Troubleshooting and Repair Manual QSK23 Series Engines

18/05/12

QuickServe Online | (4021375) QSK23 Troubleshooting and Repair Manual

T o ble hoo ingandRepai Man alQSK23Se ie Engine

B lle inN mbe 4021375 11/03Copyright 20002010CumminsInc.Allrightsreserved.

https://quickserve.cummins.com/qs2/portal/service/manual/en/4021375/

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ForewordThismanualprovidesinstructionsfortroubleshootingandrepairingthisengineinthechassis. Componentandassemblyrebuildproceduresareprovidedintheengineshopmanual.Refer toSectioniIntroductionforinstructionsonhowtousethismanual. Readandfollowallsafet instructions.RefertotheWARNINGintheGeneralSafet InstructionsinSectioniIntroduction. Themanualisorganizedtoguideaservicetechnicianthroughthelogicalstepsofidentifying andcorrectingproblemsrelatedtotheengine.Thismanualdoesnotcovervehicleor equipmentproblems.Consultthevehicleorequipmentmanufacturerforrepairprocedures. Aseriesofspecificservicemanuals(forexample:Shop,Specifications,andAlternative Repair)areavailableandcanbeorderedbyContactingyourlocalareaCumminsRegional office.ACumminsRegionalofficelistingislocatedinServiceLiterature(SectionL). TherepairproceduresusedinthismanualarerecommendedbyCumminsInc.Someservice proceduresrequiretheuseofspecialservicetools.Usethecorrecttoolsasdescribed. CumminsInc.encouragestheuserofthismanualtoreporterrors,omissions,and recommendationsforimprovement.Pleaseusethepostagepaid,preaddressedLiterature SurveyForminthebackofthismanualforcommunicatingyourcomments. Thespecificationsandrebuildinformationinthismanualarebasedontheinformationin effectatthetimeofprinting.CumminsInc.reservestherighttomakeanychangesatanytime withoutobligation.Ifdifferencesarefoundbetweenyourengineandtheinformationinthis manual,contactaCumminsAuthorizedRepairLocationorcall1800DIESELS(1800343 7357)tollfreeintheU.S.andCanada. ThelatesttechnologyandthehighestqualitycomponentsareusedtomanufactureCummins engines.Whenreplacementpartsareneeded,werecommendusingonlygenuineCummins orReConexchangeparts.LastModified:22Ma 2006Copyright 20002010CumminsInc.Allrightsreserved.


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204002Abo heMan al

Gene alInfo ma ionThisTroubleshootingandRepairManualisintendedtoaidindeterminingthecauseof enginerelatedproblemsandtoproviderecommendedrepairprocedures. Themanualisdividedintosections.Eachsectionisequivalenttoagroupusedin Cummins'filmcardsystem.Somesectionscontain efe encenumbersandp oced e numbers.Refe encenumbersprovidegeneralinformation,specifications,diagrams, andservicetoolswhereapplicable.P oced enumbersareusedtoidentifyand referencespecificrepairproceduresforcorrectingtheproblem. Thismanualdoe no containfuelsystemselectronictroubleshooting.Usethe troubleshootingtreesinthismanual,iftherearenoelectronicfaultcodes. Thismanualisdesignedsothetroubleshootingtreesareusedtolocatethecauseofan engineproblem.Thetroubleshootingtreesthendirecttheusertothecorrectrepair procedure.Therepairprocedureswithinasectionareinnumericalorder.However,the repairstepswithinagivenprocedureareorganizedintheordertherepairm be performedregardlessofthenumericalorderofthesteps.Theuserm usethe contentspagesortheindexatthebackofthemanualtolocatespecifictopicswhenno usingthetroubleshootingtrees.

La Modified:22A g2011Copyright 20002010CumminsInc.Allrightsreserved.


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204003Ho toUsetheManual

GeneralInformationThismanualisorganizedtoprovideaneasyflowfromproblemidentificationtoproblem correction. Alistoftroubleshootingsymptomscontainingthemostcommonproblemsisinthe TroubleshootingSymptoms,Section(TS).Themanualisdesignedtousethe TroubleshootingSymptomsasaguidetolocatingtheproblemanddirectingtheend usertothecorrectprocedureformakingtherepair.Completethefollowingstepsto locateandcorrecttheproblem. 1. LocatethesymptomontheSectionContentspagesofSectionTS. ReferencetothepagenumberwheretheTroubleshootingSymptomTreeis foundismadetotherightofthesymptomtreetitle. 2. TheleftcolumnofboxesintheTroubleshootingSymptomChartsindicatesa probablecauseoftheproblem,startingatthetopwiththesimplestandeasiestto repair,andcontinuingdownwardtothemostdifficult. Therightcolumnofboxesprovidesabriefdescriptionofthecorrectiveaction withareferencenumbertothecorrectprocedureusedtomaketherepair. 3. Locatetheprobablecauseintheleftcolumnthenturntotheprocedurereferenced intherightcolumn. 4. TheTroubleshootingSymptomChartsarebasedonthefollowingassumptions: Thecomponentshavebeeninstalledaccordingtothemanufacturer's specifications. Theeasiestrepairsaredonefirst. Allgenericsolutionsaredesignedforthemostcommonapplicationsand OriginalEquipmentManufacturer(OEM). RefertotheOriginalEquipmentManufacturer'sservicemanualfortheirspecifications.

LastModified:21Mar2012Copyright 20002010CumminsInc.Allrightsreserved.


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204004S mbols

GeneralInformationThefollowingsymbolshavebeenusedinthismanualtohelpcommunicatetheintentof theinstructions.Whenoneofthesymbolsappears,itconveysthemeaningdefined below:



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204005Ill

a ion

Gene alInfo ma ionSomeoftheillustrationsthroughoutthis manualaregenericandwillno look exactlyliketheengineorpartsusedin yourapplication.Theillustrationscan containsymbolstoindicateanaction requiredandanacceptableorno acceptablecondition.

Theillustrationsareintendedtoshow repairorreplacementprocedures.The procedurewillbethesameforall applications,althoughtheillustrationcan differ.

La Modified:12Ma 2002Copyright 20002010CumminsInc.Allrightsreserved.


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204006GeneralSafet Instructions

ImportantSafet Notice WARNINGI , R .T . W , .S , , , , . must , . ) NotO .B , " .T , ' . . , . , ,

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. Alwa s R , D not .R D ( [] .D .P "D . U ONLY D not , ( ) . I . Alwa s .D not . R , , , ,

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pressurewhendisconnectinganydevicefromasystemthatutilizespressure.Do notcheckforpressureleakswithyourhand.Highpressureoilorfuelcancause personalinjury. Toreducethepossibilityofsuffocationandfrostbite,wearprotectiveclothingand ONLYdisconnectliquidrefrigerant(Freon)linesinawellventilatedarea.To protecttheenvironment,liquidrefrigerantsystemsmustbeproperlyemptiedand filledusingequipmentthatpreventsthereleaseofrefrigerantgas(fluorocarbons) intotheatmosphere.Federallawrequirescapturingandrecyclingrefrigerant. Toreducethepossibilityofpersonalinjury,useahoistorgetassistancewhen liftingcomponentsthatweigh23kg[50lb]ormore.Makesureallliftingdevices suchaschains,hooks,orslingsareingoodconditionandareofthecorrect capacity.Makesurehooksarepositionedcorrectly.Alwa suseaspreaderbar whennecessary.Theliftinghooksmustnotbesideloaded. Corrosioninhibitor,acomponentofSCAandlubricatingoil,containsalkali.Do notgetthesubstanceineyes.Avoidprolongedorrepeatedcontactwithskin.Do notswallowinternally.Incaseofcontact,immediatelywashskinwithsoapand water.Incaseofcontact,immediatelyfloodeyeswithlargeamountsofwaterfora minimumof15minutes.IMMEDIATELYCALLAPHYSICIAN.KEEPOUTOF REACHOFCHILDREN. NapthaandMethylEthylKetone(MEK)areflammablematerialsandmustbe usedwithcaution.Followthemanufacturer'sinstructionstoprovidecomplete safetywhenusingthesematerials.KEEPOUTOFREACHOFCHILDREN. Toreducethepossibilityofburns,bealertforhotpartsonproductsthathavejust beenturnedoff,exhaustgasflow,andhotfluidsinlines,tubes,andcompartments. Alwa susetoolsthatareingoodcondition.Makesureyouunderstandhowto usethetoolsbeforeperforminganyservicework.UseONLYgenuineCummins orCumminsReCon replacementparts. Alwa susethesamefastenerpartnumber(orequivalent)whenreplacing fasteners.Donotuseafasteneroflesserqualityifreplacementsarenecessary. Whennecessary,theremovalandreplacementofanyguardscoveringrotating components,drives,and/orbeltsshouldonlybecarriedoutbeatrained technician.Beforeremovinganyguardstheenginemustbeturnedoffandany startingmechanismsmustbeisolated.Allfastenersmustbereplacedonrefitting theguards. Donotperformanyrepairwhenfatiguedorafterconsumingalcoholordrugsthat canimpairyourfunctioning. SomestateandfederalagenciesintheUnitedStatesofAmericahavedetermined thatusedengineoilcanbecarcinogenicandcancausereproductivetoxicity. Avoidinhalationofvapors,ingestion,andprolongedcontactwithusedengineoil. Donotconnectthejumperstartingorbatterychargingcablestoanyignitionor governorcontrolwiring.Thiscancauseelectricaldamagetotheignitionor governor. Alwa storquefastenersandfuelconnectionstotherequiredspecifications. Overtighteningorundertighteningcanallowleakage.Thisiscriticaltothenatural gasandliquefiedpetroleumgasfuelandairsystems. Alwa stestforfuelleaksasinstructed,asodorantcanfade. Closethemanualfuelvalvespriortoperformingmaintenanceandrepairs,and whenstoringthevehicleinside.


