QSKV 45/60 : Heads

CYLINDER HEAD – Familiarization

SCENE AUDIO
10000 QSK 45 and 60 engines utilize one head per cylinder. The seven bolt design head improves load clamping and therefore cylinder head durability.
10100 The cylinder head is taller to accommodate the QUANTUM fuel system. The air passages have been redesigned to improve fuel economy,
performance, and emissions.
10200 Replaceable valve guides install into the cylinder head.

The replaceable valve seat inserts install in the combustion face of the cylinder head.
10250 The cylinder head contains three integral fuel passages – timing, metering, and drain.
10300 The intake valves are made of triballoy while the exhaust valves have a stellite valve face.
10350 Both the intake and exhaust valves use rotators to improve the durability of the valves. These rotators index the valves slightly each time they are
opened.
10400 The seals installed on the top of the valve guides seal the valve stems and control the amount of oil lubricating the valve guide.
10500 The same part number single valve springs are used on both the intake and exhaust valves.
10550 A STORM fitting is installed in the coolant cavity.
10575 Each cylinder head has a metric port used for mounting the exhaust temperature sensors utilized with the optional CENSE engine system.
10600 The head gasket is a steel plate with edge molded seals around all of the oil passages, coolant passages, and capscrew holes.
10700 The redesigned rocker levers have new rocker lever ratios. The diameter of the rocker lever shaft increased to withstand the increased injection
pressures. The lubrite coating on the shafts improves rocker shaft wear. The exhaust lever is longer and bigger than the intake rocker lever to
withstand the cylinder pressures during the exhaust stroke of the engine. The injector rocker lever is made of forged steel.
10750 Both the intake and exhaust valve rocker levers use a pivot pad with a ball and socket joint to reduce wear.
10800 The stemless crossheads transfer the downward force from the valve rocker levers to the pairs of intake and exhaust valves for each cylinder.
10900 A port in each of the cast iron rocker lever covers provides a mounting for the single cylinder cutout tool.
15261 The push rods are longer due to the increased height of the cylinder head. The push rods also provide for improved socket joints.

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 QSKV 45/60 : Heads
CYLINDER HEAD – Troubleshooting & Repair
SCENE AUDIO
10000 In this section we will take a look at a few of the troubleshooting and repair procedures for the cylinder head.

Please click on the available section to continue. (generic clip C)

12000 Some troubleshooting, repair, and service procedures for the QSK 45 and 60 engines require specialized service tools. Although similar in
function with previous KV service tools, many of these tools have been redesigned to accommodate changes made on the QSK 45 and 60
engines. Service tools used when working on the components of the cylinder head include:

 Valve Setting Gauge

 Injector Puller
 Cylinder Cutout Tool
 Injection Timing Tool Adapter
 Cylinder Head Capscrew Length Gauge
 Valve Spring Compressor
 Valve Stem Seal Installation Tool
 0 to 34 Newton-meter torque wrench
 Lockplate Drivers

The use of some of these tools are covered in more detail in troubleshooting procedures in this section.
12100 The new wider valve adjustment feeler gauge is needed to ensure a proper fit between the rocker nose and the crosshead. However, this is the
same pivot pad design used on QSK19 engines.
12200 The Injector Puller is used to remove the injector from the QSK 45 and 60 engines. This puller fits the QSK 45 and 60 style injector. This injector
style is the same as the injector used on the QSK19 engine.
12500 The Cylinder Head Capscrew Length Gauge is a measuring device used to determine if a new longer cylinder head capscrew can be reused or if it
has been stretched beyond its usable length. Simply place the head of the capscrew on the notched end of the gauge and if the threaded end of the
capscrew touches the gauge it is stretched beyond its usable length and must be discarded.
12700 The valve spring compressor compresses all four of the valve springs so that the collets, retainers, and valve springs can be removed without
removing the cylinder head. This tool fits the new QSK 45 and 60 valve arrangement and uses the appropriate metric thread to match the cylinder
head.
13000 The Valve Stem Seal Installation Tool is used to properly seat the valve stem seals. The new style seals used on the QSK 45 and 60 engines are
the same as the seals used on the QSK19 engines.
13100 CYLINDER HEAD REMOVAL

In this section we will look at the procedure for removing and installing a cylinder head. Refer to the service literature for complete details on
these procedures.

Please click on the section you would like to learn about.

