electronic Engine Controls - Group 19 - Torque Values

Coolant Pressure Sensor (019-016)

V4 Engine Coolant Temperature Sensor (019-019)

V7 Electronic Control Module (ECM) (019-031)

Generator Control And Extension Harness 3 N•m [ 27 in-lb ]

Engine Position Sensor (EPS) (019-038)

Engine Speed Sensor (ESS) (019-042)

Engine Harness Ecm Connector 3 N•m [ 27 in-lb ]

V3 4 Mm [5/32 In] Hex Head Capscrew 3 N•m [ 27 in-lb ]

Qst30 Upgrade Engine Block Ground 20 N•m [ 177 in-lb ]

Fuel Shutoff Terminal Nut 3 N•m [ 27 in-lb ]

Engine Harness Cable Fastener 3 N•m [ 27 in-lb ]

Engine Harness Support Bracket 45 N•m [ 33 ft-lb ]

Datalink Connector Capscrews 1 N•m [ 9 in ]

Fuel Shutoff Valve Nuts 3 N•m [ 27 in-lb ]

Fuel Shutoff Valve (019-050)

Fuel Shutoff Valve Electrical Connection 3 N•m [ 27 in-lb ]

Lubricating Oil Level Sensor (019-056)

Intake Manifold Air Temperature Sensor (019-059)

Engine Oil Pressure Sensor (019-066)

Qsk23/45/60/78 Fueling Rail Actuator 25 N•m [ 221 in-lb ]

Timing Actuator (019-111)

Qsk23, Qsk45, Qsk60, And Qsk78 Timing 25 N•m [ 18 ft-lb ]

Fuel Timing Pressure Sensor (019-113)

V3 Fuel Pump Actuator (019-117)

Engine Fuel Temperature Sensor (019-119)

Oil Pressure/Temperature Sensor (019-155)

Intake Manifold Pressure/Temperature Sensor (019-159)

3/8 O-Ring Fitting 13.5 N•m [ 120 in-lb ]

V3 Timing Pressure Sensor (019-191)

Deutsch HDP20 and HD30 Connector Series (019-208)

Clamp Capscrews 1 N•m [ 9 in-lb ]

Rail Pressure Sensor (019-338)

Fuel Supply Pump Temperature Sensor (019-399)

All Temperature Sensors Torque = 15 N•m [133 in-lb]

All Temperature Sensors Torque = 15 N•m [133 in-lb]

Fuel Pressure Sensor Torque = 14 N•m [124 in-lb]

Intake Manifold Pressure Sensor Torque = 14 N•m [124 in-lb]

All Temperature Sensors Torque = 15 N•m [133 in-lb]

All Temperature Sensors Torque = 15 N•m [133 in-lb]

Fuel Pressure Sensor Torque = 14 N•m [124 in-lb]

Intake Manifold Pressure Sensor Torque = 14 N•m [124 in-lb]

Intake Manifold Pressure Sensor

Intake Manifold Pressure Sensor

All Temperature Sensors

Fuel Rail Pressure Sensor

Engine Position Sensor

Intake Manifold Pressure Sensor

Intake Manifold Pressure Sensor

All Temperature Sensors

Fuel Rail Pressure Sensor

Engine Position Sensor

ALL CONTINUITY CHECKS

V2 SHORT CIRCUIT TO EXTERNAL VOLTAGE V

Coolant or Intake Manifold Pressure Sensor

All Temperature Sensors

Engine Speed Sensor