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Coolantistoxic.Ifno reused,disposeofinaccordancewithlocalenvironmental regulations. Thecatalystreagentcontainsurea.Dono getthesubstanceinyoureyes.Incase ofcontact,immediatelyfloodeyeswithlargeamountsofwaterforaminimumof15 minutes.Avoidprolongedcontactwithskin.Incaseofcontact,immediatelywash skinwithsoapandwater.Dono swallowinternally.Intheeventthecatalyst reagentisingested,contactaphysicianimmediately. ThecatalystsubstratecontainsVanadiumPentoxide.VanadiumPentoxidehas beendeterminedbytheStateofCaliforniatocausecancer.Alwayswear protectiveglovesandeyeprotectionwhenhandlingthecatalystassembly.Donot getthecatalystmaterialinyoureyes.InCaseofcontact,immediatelyfloodeyes withlargeamountsofwaterforaminimumof15minutes.Avoidprolongedcontact withskin.Incaseofcontact,immediatelywashskinwithsoapandwater. TheCatalystsubstratecontainsVanadiumPentoxide.VanadiumPentoxidehas beendeterminedbytheStateofCaliforniatocausecancer.Intheeventthe catalystisbeingreplaced,disposeofinaccordancewithlocalregulations. CaliforniaProposition65WarningDieselengineexhaustandsomeofits constituentsareknowntotheStateofCaliforniatocausecancer,birthdefects, andotherreproductiveharm.

La Modified:25Jan2010Copyright 20002010CumminsInc.Allrightsreserved.


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204007Gene alRepai In

c ion

Gene alInfo ma ionT , .

WARNINGC B 1. A 2. A 3. A 4. B 5. C 6. F 7. F 8. F 9. F 10. F 11. F 12. F 13. F 14. F 15. L 16. T 17. T 18. T 19. T 20. T 21. V 22. M I C C S . C S I : .I , .

A W F H A M B M C H S C M S S B C A T

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23. HighVoltageInterlockLoop 24. HighVoltageConnectors/ConnectionsandHarnesses 25. HighVoltageBatterySystem 26. PowerInverter 27. GeneratorMotor 28. ClutchPressurePlate Followallsafetyinstructionsnotedintheprocedures Followthemanufacturer'srecommendationsforcleaningsolventsandother substancesusedduringrepairs.Somesolventshavebeenidentifiedby governmentagenciesastoxicorcarcinogenic.Avoidexcessivebreathing, ingestionandcontactwithsuchsubstances.Alwa susegoodsafetypractices withtoolsandequipment Provideacleanenvironmentandfollowthecleaninginstructionsspecifiedinthe procedures Allcomponentsmustbekeptcleanduringanyrepair.Contaminationofthe componentswillcauseprematurewear. Performtheinspectionsspecifiedintheprocedures Replaceallcomponentsorassemblieswhicharedamagedorwornbeyondthe specifications UsegenuineCumminsneworReCon servicepartsandassemblies Theassemblyinstructionshavebeenwrittentouseagainasmanycomponents andassembliesaspossible.Whenitisnecessarytoreplaceacomponentor assembly,theprocedureisbasedontheuseofnewCumminsorCummins ReCon components.Alloftherepairservicesdescribedinthismanualare availablefromallCumminsDistributorsandmostDealerlocations. Followthespecifieddisassemblyandassemblyprocedurestoreducethe possibilityofdamagetothecomponents

WeldingonaVehiclewithanElectronicControlled FuelS stem CAUTIONDisconnectboththepositive(+)andnegative()batterycablesfromthebattery beforeweldingonthevehicle.Attachtheweldergroundcablenomorethan0.61 meters[2feet]fromthepartbeingwelded.Donotconnectthegroundclampofthe weldertoanyofthesensors,wiringharness,electroniccontrolunitsorthe components.Directweldingofanyelectroniccomponentsmustnotbeattempted. Sensors,wiringharness,andelectroniccontrolunitshouldberemovedifnearby weldingwillexposethesecomponentstotemperaturesbeyondnormaloperation.


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Additionally,allelectroniccontrolunitconnectorsmustbedisconnected

LastModified:08Ma 2012Copyright 20002010CumminsInc.Allrightsreserved.


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204008Gene alCleaningIn

c ion

Defini ionofCleanPartsm befreeofdebristhatcancontaminatean engines stem.Thisdoesno necessaril meanthe havetoappearasnew. Sandinggasketsurfacesuntilthefactor machiningmarksaredisturbedaddsnovalue andisoftenharmfultoformingaseal.Itisimportanttomaintainsurfacefinishand flatnesstolerancestoformaqualit sealingsurface.Gasketsaredesignedtofillsmall voidsinthespecifiedsurfacefinish. Sandinggasketsurfaceswhereedgemoldedgasketsareusedismostoften unnecessar .Edgemoldedgasketsarethosemetalcarrierswithsealingmaterial bondedtotheedgesofthegaskettosealwhilethemetalportionformsametaltometal jointforstabilit .An ofthesmallamountsofsealingmaterialthatcansticktotheparts arebetterremovedwithabluntedgedscraperonthespotsratherthanspendingtime polishingthewholesurfacewithanairsanderordisc. Forthosegasketsthatdono havetheedgemolding,nearl allhaveamaterialthat containsreleaseagentstopreventsticking.Certainl thisisno tosa thatsome gasketsareno difficulttoremovebecausethegaskethasbeeninplacealongtime, hasbeenoverheatedorthepurposeofthereleaseagenthasbeendefeatedb the applicationofsomesealant.Theobjecthoweverisjusttoremovethegasketwithout damagingthesurfacesofthematingpartswithoutcontaminatingtheengine(don'tlet thelittlebitsfallwherethe cannotberemoved). Beadblastingpistoncrownsuntilthedarkstainisremovedisunnecessar .Allthatis requiredistoremovethecarbonbuildupabovethetopringandintheringgrooves. Thereismoreinformationonbeadblastingandpistoncleaninglaterinthisdocument. CumminsInc.doesno recommendsandingorgrindingthecarbonringatthetopof c linderlinersuntilcleanmetalisvisible.Thelinerwillberuinedandan signsofa problematthetopringreversalpoint(likeadustout)willbedestro ed.Itisnecessar to removethecarbonringtoprovideforeasierremovalofthepistonassembl .Amedium bristle,highqualit ,steelwirewheelthatisratedabovetherpmofthepowertoolbeing usedwillbejustasquickandtherewillbelessdamage.Yes,onem lookcarefull forbrokenwiresafterthepistonisremovedbutthewiresaremorevisibleandcanbe


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(engine opped),b la ge han he nningclea ance hendamage illocc hen hepa mo e ela i e oeacho he (engine a ed).While heenginei nningand he ei oilp e e,pa icle ha a e malle han hebea ingclea ancea elikel o pa be een hepa i ho damageandbe appedin heoilfil e .Ho e e , pa icle la ge han hebea ingclea ance ill emo ema e ialf omonepa andcan becomeembeddedinoneof hepa .Onceembeddedinonepa i illab ade he o he pa n ilcon ac i nolonge beingmadebe een he opa .If hedamage fficien l deg ade heoilfilm, he opa illcomein ocon ac e l inginea l ea o o fail ef omlackofeffec i el b ica ion. Ab a i epa icle canfl abo d ingcleaningi i ver impo an oblock he e pa icle f omen e ing heenginea m cha po ible.Thi i pa ic la l eof l b ica ingoilpo andoild illinghole ,e peciall ho eloca eddo n eamof he l b ica ingoilfil e .Pl g hehole in eadof ing oblo heab a i epa icle and deb i i hcomp e edai beca e hedeb i i of en impl blo nf he in o heoil d illing. Alloldga ke ma e ialmustbe emo edf om hepa ga ke face .Ho e e ,i i notnece a ocleanandpoli h hega ke face n il hemachiningma k a e e a ed.E ce i e andingo b ffingcandamage hega ke face.Man ne e ga ke a eof heedgemolded pe(a eelca ie i ha ealingmembe bonded o he eel).Wha li le ealingma e ial ha canadhe ei be emo ed i habl n edged c ape o p knife.Cleaningga ke face he eanedgemoldedga ke i ed i hab a i epad o pape i all a a eof ime.

WARNINGE ce i e andingo g inding heca bon ingf om he opof hec linde line can damage heline be ond e e.The facefini h illbedamagedandab a i e pa icle canbefo cedin o heline ma e ial hichcanca eea l c linde ea o o pi on ingfail e . Tapeoffo pl gallopening oan componen in e io befo e ingab a i epad o i eb he .If eall nece a beca eof ime o eapo e ool i hab a i e pad , ape heoild illing clo edo epl gandcleana m chof he facea po ible i h he oolb cleana o nd heoilhole/openingb hand oa op e en con amina ionof hed illing.Then emo e he apeo pl gandclean he emaining a eaca ef ll and i ho he ool.DONOT ecomp e edai oblo hedeb i o ofoild illingonana embledengine!Mo elikel hannot, hedeb i canbeblo n f he in o hed illing.U ingcomp e edai i fineifbo hend of hed illinga eopen b ha i a el heca e hendealing i hana embledengine.