13200 Before beginning to remove a cylinder head, clean the top of the engine.
13300 Remove the lockplates from the exhaust manifold capscrews for the manifold section attached to the cylinder head being removed. Loosen the
capscrews on this section of the exhaust manifold. Remove the mounting capscrews for the exhaust manifold for the cylinder head being
removed.
13500 With the cooling system drained, remove the air crossover and aftercooler assembly. This must be removed to gain access to the fuel manifold.
13600 Remove the fuel lines from each end of the fuel manifold. Remove the four capscrews attaching the fuel manifold to each cylinder head.
13610 Remove any remaining debris around the cylinder head that is being removed.
13620 Remove the rocker cover and rocker levers for the cylinder head being removed. Take care not to drop the pivot pad from the end of the rocker
levers. Remove the crossheads and push rods.
Remove the injector and holddown clamp from the engine.
13625 Using the water tube driver, push the tubes on the left bank toward the front of the engine and push the tubes on the right bank toward the rear of
the engine.
13630 Remove the rocker lever housing and discard the gasket.
13640 Remove the seven cylinder head mounting capscrews and remove the cylinder head. Remove and discard the cylinder head gasket.
13650 Clean the top of the cylinder block, cylinder liners, and capscrew holes.
13655 Refer to the service literature for additional information concerning cylinder head inspection.
13660 When installing the cylinder head, use the torque plus turn procedure and steps listed in the service literature.
13670 The capscrews connecting the fuel manifold to the fuel transfer block are slightly longer than the other fuel manifold capscrews. The fuel
manifold gaskets must be held in position with 2 capscrews per gasket. When installing the fuel manifold, it must be torqued to the cylinder heads
in the proper sequence before tightening the connection between the manifold and the fuel transfer manifold block.
13680 Install the remaining components removed for this procedure.
14000 OVERHEAD SET

Two crankshaft revolutions are required to adjust all of the valves and injectors. Both intake and exhaust valves for one cylinder and the injector
for another cylinder are adjusted at same index mark before rotating the crankshaft to the next mark.

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 QSKV 45/60 : Heads
CYLINDER HEAD – Troubleshooting & Repair
SCENE AUDIO
14200 On the left bank of QSK 45 and 60 engines, the exhaust valves are toward the front of each cylinder and the intake valves are toward the rear of
the cylinder. On the right bank this pattern reverses, with the intake valves toward the front of each cylinder and the exhaust valves toward the
rear.
14300 The engine timing marks are located on the vibration damper. These marks align with a pointer on the front cover to indicate engine position.

Timing marks are also located on the inboard side of the flywheel. These marks are visible through the access port directly above the engine
barring device installed on the flywheel housing on the side of the engine opposite the starter. “A” timing marks on the flywheel are used when
the access port is on the right side of the engine and “C” timing marks are used when the access port is on the left side of the engine. The “A” and
“C” letters are visible through the inspection ports.
14400 VS marks indicate valve set positions. TDC marks indicate top dead center and are not used in the valve and injector setting procedure.
14500 Use the barring device and rotate the engine until one of the timing marks is aligned with the indicator.

Although valve setting can begin with any cylinder, for this example we will assume that we will start with cylinder 6 on the left bank of the
engine.
14600 The valves are ready to be adjusted on the cylinder with all of the valves closed. If the valves have been previously adjusted, check the rocker
levers on both cylinders indicated by the timing mark to see which set of rockers are loose. Loose rocker levers indicate the valves are closed.
14650 However, if the rocker levers have just been installed and have not been adjusted, hold both rocker levers for each of the indicated cylinders
against the crosshead. Turn down each of the adjusting screws until it touches the push rod. The cylinder that has the push rods approximately the
same height is ready for valve adjustment.
14800 To adjust the valves, select a feeler gauge for the correct intake valve lash specification. New wider feeler gauges are used on QSK 45 and 60
engines to ensure good contact between the movable rocker lever pivot pad and the feeler gauge. Insert the gauge between the pad of the intake
rocker lever and the crosshead.
14900 The “torque” method or the “feel” method may be utilized. Refer to the service literature for more details
15000 Hold the adjusting screw in position and tighten the locknut. Torque the locknut to specification. Remove the feeler gauge. If the gauge cannot be
removed the lash is too tight.
15100 Repeat the setting procedure, using the correct feeler gauge, for the exhaust rocker lever.
15200 INJECTOR ADJUSTMENT

Refer to the valve and injector adjustment chart to determine the proper VS mark to adjust the injector for each cylinder. If the screw chatters
during injector setting, repair the screw and lever as required.
15300 Be sure the parts of the injection train are in alignment and squeeze the oil out of the injector by tightening the adjusting screw to the value shown
in the service literature specification.
15400 Loosen the adjusting screw at least one full revolution. Tighten the adjusting screw again to the final setting listed in the service literature.
15700 Hold the adjusting screw in position and tighten the locknut. Torque the locknut to specification.
15900 Rotate the engine to the next setting position and continue until all of the valves and injectors have been set.