LBNG QSK60G & QSK60G - High

Efficiency Series Gas Engines

Module 10 - Special Tools

CUMMINS inc.
 Tools Module

Learning Objectives
After completing this module you will be aware of the
special tools requirements for the QSK Gas engine
range.
Agenda
 Details of Electronic Tools & INSITE
 Consumable Items
 Mechanical Service Tool List

2 QSK60G / Tools / KLD / April 2010 / REV 1.01.

 Electrical Tools

Danfoss Sensors

Engine Harness Repair Kit

Kavlico Sensor Breakout Kit
3 QSK60G / Tools / KLD / April 2010 / REV 1.01.
 Electronic Tools
Gas Detector
Safety & Service aid. Detects minute levels of
combustible gasses including; Methane, Butane,
Propane and Natural Gas.
Common Features:
Audible / visual alarm & battery state indicator.
Cummins Part No: 3823984
Digital Multimeter
Fluke model 88 plus PV 350 module recommended.
Cummins Part No’s: 3824648 & 3824645.
Laptop
Laptop with INSITE service tool INSITE >7.4 Software
(3886388) software and Cummins INLINE Adapter
(3163094/ 4918190/ 4918416).
Minimum specification:
Pentium300Mhz Processor, 32 Mb of RAM, 8.0Gb hard
drive, CD ROM and modem. Windows ™ 95, 98 or NT
operating systems. 1 available standard COM port.
4 QSK60G / Tools / KLD / April 2010 / REV 1.01.
 The New INLINE 4
& INLINE 5 Data Link Adaptors

 Cummins latest data link adapters offer enhanced performance and high speed .
 These adapters are the only adapters available that Cummins certifies to be 100%
compatible with Cummins software applications. The INLINE 4 and INLINE 5 can
communicate with your PC or PDA through a 9-pin serial connector. The INLINE 5 also
can communicate with your PC over a Universal Serial Bus (USB) through a 5-pin mini-
connector. Either adapter connects to vehicle power and the SAE J1708/J1587 and
J1939/CAN data links via a 25-pin serial connector.
 If you download new calibrations to ECMs, you should take advantage of the high-
speed communications capabilities inherent in these Cummins adapters.
 Each Cummins INLINE kit contains a data link adapter, basic cables, and the INLINE
PC software driver. Load the software driver, connect the hardware, and you are ready
to go !
 Order Cummins INLINE products from your local Cummins distributor,
www.powerstore.cummins.com or in the US call 1-800-646-5609.

5 Our energy working for you. QSK60G / Tools / KLD / April 2010 / REV 1.01.
 Cummins INLINE 4
Data Link Adaptor

Cummins INLINE 4 features: INLINE 4 product kit (P/N 4918190) includes:

 Supports SAE J1708/J1587 and J1939/CAN data links INLINE 4 data link adapter (P/N 3165032)
 Supports RS-232 PC/PDA serial port at up to 115.2k DB9F/DB9M 6 ft. cable (P/N 4918418)
baud rate DB25F/9-pin data link cable (P/N 3165159)
 Is fully compliant with TMC's RP1210 standard DB25F/6-pin data link cable (P/N 3165160)
 Small enough to fit in pocket INLINE 4 software CD (P/N 4918191)
 Aluminum housing provides ruggedness Storage case (P/N 3165143)
 Derives 8 V to 50 V DC power from vehicle
 Includes advanced processor for maximum speed and
performance
 Internal Flash memory allows firmware upgradeability
 Includes 4 LEDs to indicate power and RS-232,
J1708/J1587, and J1939/CAN communications
 Certified to meet European CE requirements
 Rated for -40° to +85° C operating temperature
 INLINE 4 meets Cummins in-cab environmental test
requirements

6 QSK60G / Tools / KLD / April 2010 / REV 1.01.

 Cummins INLINE 5
Data Link Adaptor

Cummins INLINE 5 features:

INLINE 5 product kit (P/N 4918416) includes:
 Supports SAE J1708/J1587 and J1939/CAN data
links INLINE 5 data link adapter (P/N 3165033)
 Supports USB full speed port at up to 2M baud rate USB 2 meter cable (P/N 4918419)
DB9F/DB9M 6 ft. cable (P/N 4918418)
 Supports RS-232 PC/PDA serial port at up to 115.2k
baud rate DB25F/9-pin data link cable (P/N 3165159)
 Is fully compliant with TMC's RP1210 standard DB25F/6-pin data link cable (P/N 3165160)
INLINE 5 software CD (P/N 4918417)
 Small enough to fit in pocket
Storage case (P/N 3165143)
 Aluminum housing provides ruggedness
Protective boot (P/N 4918436)
 Derives 8 V to 50 V DC power from vehicle
 Includes advanced processor for maximum speed
and performance
 Internal Flash memory allows firmware
upgradeability
 Includes 5 LEDs to indicate power and USB, RS-
232, J1708/J1587, and J1939/CAN communications
 Certified to meet European CE requirements
 Rated for -40° to +85° C operating temperature
 INLINE 5 meets Cummins in-cab environmental test
requirements