GasketSurfaces


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Theobjectofcleaninggasketsurfacesistoremoveanygasketmaterial,notrefinishthe gasketsurfaceofthepart. CumminsInc.doesnotrecommendanyspecificbrandofliquidgasketremover.Ifa liquidgasketremoverisused,checkthedirectionstomakesurethematerialbeing cleanedwillnotbeharmed. Airpoweredgasketscraperscansavetimebutcaremustbetakentonotdamagethe surface.Theangledpartofthescrapermustbeagainstthegasketsurfacetopreventthe bladefromdiggingintothesurface.Usingairpoweredgasketscrapersonpartsmadeof softmaterialstakesskillandcaretopreventdamage. Donotscrapeorbrushacrossthegasketsurfaceifatallpossible.

Sol entandAcidCleaningSeveralsolventandacidtypecleanerscanbeusedtocleanthedisassembledengine parts(otherthanpistons.SeeBelow).Experiencehasshownthatthebestresultscan beobtainedusingacleanerthatcanbeheatedto90 to95 Celsius(180 to200 Fahrenheit).Keroseneemulsionbasedcleanershavedifferenttemperature specifications,seebelow.Acleaningtankthatprovidesaconstantmixingandfiltering ofthecleaningsolutionwillgivethebestresults.CumminsInc.doesnotrecommend anyspecificcleaners.Alwaysfollowthecleanermanufacturer'sinstructions.Removeall thegasketmaterial,orings,andthedepositsofsludge,carbon,etc.,withawirebrushor scraperbeforeputtingthepartsinacleaningtank.Becarefulnottodamageanygasket surfaces.Whenpossible,steamcleanthepartsbeforeputtingtheminthecleaningtank.

WARNINGWhenusingsolvents,acids,oralkalinematerialsforcleaning,followthe manufacturersrecommendationsforuse.Weargogglesandprotectiveclothingto reducethepossibilityofpersonalinjury. Experiencehasshownthatkeroseneemulsionbasedcleanersperformthebestto cleanpistons.Thesecleanersshouldnotbeheatedtotemperatureinexcessof77 C (170 F).Thesolutionbeginstobreakdownattemperaturesinexcessof82 C(180 F) andwillbelesseffective. Donotusesolutionscomposedmainlyofchlorinatedhydrocarbonswithcresols, phenolsand/orcresyliccomponents.Theyoftendonotdoagoodjobofremoving depositsfromtheringgrooveandarecostlytodisposeofproperly.https://quickserve.cummins.com/qs2/portal/service/manual/en/4021375/ 4/9

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Sol ion i hapHabo eapp o ima el 9.5 illca he efo edono ehighalkaline ol ion .

eal min m o

nblack

Chemical i hapHabo e7.0a econ ide edalkalineand ho ebelo 7.0a eacidic. A o mo ef he a a f om hene al7.0, hechemical becomehighl alkalineo highl acidic. Remo eall hega ke ma e ial,o ing ,and hedepo i of l dge,ca bon,e c., i ha i eb ho c ape befo ep ing hepa inacleaning ank.Beca ef l ono damagean ga ke face .Whenpo ible eho highp e e a e o eam clean hepa befo ep ing hemin hecleaning ank.Remo ing hehea ie di befo eplacingin he ank illallo hecleane o o kmo eeffec i el and he cleaningagen illla longe . Rin eall hepa inho a e af e cleaning.D comple el i hcomp e he in e a e f omall hecap c e hole and heoild illing . edai .Blo

If hepa a eno obe edimmedia el af e cleaning,dip hemina i able p oofingcompo nd.The p oofingcompo ndm be emo edf om hepa befo ea embl o in alla ionon heengine.

S eamCleaningS eamcleaningcanbe ed o emo eall pe ofdi ha cancon amina e he cleaning ank.I i agoodme hodfo cleaning heoild illing andcoolan pa age

WARNINGWhen inga eamcleane , ea afe gla e o aface hield,a ella p o ec i eclo hing.Ho eamcanca e e io pe onalinj . Dono eamclean hefollo ingcomponen : Elec icalComponen Wi ingHa ne e Injec o F elP mp Bel andHo e Bea ing (ballo ape olle ) Elec onicCon olMod le(ECM) ECMConnec o


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D C NO S

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outmorequickly.Thefollowingguidelinescanbeusedtoadapttomanufacturer's instructions: 1. Beadsize:U.S.sizeNumber16 20forpistoncleaningwithplasticbeadmedia, PartNumber3822735 2. OperatingPressure 270kPa(40psi)forpistoncleaning.Pressureshouldnot causebeadstobreak. 3. Steamcleanorwashthepartswithsolventtoremovealloftheforeignmaterial andplasticbeadsaftercleaning.Rinsewithhotwater.Drywithcompressedair.

CAUTIONThebeadblastingoperationmustnotdisturbthemetalsurface.Ifthemetalsurfaceis disturbedtheenginecanbedamagedduetoincreasedpartsclearanceor inadequatesurfacefinishonpartsthatmoveagainstotherparts. Whencleaningpistons,itisnotnecessarytoremoveallthedarkstainfromthepiston. Allthatisnecessaryistoremovethecarbonontherimandintheringgrooves.Thisis bestdonebydirectingtheblastacrossthepartasopposedtostraightatthepart.Ifthe machiningmarksaredisturbedbytheblastingprocess,thenthepressureistoohighor theblastisbeingheldononespottoolong.Theblastoperationmustnotdisturbthe metalsurface. Walnutshellbeadblastmaterialissometimesusedtocleanferrousmetals(ironand steel).Walnutshellblastingproducesagreatamountofdustparticularlywhenthe pressureiftheairpressureontheblastingmachineisincreasedabovemedia manufacturer'srecommendation.CumminsInc.recommendsnotusingwalnutshell mediatocleanenginepartsduetotheriskmediaembedmentandsubsequent contaminationoftheengine. CumminsInc.nowrecommendsglassbeadmediaNOTusedtocleananyengineparts. Glassmediaistooeasilyembeddedintothematerialparticularlyinsoftmaterialsand whenairpressuresgreaterthanmediamanufacturer'srecommendareused.Theglass isanabrasivesowhenitisinamovingpart,thatpartisabradingallthepartsincontact withit.Whenhigherpressuresareusedthemediaisbrokenandformsadustofavery smallsizethatfloatseasilyintheair.Thisdustisveryhardtocontrolintheshop, particularlyifonl compressedair(andnothotwater)isusedtoblowthemediaafterit isremovedfromtheblastingcabinet(blowingthepartoffinsidethecabinetmayremove largeaccumulationsbutneverremovesallthemedia). Beadblastingisbestusedonstubborndirt/carbonbuildupthathasnotbeenremoved byfirststeam/higherpressurewashingthenwashinginaheatedwashtank.Thisis particularlytrueofpistons.Steamandsoakthepistonsfirstthenusetheplasticbead methodtosafelyremovethecarbonremaininginthegrooves(insteadofrunningthe riskofdamagingthesurfacefinishofthegroovewithawirewheelorendofabroken pistonring.Makesurethepartsaredryandoilfreebeforebeadblastingtoprevent cloggingthereturnontheblastingmachine.


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Alwa s " " .K .K .R .I not / Never .D .T . .T

.T not .

FuelS stemW , T H . E C C , W F . , .T , / .T , .I , , 76 . [0.003 ] , . , , .R , . .D , not .U .S , .I . . , , , not ,

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diameter.Onemicronmeasures0.001mm[0.00004in.].Thecontaminantsbeing filteredoutaresmallerthancanbeseenwiththehumaneye,amagnifyingglass,ora lowpoweredmicroscope. Thetoolsusedforfuelsystemtroubleshootingandrepairaretobecleanedregularlyto avoidcontamination.Likefuelsystemparts,toolsthatarecoatedwithoilorfuelattract airbornecontaminants.Rememberthefollowingpointsregardingyourfuelsystemtools: Fuelsystemtoolsaretobekeptascleanaspossible. Cleananddrythetoolsbeforereturningthemtothetoolbox. Ifpossible,storefuelsystemtoolsinsealedcontainers. Makesurefuelsystemtoolsarecleanbeforeuse.

La Modified:27Jan2012Copyright 20002010CumminsInc.Allrightsreserved.


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204009AcronymsandAbbreviations

GeneralInformationThefollo ingli con ain omeof heac on m andabb e ia ion ANSI API ASTM BTU BTDC C CO CCA CARB C.I.B. C.I.D. CNG CPL cSt DEF DOC DPF ECM EFC EGR EPA Ame icanNa ionalS anda d In i Ame icanPe ole mIn i e e edin hi man al.

Ame icanSocie ofTe ingandMa e ial B i i hThe malUni Befo eTopDeadCen e Cel i Ca bonMono ide ColdC ankingAmpe e Califo niaAi Re o ce Boa d C ome In e faceBo

C bicInchDi placemen Comp e edNa Li alGa

Con olPa Cen i oke Die elE ha

Fl id

Die elO ida ionCa al Die elPa ic la eFil e EngineCon olMod le Elec onicF elCon ol E ha Ga Reci c la ion

En i onmen alP o ec ionAgenc


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F ftlb FMI GVW Hg hp H2O inHg inH20 ICM IEC km/l kPa LNG LPG LTA MIL MPa mph mpq N m NOx NG O2 OBD OEM OSHA PID ppm psi PTO REPTO

Fahrenheit FootPoundForce FailureModeIndentifier GrossVehicleWeight Mercur Horsepo er Water InchesofMercur InchesofWater IgnitionControlModule InternationalElectrotechnicalCommission KilometersperLiter Kilopascal LiquidNaturalGas LiquifiedPetroleumGas Lo TemperatureAftercooling MalfunctionIndicatorLamp Megapascal MilesPerHour MilesPerQuart Ne tonmeter MonoNitrogenO ides NaturalGas O gen OnBoardDiagnostics OriginalEquipmentManufacturer OccupationalSafet andHealthAdministration ParameterIdentificationDescriptions PartsPerMillion PoundsPerSquareInch Po erTakeoff RearPo erTakeOff


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RGT pm SAE SCA SCR STC SID VDC VS VSS

RearGearTrain RevolutionsPerMinute SocietyofAutomotiveEngineers SupplementalCoolantAdditive SelectiveCatalyticReduction StepTimingControl SubsystemIdentificationDescriptions VoltsofDirectCurrent VariableSpeed VehicleSpeedSensor

La Modified:30Ap 2012Copyright 20002010CumminsInc.Allrightsreserved.


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100001EngineIden ifica ion

C mmin EngineNomenclaThemodelnameprovidesidentification datafortheengine.Refertotheillustration forthemodelnameidentification. Theapplicationscodesare: A=Agricultural C=Construction D=Generatordrive F=Firepump G=Generatorset L=Locomotive M=Marine P=Powerunit R=Railcar T=Tacticalmilitar .

e

EngineDa apla eTheenginedataplateshowsspecific informationabouttheengine.Theengine serialnumber(ESN),ControlPartsList (CPL),model,horsepowerandrpmratings ,andEnvironmentalProtectionAgenc


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(EPA)info ma ionp o ideinfo ma ionfo o de ingpa and e iceneed . Theengineda apla em no be changed nle app o edb C mmin Inc.

F elP mpDa apla eThef elp mpda apla ei loca edon he opof hef elp mp.I p o ide info ma ionfo f elp mpcalib a ion.

ECMDa apla eThee e nalECMda apla ei loca edon opof heECM. Theda apla econ ain hefollo ing: ECMpa n mbe (P/N) ECM e ialn mbe (S/N) Man fac e da ecode(D/C)


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Supplieridentifier(S/I) InputvoltageratingoftheECM (V/R). Thedataplateontherightcontainsengine andcalibrationinformation.Thisincludes theengineserialnumber(ESN),ECM calibrationdate(Date),andECM calibrationcode.

La Modified:14Ap 2003Copyright 20002010CumminsInc.Allrightsreserved.


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Vie Rela edTopic

100002EngineDiagrams

EngineViewsTheill a ion ho heloca ion of hemajo e e nalenginecomponen ,fil e , ando he e iceandmain enancepoin .Somee e nalcomponen illbea diffe en loca ion fo diffe en enginemodel .

Lef SideInd

ial

1. G idhea e (Ind ialonl ) 2. G idhea e ela (Ind ialonl ) 3. F elfil e 4. F elinle ( ofil e ) 5. F elinle ( oECVA) 6. Ai in akeconnec ion(Ind ialonl )


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7. Fueltimingsuppl 8. Fuelpipe(tofuelrail) 9. Fuelpipe(return) 10. Fuelpipe(forinjectiontiming) 11. Fuelrailsuppl 12. Camfollowercover 13. OEMelectricalconnections(Industrialonl ) 14. Oilpressurecheckpoint(afterfilters) 15. Oilpressurecheckpoint(beforefilters) 16. Enginebarringdevice 17. Oilfilters 18. ECVA/ECM 19. Wiringharness 20. Oilfillport 21. Fuelraildampeninghose 22. Engineoildrainvalve 23. Oillevelsensor(optional) 24. Dipstick 25. Blowb tube 26. Fuelpump 27. Fuelpumppressuresensor 28. Oilpressurecheckpoint(tofrontidlergears) 29. Fuelpumpactuator 30. Oilpressuresensor 31. Fuelpipe(pumptoECVA) 32. Fuelpipe(filterstopump) 33. Alternator 34. Intakemanifoldpressuresensor(Industrialonl ) 35. Intakemanifoldtemperaturesensor(Industrialonl ) 36. Refrigerantcompressormountinglocation 37. Coolantfilter(Industrialonl ) 38. Crankcasebreatherassembl .


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Lef SidePo e Gene a ion

1. In akemanifold(Po e Gene a iononl ) 2. C ankca eb ea he 3. In akemanifoldp e e en o (Po e Gene a iononl ) 4. In akemanifold empe a e en o (Po e Gene a iononl ) 5. Coolan fil e (Po e Gene a iononl ) 6. InlineBconnec o (Po e Gene a iononl ) 7. InlineAconnec o (Po e Gene a iononl ) 8. InlineCconnec o (Po e Gene a iononl ) 9. Da alinkconnec o (Po e Gene a iononl ) 10. Engine peed en o (Po e Gene a iononl ) 11. Oilp e echeckpoin (af e fil e ) 12. Oilp e echeckpoin (befo efil e ) 13. F el imingp e e en o 14. F el ailp e e en o 15. Wi ingha ne 16. Ba ome icp e e en o 17. F el aildampeningho e 18. F el ailac a o 19. F el h off al e 20. F el empe a e en o 21. F el imingac a o 22. F elp mpp e e en o 23. F elp mpac a o 24. Oilp e e en o .

Righ SideInd

ialandPo e Gene a ion


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1. T bocha ge 2. E ha manifold(3piece) 3. Rocke le e co e 4. The mo a ho ing 5. Enginecoolan o le 6. Coolan empe a e en o 7. Coolan b pa be 8. Oilp e echeckpoin (pi oncoolingno 9. Wa e p mp 10. Enginecoolan inle 11. Oilpan 12. T bocha ge oil ppl line 13. T bocha ge oild ainline 14. Oilcoole ho ing 15. S a e 16. Fl heelho ing 17. Oilp e echeckpoin (af e oilcoole ) 18. Engineda apla e 19. Rocke le e ho ing.

legalle )

TopVie Ind

ialandPo e Gene a ion

1. Coolan en be 2. E ha manifold 3. Rocke le e co e 4. T bocha ge 5. Engine peed en o (Ind ialonl ) 6. In akemanifold 7. Cha geai piping( bocha ge oCAC) 8. F elfil e head


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9. Coolantfilterhead(Industrialonl ) 10. Fanhubassembl 11. Enginecoolantoutlet.

FrontViewIndustrialandPowerGeneration

1. Frontengineliftingbracket 2. Alternator 3. Blowb tube 4. Coolingfandrivebelt 5. Drivepulle (foralternatorandrefrigerantcompressor) 6. Oildrainvalve 7. Oilpan 8. Vibrationdamper 9. Frontgearcover 10. Coolingfanbelttensioner(Industrialonl ) 11. Coolanttemperaturesensor 12. Thermostathousing 13. Fanhubassembl 14. Enginecoolantoutlet.


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RearViewIndustrialandPowerGeneration

1. Oilpressurecheckpoint(afteroilcoolers) 2. Flywheelhousing 3. Oilpan 4. Engineoildrainvalve 5. Enginespeedsensor(Industrialonl ) 6. OEMelectricalconnections(Industrialonl ).

LastModified:08Jul2003Copyright 20002010CumminsInc.Allrightsreserved.


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ViewRelatedTopic

001999C linderBlockOverview

GeneralInformationTheQSK23c linderblockisarobust designmadeofaonepieceironcasting.It hasasolidanddurabledesigntoabsorb internalforcesandtoenableresilient mounting.Theonepieceironblock emplo sbothfrontandreargearhousings. Theoilpumphousingandwaterjacketare alsointegratedintothec linderblock. Crankshaft TheQSK23crankshaftismadeofforged hightensilesteel. VibrationDamper TheQSK23usesaviscousvibration dampermountedonthecrankshaftnose. Thevibrationdamperreducesthe crankshafttorsionalvibrationandreduces geartrainloading. C linderLiner TheQSK23usesapressedin,removable, c linderliner.Thelinerhasa170mm [6.69in]boreandincorporatesatopstop linerdesign.Thetopstoplinerdesign featuresspecialhoningforoilcontroland relatedpistonringwear.Italsoprovides improvedtopringcooling,improved


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resistancetolinercavitation,and improvementstothecylinderhead attachmentjointduetolowbendingstress. Piston TheQSK23usessinglepieceferrouscast ductileironpistons.Thesepistonsreduce pistontolinerclearanceforimprovements inoilconsumption,andoptimizeliner ovalityandtherebythelikelihoodofliner ringing .Castironisusedforitshigh strengthandsuperiordurability.

Camshaft TheQSK23camshaftmeasures105mm [4.13in]indiameter.Abigcamdiameter wasincorporatedtodrivehighpressure unitinjectors.Aspecialsurfacetreatment wasappliedoncamfollowerroller surfacestomaintainadequatelubrication.

La Modified:08J l2003Copyright20002010CumminsInc.Allrightsreserved.


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V

R

T

002999C linderHeadOverview

GeneralInformationT QSK23 .T .T T T . , .T . QSK23 , not QSK78 . QSK23 , .T .

T

16.5 230 12 170 . not

T


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La Modified:08J l2003Copyright 20002010CumminsInc.Allrightsreserved.


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ViewRelatedTopic

003999RockerLe ersO er ie

GeneralInformationRockerLeverCovers TheQSK23rockerlevercoversaremade ofcastaluminumandutili ereusableo ringt pevalvecovergaskets.

InjectorLevers TheQSK23injectorleversaremadefrom forgedsteel. RockerLevers EachQSK23rockerleverisasinglepiece, soliddesignwithaprecisiongroundnose radius. RockerLeverShaft TheQSK23usesalarge45mm[1.77in] rockerlevershaftdiameterduetohigh injectortrainloads.


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Thevalvesandinjectorsareadjusted usingtheouterbasecircle(OBC)feeler gauge,orscrewdrivermethod.