7 QSK60G / Tools / KLD / April 2010 / REV 1.01.

 Sensor Break-Out Cables

Allows testing of all engine mounted Pressure Sensors

in-situ, without causing damage to engine harness.
Danfoss sensors;
Combined Temp/Pressure breakout;
Cummins Part No: 3162898.
Pressure only breakouts;
Cummins Part No’s: 3824774/5/6.
Kavlico sensors; (USED ON LEGACY PRODUCT ONLY)
Danfoss sensors
Pressure & Temp Kit for Kavlico sensors only ;
Cummins Part No: PT 3824773.

NOTES:
• Pressure Sensors can only be tested whilst still
connected and powered.
• QSV PhII, QSK60G & Synergy products all Launched
with Danfoss Sensors.
• Date to be announced for QSK19G to Launch with
Danfoss Sensors.
Kavlico Breakout Kit
• ECM Breakout connector also available;
8 Cummins Pt No.3822758 QSK60G / Tools / KLD / April 2010 / REV 1.01.
 Spark Plug Tool

Cummins Part #: WARNING: USE OF RUBBER

3162231 BOOT TYPES ARE PROHIBITED

Torque plug to 50-56N.m

NOTE:
No rubber
6” extension
NOT supplied insert
as part of tool.
This is
required in
Wire Clip
order to reach
spark plug.

22mm Clip Type Shown SPC#: 8060002

Socket only Cummins Part No. 3162231

An 18mm spark plug thread and seat chaser tool is

also recommended (Plug - 18mm thread / 22mm Hex)
9 QSK60G / Tools / KLD / April 2010 / REV 1.01.
 Electronic Tools

Exhaust Gas Analyser, required

for tuning of engine emissions
(open and closed-loop) and
obtaining stable operation at
rated speed and load.
Capable of measuring:
• Oxygen (O2).
• Carbon Monoxide (CO).
• Carbon Dioxide (CO2).
• Oxides of Nitrogen (NOx).
Seek supplier information and
training for instruction.

TESTO XL350 Shown

10 QSK60G / Tools / KLD / April 2010 / REV 1.01.
 Consumable Items

Cleaning Fluid:
• General Purpose Alcohol based Contact Cleaner.
• Must be Non Silicone based.
• Suitable for cleaning harness electrical connectors & components.
Cummins Part No. 3824510 (16 oz. aerosol)
CONTACT
Dielectric Grease (Dupont Krytox 205) :
Must be Silicone based (increases temperature rating). CLEANER
• Suitable for lubrication of spark plug boots before installation. 16 oz.
Cummins Part No. 3164956. Pt.3824510

Anti-seize:
• Should be a copper compound and not lead based.
• Suitable for application to O² sensor before installation.
Cummins Part No. 3824732 (4 oz. tube).

Rubbing Alcohol - Local Supply

• For cleaning Porcelain Spark plug bodies.

11 QSK60G / Tools / KLD / April 2010 / REV 1.01.

 Service Tools
Mechanical / Distributor List

 Liner Press Tool 3163329

 Liner Puller 3824830
 F&R seal R&I Tool 3163358
 Pulley Installation Tool 3163372
 Cylinder Head Capscrew Length Gauge 3163328
 Engine Lifting Fixture 3163264
– Four Straps/not chains

12 QSK60G / Tools / KLD / April 2010 / REV 1.01.

 Service Tools
Mechanical / Distributor List

 Valve Spring Compressor

 Valve Stem Seal Installation
 Valve Guide Installation Tool
 Counter Bore Salvage
 Heavy Component Lifting Eye 12 mm
 Cam Gear Puller (hydraulic)
 Camshaft Pilots
 Camshaft Bushing R&I Tool
 Camshaft Bore Salvage Kit

13 QSK60G / Tools / KLD / April 2010 / REV 1.01.

 Service Tools
Mechanical / Distributor List

 Belt Tension Gauge TBA

 Piston Removal Tool TBA
 Valve Setting Gauge TBA

14 QSK60G / Tools / KLD / April 2010 / REV 1.01.

 LBNG QSK60G & QSK60G - High
Efficiency Series Gas Engines

Module 10 - Special Tools

End

CUMMINS inc.