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ViewRelatedTopic

004999CamFollo e /Tappe O e ie

Gene alInfo ma ionAspecialsurfacetreatmentisappliedto theQSK23camfollowerrollersurfacesto maintainadequatelubrication.Thecam follower,pushtube,androckerleverare optimizedtokeeprigidityduringinjection pressures,toreduceweight,andreduce thepossibilityofdrivesystemnofollow conditions.Camfollowerrollerpinsare assembledusingliquidnitrogen. Replacementrollersandpinsareno availableforservice.Iftherollerfails,the entirecamfollowerrollerassemblym bereplaced.Thecamfollowerrollersare microfinishedandhaveacomplexcrown. Therollersm no beregroundfor service.



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ViewRelatedTopic

005999FuelS stemOverview

GeneralInformationFuelSystem TheQSK23engineisequippedwiththe Quantum fuelsystem.TheQuantum fuelsystemprovidesfullelectroniccontrol oftheenginewithhighpressurefuel injection. Operation TheQSK23fuelpumpsuppliesregulated pressuretothecontrolvalveassemblyfor therailandtimingasafunctionofspeed. Thefuelissuppliedtoboththerailand timingactuators.Theactuatorsactas throttlestocontroltheamountoffuel meteredtotheinjectorandtimingsupply lines.Timingandrailpressuresensors, aftertheactuators,measuretheactual suppliedpressures.TheECMcompares theactualsuppliedpressurestothe desiredsupplypressures.Desiredsupply pressureisbasedonthrottlepositionand speedinputs.TheECMthen communicatestotheactuatortochange spoolplungerpositionwhichchangesthe floworificeareauntilthedesired pressuresareobtained. FuelFilter


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TheQSK23requirestwo10micronfuel filterswithwaterseparators,Fleetguard PartNumberFS1006,toprovideinjector andcontrolvalveprotection.

FuelPump TheQSK23hasanelectronically controlledfuelpumpthatregulatesoutput pressuretospecificvaluesbasedona givenenginespeed.Thepumphasafuel bypassregulatorcircuitcontrolledbyan actuator.Theactuatorreceivesits commandfromtheECMbasedonthe pumppressuresensorandtheengine speedsensor. TheQSK23fuelpumpisverysimilartothe pumpusedonQSK45,QSK60,and QSK78seriesengines.

ElectronicControlValveAssembly (ECVA) Theelectroniccontrolvalveassemblyis locatedonthefuelpumpsideofthe engine.Theassemblycontainsthe followingactuatorsandsensors: 1. Timingrailpressuresensor 2. Fuelrailpressuresensor 3. Barometricpressuresensor 4. Fuelrailactuator 5. Fueltemperaturesensor 6. Timingrailactuator 7. Fuelsupplyinlet 8. Timingrailoutlet 9. Fuelrailoutlet 10. Fuelshutoffvalve.


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200001FlowDiagram,FuelS stem

FuelS stem

1. Fuelinletfromtank 2. Fuelfilterswithwaterseparation 3. Fuelpumpinlettube 4. Fuelpump 5. Fuelcontrolvalvesuppl tube 6. Fueltimingsuppl tube 7. Fuelrailsuppl tube 8. Fuelraildampeninghose 9. Electronicfuelcontrolvalveassembl 10. Injector 11. Fuelreturntube 12. Fueldrain(enginetofueltank)


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13. ECM.

1. Fuelinletfrompump 2. Fueltimingactuator 3. Fueltemperaturesensor 4. Fuelshutoffvalve 5. Fuelrailactuator 6. Fuelraildampeninghose 7. Fueltofuelrail 8. Fueltofueltiming.



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ViewRelatedTopic

006999Injec o andF elLine O e ie

Gene alInfo ma ionFuelTubes TheQSK23fuelrailsupply(1),timingrail supply(2),andfueldrain(3)areintegrated intotheintakemanifoldhousing. Fuelsupplyanddrainlinesaresizedto providesufficientflowforinjectionand timingfunctions.Straightthreadfaceoring fittingsareusedforsuperiorleak prevention. Therecommendedfuelpumpinletline sizeprovidesamaximumcleanfilter restrictionof102mmHg[4inHg]athigh idlenoload. Thefueldrainfittingprovidesamaximum drainlinerestrictionof203mmHg[8in Hg]. Thefueltemperatureatthefuelpumpinlet m no exceed71 C[160 F].Afuel coolerinthefueldraincircuitwillpossibly berequired.Thefuelcooleristobe providedbytheoriginalequipment manufacturer(OEM).


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Thefuelrailsintheintakemanifold receivefuelfromtheElectronicControl ValveActuator(ECVA)throughafuelrail supplytube(1)andfueltimingsupplytube (2).Thefuelthenpassesthroughthefuel rails,throughthecylinderhead,andinto theinjectors.Unusedfuelflowsback throughthecylinderhead,intothefuelrail, andoutthroughthefueldrainfitting(3)to returntothefueltank. Industrialapplicationswithdualintake manifoldswillhaveasteelreturnline connectingthetwomanifoldstothefuel drainfitting.

Quantum Injector TheQSK23Quantum injectorbegins operationwithmetering.Thelower plungerretractsduringtheinnerbase circleportionofthecamshaftprofile,thus uncoveringtherailfeedport.Thefuelis PressureTime(PT)meteredintothe nozzle.Theamountmeteredisafunction ofrailpressureandenginespeed.This supplypressurewillbeashighas1379 kPa[200psi]atmaximumfueling/speed andaslowas13.8kPa[2psi]atidle. ThetimingfuelisalsoPTmeteredthrough aseparatemeteringportintoachamber betweentheupperandtimingplungersin thebarrel.Thisalsooccursduringthe innerbasecircleportionofthecamshaft profilebeginningwhentheupperplunger retractsanduncoversthetimingfeedport. Timingmeteringendswhenthecamshaft drivestheupperplungerdownward, coveringthemeteringfeedportand trappingthefuelbetweentheupperand timingplungers.Thistrappedfuelactsas asolidhydrauliclink.Thelowerplunger alsomovesdownward,closingtherail feedportandendinginjectedfuel metering.


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Theamountoffuelmeteredintothetiming chamberdeterminestheamountof separationoftheupperandtiming plungers.Thisseparationamount,called overtravel,variesfromanapproximate minimumof2mm[0.078in]attorquepeak fuelingtoamaximumof9mm[0.354in]at highidlefueling.Theamountofovertravel ischangedtovarythestartofinjectionfor allspeedandfuelingconditions.



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ViewRelatedTopic

007999LubricatingOilS stemOverview

GeneralInformationTheQSK23enginehastwospinon lubricatingfiltercanisters.Thesefilterscan bereplacedwithFleetguard mediawith awiremeshbackingtoobtain10micron filteringcapabilityandlonglife. Theventuricombofilterdesignprovides forbothfullflowandbypasslubricatingoil filtrationinthesamecanister,eliminating therequirementforbypassfilters.The filtersareonl mountedontheleftside (fuelpumpside)oftheengine. CumminsInc.recommendsusing Fleetguard venturicombofilters,Part NumberLF9325,ateachoilchange interval.

TheQSK23usesanoilpumpidlergear whichdrivesthelubricatingoilpumpatthe frontoftheengine. TheQSK23highpressurereliefvalveis locatedinternallyinthelubricatingoil pump.Thereliefpressureis883kPa[128 psi]. Thehighpressurereliefvalvealsoserves


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astheprimaryoilpressureregulator locatedinternaltothelubricatingoilpump. Regulatedoilriflepressureis393to552 kPa[57to80psi]atratedrpm.

TheQSK23usestwooilcoolersin parallel.Eachcoolerhousingcontainsa thermostatwhichbeginopeningat85C [185F]andfullyopenat100C[212F]. Lubricatingoilisroutedfromtheoilpump throughtheoilcoolers,acrosstherearof theengine,andtotheoilfilters.Theoil thenflowstothemainoilgallerywhich suppliesoiltothecrankshaft,rodbearings, pistoncoolingnozzlegallery,camshaft, frontandreargeartrain,andturbocharger. Therearemultipleoilpressureportsfor OEMusage.



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200002FlowDiagram,LubricatingOilS stem

FlowDiagram

1. L 2. L 3. L 4. L 5. L 6. L 7. L

b b b b b b b

ica ingoilpan ica ingoil c ion be ica ingoilp mp ica ingoilp e e eg la o al e ica ingoilcoole ica ingoilcoole he mo a (open) ica ingoilcoole he mo a (clo ed).


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1. Lubricatingoilflowfromoilcoolers 2. Lubricatingoilflowtofilters 3. Lubricatingoilfilterb passvalve(s) 4. Lubricatingoilfilter(s) 5. Lubricatingoilfromfilters 6. Mainlubricatingoilrifle 7. Lubricatingoilflowtoc linderhead 8. Lubricatingoilflowtorearidlergear 9. Normallubricatingoilflowthroughfilter 10. B passlubricatingoilflow.


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1. Lubricatingoilflowfromfilters 2. Mainlubricatingoilrifle 3. Lubricatingoildrillingtoturbochargersuppl 4. Lubricatingoildrillingtopistoncoolingno leoilrifle 5. Lubricatingoilflowtocamshaftbushingsandc linderhead 6. Lubricatingoilflowtomainbearingsandcrankshaft 7. Lubricatingoilflowtofrontidlergears 8. Lubricatingoilflowtopistoncoolingno les 9. Turbochargeroilsuppl tube 10. Turbochargeroildraintocrankcase.


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1. Pi onpinb hing 2. Connec ing od 3. C ank haf .


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1. Lubricatingoilflowthroughcylinderhead 2. Lubricatingoilflowthroughrockerhousing 3. Lubricatingoilflowaroundrockershaftcapscrewandthroughrockershaft 4. Lubricatingoilflowthroughrockerlevers 5. Lubricatingoilflowthroughinjectorlever 6. Lubricatingoilreturntopan.



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200004FlowDiagram,AirIntakeS stem

AirIntakeS stem

1. Intakeairinlettoturbocharger 2. Turbochargedairtochargeaircooler 3. Chargeaircooler 4. Intakemanifold 5. Gridheater(Industrialonl ) 6. C linderheadintakeairport 7. Intakevalve.

LastModified:17Mar2003


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Copyright 20002010CumminsInc.Allrightsreserved.


2/2

18/05/12


ViewRelatedTopic

010999AirIntakeS stemOverview

GeneralInformationTheQSK23airintakesystemusesa remotechargeaircoolertoreducetheair temperatureintotheintakemanifold.The chargeairfromtheengineturbochargeris routedtotheintakemanifoldbymeansof aradiatormounted(airtoair)coolerrather thanthroughtheconventionalintegral enginemountedaftercoolercore(airto coolant)design.Theadvantageofcooling chargeairdirectlybyambientairisthatthe lowestpracticalchargeairtemperature canbeattainedwiththeminimumcost penalty.

TheQSK23engineusesasinglehigh efficiencyHolset HX82singlestage turbochargeronthepowergenerator applicationandaSchwitzerS500 turbochargerontheindustrialapplication. TheQSK23turbochargerismountedon therightsideoftheengine.


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009999D i eUni O e ie

Gene alInfo ma ionTheDriveUnitssectionconsistsofthe removal,inspection,andinstallationofthe alternatordrivegearandshaft. Thealternatordrivegearandshaftalso drivesthefuelpumpandanOEMsupplied refrigerantcompressoronsomeindustrial applications.Thefuelpumpengagesthe drivegearviaaspidergearfromtherear ofthefrontcoverandismountedtothe block. Thealternatordrivegearandshaft revolvesata1:1ratiotothecrankshaftand inthesamedirection.Thedrivecontains 55teethandisdrivenbythecrankgear throughanidlergearandissplash lubricated.



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200003FlowDiagram,CoolingS stem

CoolingS stem

1. Coolantinletfromradiator 2. Waterpump 3. Coolantflowthroughlubricatingoilcooler 4. Coolantflowaroundc linderliners 5. Coolantflowtoc linderhead 6. Coolantflowfromc linderheadtocoolantmanifold 7. Coolantmanifoldtothermostathousing 8. Coolantfiltersuppl andreturntubes


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9. Coolantfilter.

1. Coolantflowtocylinderhead(fourportspercylinderhead) 2. Coolantflowtowatermanifold(oneportpercylinderhead) 3. Coolantflowtothermostathousing 4. Radiatorbypassopen 5. Coolantflowtowaterpump 6. Coolantflowtooilcoolers 7. Radiatorbypassclosed 8. Coolantflowtoradiator 9. Coolantflowforoptionaltorqueconverter(normallyplugged)



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Vie Rela edTopic

008999CoolingS stemOverview

GeneralInformationCoolingS em

TheQSK23engine e a anda djacke a e cooling emfo heengine.Each headha fo coolan inle po andone coolan o le po .The ei al oacoolan en po a he opofeachheadon he e ha ide. Coolan flo f om he a e p mp n h o gh heoilcoole ca i ie ,a o nd he c linde line , hen p h o gh hefo inle pa age in hec linde head . Coolan hene i hehead h o gha ingleo le po ,in o he e nmanifold and o he he mo a ho ing.

FanD i e Thepo e fand i e edon heQSK23 engine e anadj ablefanbel en ione fo po e gene a ion applica ion o ana oma icfanbel en ione ,a ho n,onind ial applica ion .


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200003FlowDiagram,CoolingS stem

CoolingS stem

1. Coolantinletfromradiator 2. Waterpump 3. Coolantflowthroughlubricatingoilcooler 4. Coolantflowaroundc linderliners 5. Coolantflowtoc linderhead 6. Coolantflowfromc linderheadtocoolantmanifold 7. Coolantmanifoldtothermostathousing 8. Coolantfiltersuppl andreturntubes


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9. Coolantfilter.

1. Coolantflowtocylinderhead(fourportspercylinderhead) 2. Coolantflowtowatermanifold(oneportpercylinderhead) 3. Coolantflowtothermostathousing 4. Radiatorbypassopen 5. Coolantflowtowaterpump 6. Coolantflowtooilcoolers 7. Radiatorbypassclosed 8. Coolantflowtoradiator 9. Coolantflowforoptionaltorqueconverter(normallyplugged)



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009999D i eUni O e ie

Gene alInfo ma ionTheDriveUnitssectionconsistsofthe removal,inspection,andinstallationofthe alternatordrivegearandshaft. Thealternatordrivegearandshaftalso drivesthefuelpumpandanOEMsupplied refrigerantcompressoronsomeindustrial applications.Thefuelpumpengagesthe drivegearviaaspidergearfromtherear ofthefrontcoverandismountedtothe block. Thealternatordrivegearandshaft revolvesata1:1ratiotothecrankshaftand inthesamedirection.Thedrivecontains 55teethandisdrivenbythecrankgear throughanidlergearandissplash lubricated.



1/1

18/05/12


ViewRelatedTopic

010999AirIntakeS stemOverview

GeneralInformationTheQSK23airintakesystemusesa remotechargeaircoolertoreducetheair temperatureintotheintakemanifold.The chargeairfromtheengineturbochargeris routedtotheintakemanifoldbymeansof aradiatormounted(airtoair)coolerrather thanthroughtheconventionalintegral enginemountedaftercoolercore(airto coolant)design.Theadvantageofcooling chargeairdirectlybyambientairisthatthe lowestpracticalchargeairtemperature canbeattainedwiththeminimumcost penalty.

TheQSK23engineusesasinglehigh efficiencyHolset HX82singlestage turbochargeronthepowergenerator applicationandaSchwitzerS500 turbochargerontheindustrialapplication. TheQSK23turbochargerismountedon therightsideoftheengine.


1/2

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200004FlowDiagram,AirIntakeS stem

AirIntakeS stem

1. Intakeairinlettoturbocharger 2. Turbochargedairtochargeaircooler 3. Chargeaircooler 4. Intakemanifold 5. Gridheater(Industrialonl ) 6. C linderheadintakeairport 7. Intakevalve.

LastModified:17Mar2003


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ViewRelatedTopic

011999E ha

S

emO e ie

Gene alInfo ma ionTheQSK23exhaustmanifoldhasbeen aerodynamicallydesignedtoreduce pumpinglossesandtoenhancepulse flow.Inaddition,themanifoldconnection hasbeendesignedtoallowforthermal expansion. Themaximumallowableexhaustsystem backpressurefortheQSK23engineis 76.2mmHg[3inHg].



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200005Flo Diagram,E haustS stem

E haustS stem

1. Cylinderheadexhaustport 2. Exhaustmanifold 3. Turbochargerexhaustoutlet.



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013999E ec ica E

i

e O e ie

Ge e a I f

ai

Thebasicheav dut electricals stem consistsof: Batteries(1)(Usuall twoorfour connectedinparallel) Startingmotor(2) Alternator(3) Magneticswitch(4) Ignitionswitch(5) Necessar wiring( shown) Allcomponents matched. becarefull

Theaccompan ingillustrationsshow t picalparallelandseriesbatter connections. Parallelconnection

Seriesconnection


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ViewRelatedTopic

016999Mo n ingAdap a ion O e ie

Gene alInfo ma ionTheQSK23isavailablewithaSAE0or SAE1flywheel/flywheelhousing combination.TheSAE0flywheelhasa ringgearcountof138teeth.TheSAE1 flywheelringgearhas118teeth. Tappedholesfortransmissionmounting are: 247/1614UNC2BforSAE number1flywheelhousing 16M12x1.75forSAEnumber0 flywheelhousing. Theflywheelhousinghastwomagnetic pickuplocations.Amagneticpickuphole iscurrentlydedicatedforusebythe electronicenginecontrolsystem.The magneticpickupholeavailablefor customeruseisM22x1.5.



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00001T o ble hoo ingP oced Techni e

e and

Gene alInfo ma ionAthoroughanalysisofthecustomer'scomplaintisthekeytosuccessful troubleshooting.Themoreinformationknownaboutacomplaint,thefasterandeasier theproblemcanbesolved. TheTroubleshootingSymptomChartsareorganizedsothataproblemcanbelocated andcorrectedbydoingtheeasiestandmostlogicalthingsfirst.Completeallstepsin thesequenceshownfromtoptobottom. Itisno possibletoincludeallthesolutionstoproblemsthatcanoccurhowever,these chartsaredesignedtostimulateathoughtprocessthatwillleadtothecauseand correctionoftheproblem. Followthesebasictroubleshootingsteps: Getallthefactsconcerningthecomplaint Analyzetheproblemthoroughly Relatethesymptomstothebasicenginesystemsandcomponents Consideranyrecentmaintenanceorrepairactionthatcanrelatetothecomplaint Doublecheckbeforebeginninganydisassembly Solvetheproblembyusingthesymptomchartsanddoingtheeasiestthingsfirst Determinethecauseoftheproblemandmakeathoroughrepair Afterrepairshavebeenmade,operatetheenginetomakesurethecauseofthe complainthasbeencorrected

La Modified:17No 2010Copyright 20002010CumminsInc.Allrightsreserved.


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t00002TroubleshootingS mptomsCharts

GeneralInformationUsethechartsonthefollowingpagesofthissectiontoaidindiagnosingspecificengine symptoms.Readeachrowofblocksfromtoptobottom.Followthroughthechartto identifythecorrectiveaction.

WARNINGTroubleshootingpresentstheriskofequipmentdamage,personalinjuryordeath. Troubleshootingmustbeperformedbytrained,experiencedtechnicians.

LastModified:03Apr2002Copyright 20002010CumminsInc.Allrightsreserved.


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Vie Rela edTopic

00004

EngineNoi eDiagno icP oced

e Gene alInfo ma ion

Whendiagno ingenginenoi ep oblem ,make e ha noi e ca edb acce o ie , cha heai comp e o andpo e akeoff,a eno mi akenfo enginenoi e .Remo e heacce o d i ebel oelimina e noi eca edb he e ni .Noi e illal o a el oo he me alpa no ela ed o hep oblem.The eofa e ho copecanhelploca eanenginenoi e. Enginenoi e hea da hec ank haf peed,engine pm,a enoi e ela ed o hec ank haf , od ,pi on ,and pi onpin .Noi e hea da hecam haf peed,onehalfof heengine pm,a e ela ed o he al e ain.Ahand helddigi al achome e canhelp ode e mineif henoi ei ela ed ocomponen ope a inga hec ank haf o cam haf peed. The ei no adefini e leo e ha illpo i i el de e mine he o ceofanoi ecomplain . Engined i encomponen andacce o ie , cha gea d i enfancl che ,h d a licp mp ,bel d i en al e na o ,ai condi ioningcomp e o ,and bocha ge cancon ib e oenginenoi e.U e hefollo ing info ma iona ag ide odiagno ingenginenoi e.

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Thenoi eca edb aloo emainbea ingi alo dd llknockhea d hen heenginei p llingaload.Ifallmain bea ing a eloo e,alo dcla e illbehea d.Theknocki hea d eg la l e e o he e ol ion.Thenoi ei helo de hen heenginei l ggingo nde hea load.Theknocki d lle hanaconnec ing odnoi e.Lo oilp e ecanal oaccompan hi condi ion. If hebea ingi no loo eeno gh op od ceaknockb i elf, hebea ingcanknockif heoili oo hin,o if he e i nooila hebea ing. Ani eg la noi ecanindica e o nc ank haf h Anin e mi en ha pknockindica e e ce ca eachangein henoi e. bea ing .

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AdditionalComments:

___________________________________________________________________________________________________ ___________________________________________________________________________________________________ Thischecklistcanbecopiedforconvenience.

FuelConsumptionGeneralInformationThecauseofexcessivefuelconsumptionishardtodiagnoseandcorrectbecauseofthepotentialnumberof factorsinvolved.Actualfuelconsumptionproblemscanbecausedbyanyofthefollowingfactors: Enginefactors Vehiclefactorsandspecifications Environmentalfactors Drivertechniqueandoperatingpractices Fuelsystemfactors Lowpower/driveabilityproblems. Beforetroubleshooting,itisimportanttodeterminetheexactcomplaint.Isthecomplaintbasedonwhetherthe problemisrealorperceived,ordoesnotmeetdriverexpectations?The FuelConsumptionCustomer ComplaintForm isavaluablelistofquestionsthatcanbeusedtoassisttheservicetechnicianindeterminingthe causeoftheproblem.Completetheformbeforetroubleshootingthecomplaint.Thefollowingaresomeofthe factorsthatmustbeconsideredwhentroubleshootingfuelconsumptioncomplaints. 1. ResultofaLowPower/DriveabilityProblem:Anoperatorwillchangedrivingstyletocompensateforalow power/driveabilityproblem.Somethingsthedriverislikelytodoare,(a)shifttoahigherenginerpmor(b)run onthedroopcurveinalowergearinsteadofupshiftingtodriveatpartthrottleconditions.Thesechangesin drivingstylewillincreasetheamountoffuelused. 2. DriverTechniqueandOperatingPractices:Asageneralrule,a1mphincreaseinroadspeedequalsa0.16 km[0.1mpg]increaseinfuelconsumption.Thismeansthatincreasingroadspeedfrom50to60mphwill resultinalossoffuelmileageof1.6km[1mpg]. 3. EnvironmentalandSeasonalWeatherChanges:Asageneralrule,therecanbeasmuchasa1.6to2.4km [1to1.5mpg]differenceinfuelconsumptiondependingontheseasonandtheweatherconditions. 4. ExcessiveIdlingTime:Idlingtheenginecanusefrom0.11to0.33liters[0.5to1.5gal]perhourdependingon theengineidlespeed. 5. TruckRouteandTerrain:East/westroutesexperiencealmostcontinualcrosswindsandheadwinds.Less fuelcanbeusedonnorth/southrouteswherepartsofthetriparenotonl warmer,butseelesswind resistance. 6. VehicleAerodynamics:Thelargestsinglepowerrequirementforatruckisthepowerneededtoovercomeair resistance.Asageneralrule,each10percentreductioninairresistanceresultsina5percentincreasein mpg. 7. RollingResistance:Rollingresistanceisthesecondlargestconsumerofpoweronatruck.Thetypeoftire andtreaddesignhaveasizeableeffectonfueleconomyandperformance.Changingfromabiasplytoalow profileradialtirecanreducerollingresistancebyabout36percent. Additionalvehiclefactors,vehiclespecifications,andaxlealignmentcanalsoaffectfuelconsumption.

FuelConsumptionCustomerComplaintForm


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CustomerName/Company__________________________________________________________Date ________________ Answerthefollowingquestions.SomequestionsrequiremakinganXnexttotheappropriateanswer. 1. Whatfuelmileageisexpected?________Expectedmpg 2. Whataretheexpectationsbasedon?Originalmileage________,Otherunitsinfleet________,Competitive engines________Previousengineowned________,Expectationsonly________,VE/VMSreport ________ 3. Whendidtheproblemoccur?SinceNew________,Suddenly________,Gradually________ 4. Didtheproblemstartafterarepair?Yes________No________Ifso,whatwasrepairedandwhen? ____________________________________________________________ 5. IsthevehiclealsoexperiencingaDriveabilityproblem(LowPowerorPoorAcceleration/Response)?Yes ________No________ IfansweredYes,fillouttheDriveability/LowPower/ExcessiveFuelConsumptionChecklistandgototheEngine PowerOutputLowperformancetree. 6. Istheproblemseasonal?Yes________No________ 7. Weatherconditionsduringfuelconsumptioncheck?Rain_____,Snow_____,Windy_____,Hot Temperatures_____,ColdTemperatures_____ 8. Howisthefuelmileagemeasured?Tank_____,Trip_____,Month_____,Year_____Hubometer_____, Odometer_____ 9. Areaccuraterecordskeptoffueladdedontheroad?Yes________No________ 10. Doroutesvarybetweencomparedvehicles?Yes________No________ 11. Haverouteschangedfortheenginebeingchecked?Yes________No________ 12. Whataretheloadshauled,comparedtocomparisonunit?GVW_______________Heavier________, Lighter________ 13. Whatisthealtitudeduringoperation?Below10,000feet________,Above10,000feet________ 14. Howmuchofthetimeisthetruckspentidling?Hours/day__________ 15. Isthedrivertechniqueoroperatingpracticesaffectingfueleconomy? Highroadspeed:mph__________ Operateatratedspeedorabove:rpm__________ Incorrectshiftrpm:Shiftrpm__________,TorquePeak__________ Operateatacruisespeed:rpm__________ Believecompensatingforlowpower:Yes________No_______ Ifafterfillingoutthisformitappearsthattheproblemisno causedbyvehiclefactors,environmentalfactors,or drivertechnique,fillouttheDriveability/LowPower/ExcessiveFuelConsumptionChecklistandgototheFuel ConsumptionExcessiveperformancetree. Thisformcanbecopiedforconvenience.

OilCon

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Inadditiontotheinformationthatfollows,aservicepublicationisavailableentitledTechnicalOverviewofOil Consumption,BulletinNo.3379214. CumminsInc.defines AcceptableOilUsage asoutlinedinthefollowingtable. AcceptableOilUsage AnyTimeDuringCoveragePeriod Engine Family Hours per Quart Hours Hoursper perLiter ImperialQuart Miles Per Quart Miles per Liter Milesper Imperial Quart KMper Quart KM per Liter KMper Imperial Liter


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A 4B 6B 6C V/VT378 V/VT504 V/VT555 LSeries MSeries NSeries V/VT/VTA 903 KT/KTA19 QSK23 V/VT/VTA28 KT/KTA38 KTA50

10.0 10.0 10.0 10.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 3.0 1.7 2.0 1.5 1.1

10.6 10.6 10.6 10.6 4.3 4.3 4.3 4.3 4.3 4.3 4.3 3.2 1.8 2.1 1.6 1.2 2.0

12.0 12.0 12.0 12.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 3.75 2.5 1.8 1.3

400 400 400 400 250 250 250 250 250 250 200

425 425 425 425 265 265 265 265 265 265 210

475 475 475 475 310 310 310 310 310 310 250

650 650 650 650 400 400 400 400 400 400 320

675 675 675 675 425 425 425 425 425 425 340

775 775 775 775 485 485 485 485 485 485 390

AcceptableOilUseage(TransitBus,ShuttleBusandSchoolBus) AnyTimeDuringCoveragePeriod Engine Hours Hours Hoursper Family perQuart perLiter ImperialQuart B C L,M,N 10.0 8.0 4.0 10.6 8.5 4.3 12.0 10.0 5.0 Miles per Quart 200 150 100 Miles Milesper KMper KMper perLiter ImperialQuart Quart Liter 210 160 105 240 180 120 320 240 160 340 255 170 KMper Imperial Liter 385 290 195

EngineLubricatingOilConsumptionReport Owner'sName Address City EngineApplication (Describe) DateofDelivery Month EquipmentManufacturer State/Province EquipmentSerial Number Day Year EngineSerialNumber EngineModel&HP FuelPumpSerialNumber ComplaintOriginally Registered Date Mile/Hours/KM

OilandFilterChangeInterval Oil EngineOperation Miles/Hours/Kilometers Filters LubricatingOilAdded QuartsLitersOil Added

DateAddedOil

BrandandViscosityofOil Used


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StartTest

LastMileage/Hours/Kilometers_________________________MinusStartMileage/Hours/Kilometers ___________________________________ EqualsTestMileage/Hours/Kilometers____________________________DividedB OilAdded __________________________________________ Equals___________________________________________Usage Rate________________________________________________________________ CustomerSignature CumminsDealer CumminsInc.Form4755 CumminsDistributor

OilConsumptionReport CustomerName: EngineModel: EngineSerialNo.: VehicleMake/Model: Reviewofmaintenancehistor : Listan previousfailuresthatcouldhavehadadetrimentaleffectonc lindercomponentlife.Failurescould includefuel,coolant,and/orforeignabrasivesintheoil,secondringgroovebeatout,filterplugging,etc. Dist/Dir: Mi/Km/Hr: CPLNo.: Date:

LubeOilUsed: Brand Viscosit ChangeInterval(mi/km/hr)

CombinationOilFilter:


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M de Ee e Cha geI e a ( i/ B a Oi Fi e : /h )

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Had hef e bee a e ed i h?__________Wha i a i ai e e eadi g ?__________If e , he be e e fac ecifica i a d hec e e ee a ehi i c i a ea d hee igibi i e i e e be e agai . Warning:Governmentalagencieshavedeterminedthatusedengineoilisto icandcarcinogenic.Avoid breathing,injestion,ande cessivecontact.D ai a d efi i a chec di ic a i g a d e fi di g . O af e ab echec a ec e ed, ea c ec eda d e d c e gi e de e i eca ef hefai ea d e ai a e i ed. S a e ea Sig ed:__________________________________________________ f i c i . e ai i c e ed,di a e be


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CoolantLossPreTroubleshootingGuideBeforetroubleshooting,itiscriticaltoknowwherethecoolantisbeinglost.Itisnotalwaysobviouswherethe missingcoolanthasgone. Beforetroubleshooting,itisimportanttodeterminetheexactcomplaintbyinterviewingthedriver,lookingatthe servicehistoryandlookingattheECMinformation. DriverInterviewQuestions Driver'sName: EngineSerialNumber(ESN) Whatisthecomplaint? Howisthisengineused? Whataretheloadfactors? Whereisthevehicledriven? 1. Howistheradiatorfilled? 2. IstheradiatorfilledtotheHighorLowmarkwhentheengineiscold(lessthan60C[140F]? 3. Whattypeofcoolantisadded? 4. Isthrereanycoolantonthegroundunderyourvehicleorengine? 5. Istheregreenorwhitestreaksontheengineornearthecoolantoverflowhose? 6. Isthereanyspecificcondition(weather,altitude,orload)whenindicationsofcoolantlossisevident? 7. Doestheengineeveroverheat? 8. Doesthewarninglightflash? 9. Underwhatconditions? 10. Whattemperaturedoesthecoolantrunatnormally? 11. Doesthecoolingfanoperatecorrectly(fanona99C[210F]? 12. Isthereanywhitesmokeatoperatingtemperature,orhasanyonetoldyouthatwhitesmokeiscomingoutof theexhaust? 13. Isoilanalysisperformedaspartofthemaintenance? 14. Arethereelevatedlevelsofsodiumorpotassium? 15. Hasanyincreaseinmoisturecondensationonthedipstickoroilfillcap,ormoistureintheblowbybeen noticed? 16. Hasamilkyappearancebeennoticedinthelubeoilthatmightindicatecoolantispresent. 17. Whatothercommentsdidthedriver/operatorhavethatmighthelpCumminsInc.maketherightrepair? ServiceHistor Review Repeatcylinderheadorcylinderheadgasketrepairscanindicatetheproblemislikelynotthecylinderheador cylinderheadgasket.Repeatproblemscanindicateadeeperproblemintheengine.Keepthisinformationinmind whilegoingthroughthetroubleshootingprocedure. Lookatthisengine'swarrantyclaimshistory:whoworkedonenginelastandwhatdidtechniciando?Howmany milesmiles/kilometersareontheengine?Hasacylinderheadorcylinderheadgasketbeenreplacedbefore?At whatenginehoursweretheserepairsmade? ECMDataReview PrintoutanINSITE electronicservicetoolImageReportfromtheECM.Lookforhightemperaturealarmsorlow coolantlevelalarms.Eitherindicationconfirmsacomplaintofloosingcoolant. AreanyfaultcodesloggedintheEngineProtectionFaultHistory?


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ECMFaultCode235LowCoolant(howmaytimes)? ECMFaultCode151HighCoolantTemperature(howmanytimes)? Atthispoint,doyouknowwherethecoolantisgoing?Ifnotandthecoolantlossisnotsevere,suggestmountinga catchbottleontheradiatoroverflowtubetocatchanyoverflowthatcanpossiblybeblowingoutandbecominglost whileatspeed.Sendthevehicleouttocollectmoredataaboutwherethecoolantisorisnotgoing.Ifthecatch bottlehassomecoolantinit,referbacktotheCoolantLossExternal(outtheoverflow)interviewquestions.



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AirCompressorAirPressureRisesSlowlS mptomTreet004P in ableVe ion Thisiss mptomtree Cause Correction

Ai

emleak

Block he ehicle heel andcheck heai emfo leak i h p ingb ake appliedand elea ed.Checkfo leak f om heai comp e o ga ke and he ai emho e ,fi ing , ank ,and al e .Refe o heman fac e ' in c ion and pecifica ion .

Ai go e no i malf nc ioningo not e co ec l

Check heai go e no fo co ec ope a ion.Refe o heman fac e ' in c ion and pecifica ion .

Ca bonb ild pi e ce i ein heai di cha geline,check al e,o c linde head

Checkfo ca bonb ild p.Replace heai comp e o di cha geline,ifnece a . Check he bocha ge fo oilleak . Check hein ake befo oil.Refe o he man fac e ' in c ion and


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specifications.

Airsystemcomponentismalfunctioning

Checktheoperationofcheckvalves, alcoholevaporators,airdryers,andother OEMinstalledairsystemcomponents. Refertothemanufacturer'sinstructions andspecifications.

Unloadervalveismalfunctioning

Checktheunloadervalveandunloader bodyseal.Refertothemanufacturer's instructionsandspecifications.

Aircompressorintakeorexhaustvalve leaksair

Inspecttheaircompressorintakeand exhaustvalveassemblies.Refertothe manufacturer'sinstructionsand specifications.

LastModified:14Ma 2003Copyright 20002010CumminsInc.Allrightsreserved.


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AirCompressorNoiseisE cessiveS mptomTreet006PrintableVersion Thisiss mptomtree Cause Correction

Carbonbuildupise cessiveintheair dischargeline,checkvalve,orc linder head

Checkforcarbonbuildup.Replacetheair compressordischargeline,ifnecessar . Check he bocha ge fo oilleak . Check hein ake befo oil.Refertothe manufacturer'sinstructionsand specifications.

Unloadervalveismalfunctioning

Checktheunloadervalveandunloader bod seal.Refertothemanufacturer's instructionsandspecifications.

Aircompressorintakeore haustvalve leaksair

Inspecttheaircompressorintakeand e haustvalveassemblies.Refertothe manufacturer'sinstructionsand specifications.


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S i edd i ec e ce i e

i g gea i

Chec hec i gf ea .Refe he a fac e ' i ci a d ecifica i .

Pi b e ea i e ce

i e

Chec f i b e ea .Refe he a fac e ' i ci a d ecifica i .

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Re ace eb i d heai c e . Refe he a fac e ' i ci a d ecifica i .Re ace hede icca e e e heT b /CR2000ai d e (if e i ed).Refe he a fac e ' i ci .

Ai c ai i

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d i egea e gi egea da aged

I ec heacce d i egea a d gea ai .Refe heOEM e ice a a.

LastModified:14Ma 2003


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AirCompressorPumpingE cessLubricatingOil intotheAirS stemS mptomTreet007PrintableVersion Thisiss mptomtree Cause Correction

Lubricatingoildrainintervalise cessive

Verif thecorrectlubricatingoildrain interval.RefertoSection2inthe OperationandMaintenanceManual, QSK23SeriesEngine,Bulletin4021374.

Engineangularit duringoperation e ceedsspecification

Refertotheenginespecificationdata sheet.

Aircompressorpumpingtimeise cessive

Replacethedesiccantcartridgeonthe Turbo/CR2000airdr er.RefertotheOEM servicemanual.Checktheaircompressor dut c cle.Installalargeraircompressor, ifnecessar .Refertothemanufacturer's instructionsandspecifications.


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Lubricatingoildrainlineisrestricted

Removetheaircompressorandcheckthe oildrainholesintheaircompressorand theaccessorydrive.Refertothe manufacturer'sinstructionsand specifications.

Turbochargercompressoroilsealis leaking

Checkthecompressoroilseal.Referto themanufacturer'sinstructionsand specifications.

Aircompressorisexcessivelywornor internallydamaged

Replaceorrebuildtheaircompressor. Refertothemanufacturer'sinstructions andspecifications.Replacethedesiccant elementontheTurbo/CR2000airdryer(if equipped).Refertothemanufacturer's instructions.

LastModified:14Ma 2003Copyright 2000

Troubleshooting and Repair Manual QSK23 Series Engines

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Transcript of Troubleshooting and Repair Manual QSK23 Series Engines