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Contents
Safety ............................................................................................................................................................3
General information .....................................................................................................................................3
Safety regulations for startup and operation, special Instructions for applications with gaseous fuel.......3
Gas System................................................................................................................................................3
General Repair Instructions ......................................................................................................................4
Gas Engine generator....................................................................................................................................5
Working Principle..........................................................................................................................................5
There are two main engines:.........................................................................................................................5
QSK45G ENGINE............................................................................................................................................6
Front View of Engine.................................................................................................................................6
Right Side View of Engine .........................................................................................................................6
Left Side View of Engine............................................................................................................................6
Top View of Engine ...................................................................................................................................7
Back View of Engine..................................................................................................................................7
Caution..........................................................................................................................................................8
Winter fronts and Shutters...........................................................................................................................8
Engine Shutdown..........................................................................................................................................8
Electronic Components.................................................................................................................................9
Operating Instructions..................................................................................................................................9
QSK60G ENGINE............................................................................................................................................9
Lubricating Parts .......................................................................................................................................9
Piston Cooling .........................................................................................................................................10
Front Side View.......................................................................................................................................10
Full-Flow Oil Filter Head..........................................................................................................................10
Cooling System........................................................................................................................................11
Thermostat Housing Flow- LTA (Two Pump-Two Loop) .........................................................................11
Air Fuel Mix.............................................................................................................................................11
Exhaust System .......................................................................................................................................12

3. 3
Safety
General information
 This product may pose a risk of injury or damage in the following cases:
• Incorrect use
• Operation, maintenance and repair by unqualified personnel
• Modifications or conversions
• Noncompliance with the safety instructions and warning notices Safety.
Safety regulations for startup and operation, special Instructions for
applications with gaseous fuel
Gas System
 Gas supply shut-off: The incomplete machine does not have its own gas supply shutoff
device. This must be designed by the plant designer according to site conditions.
 The connection to the gas supply network is made by the plant designer in accordance
with regulations
 The plant designer must use certified gas trains for the fuel supply to the product and
connection to the gas supply network. The connection conditions and dimensions must be
coordinated with the manufacturer.
 In flow direction, gas trains have:
• A manual shutoff fitting
• A gas filter
• Two gas shutoff valves
• A pressure regulating device
 The gas train must be fitted with an automatic leak check.
 The gas shutoff valves are activated via two different paths from the control system,
whereby one gas shutoff valve respectively is activated via one of the paths.
 Gas trains must be monitored to detect minimum pressure.
 The plant designer must ensure that the gas train is positioned directly in front of the
engine, however a maximum of three meters before the interface of the engine. The
interface is the flange in front of the gas volume regulator of the product.
 In the case of network supply pressures higher than 120 mbar, additional equipment is
required on the gas train.
 The gas pressure regulator must be equipped with an approved safety shut-off valve and a
safety discharge valve to ensure safety in case of excessive outlet pressure at the pressure
regulator. Gas discharge must be routed to a safe area (to atmosphere).
 If the gas supply is connected to a vessel or if gases containing oxygen are used, the gas
train must be equipped with a temperature-monitored flame arrester.

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General Repair Instructions
 Have maintenance or repair work carried out by qualified and authorized personnel only.
 Allow the product to cool down to less than 50°C before starting maintenance work (risk
of explosion of oil vapors, fluids and lubricants, risk of burning).
 Before starting work, relieve pressure in systems and compressed-air lines which are to
be opened. Use suitable containers of adequate capacity to catch fluids and lubricants.
 When changing the oil or working on the fuel system, ensure that the service room is
adequately ventilated.
 Never carry out maintenance and repair work with the product in operation, unless:
• Expressly permitted to do so following a written procedure.
• The product is running in the low load range and only for as long as absolutely
necessary.
 Secure the product against unintentional starting, e.g. with start interlock.
 Attach “Do not operate” sign in the operating area or to control equipment.
 Disconnect the battery. Lock contactors.
 Close the main valve on the compressed-air system and vent the compressed-air line
when pneumatic
 Starters are fitted.
 Disconnect the control equipment from the product.
 The following applies to starters with copper-beryllium alloy pinions:
• Wear breathing protection of filter class P3 during maintenance work. Do not
blow out the interior of the flywheel housing or the starter with compressed air.
Clean the flywheel housing inside with a class dust extraction device.
• Observe the safety data sheet
Below is a partial listing of engine is classified as safety-related:
 Air Compressor
 Flywheel Mounting Cap Screws
 Air Controls
 Fuel Shutoff Assemblies
 Air Shutoff Assemblies
 Fuel Supply Tubes
 Balance Weights
 Lifting Brackets
 Cooling Fan
 Throttles Controls
 Fan Hub Assembly
 Turbocharger Compressor
 Fan Mounting Bracket(s)
 Turbocharger Oil Drain Line(s)

5. 5
 Fan Mounting Cap Screws
 Turbocharger Oil Supply Line(s)
 Fan Hub Spindle
 Turbocharger Turbine Casing
 Flywheel
 Flywheel Crankshaft Adapter
Gas Engine generator
An engine-generator is the combination of an electrical generator and an engine (prime mover)
mounted together to form a single piece of equipment. This combination is also called an engine-
generator set or a gen-set. In many contexts, the engine is taken for granted and the combined
unit is simply called a generator.
Working Principle
An electricity generation, a generator is a device that converts mechanical energy to electrical
energy for use in an external circuit. The source of mechanical energy may vary widely from a
hand crank to an internal combustion engine. Generators provide nearly all of the power for
electric power grids.
There are two main engines:
 QSK45G ENGINE
 QSK60GENGINE

6. 6
QSK45G ENGINE
Front View of Engine
There are following parts of gas engine in front view:
 After cooler
 Air filter
 Thermostat housing
 Water filter
 Intake manifold
 Ignition control module
 Crankcase breather
 Vibration damper
 LTA coolant pump
 Front gear housing
 Throttle actuator
Right Side View of Engine
There are following parts of gas engine in right side view:
 Alternator
 CENSE module
 Coil on plug
 Exhaust outlets
 Turbocharger
 Fuel inlet
 Gas mass flow sensor
 Fuel control valve
 Air filter
 After cooler
 Thermostat housing
 Hot side (thermostat)
 Ignition control module
 Low temperature coolant circuit pipe
 Water pump (engine)
 Oil filters
 Oil pans
Left Side View of Engine
There are following parts of gas engine in left side view:
 Air filter

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 Turbocharger coolant return hose
 Crossover air pipes
 Turbocharger
 Exhaust outlets
 AVR/control box
 Emergency stop
 DC terminal box
 Air outlet(alternator fan)
 Flywheel housing
 Oil pan
 Crankcase breather
 Crankcase breather drain
 Crankcase breather oil drain
 Left bank CM558(ECM)
 LTA coolant pump
 Ignition control module
 Coil on plug
 Water transfer pipes
 After cooler
Top View of Engine
There are following parts of gas engine in top view:
 DC terminal box
 Alternator
 Exhaust outlets
 Coil on plug
 Wiring harness
 Air filters
 After cooler
 Frame rail
 Low temperature water pipe
 High temperature water pipe
 Rocker cover
 Crossover air pipes
Back View of Engine
There are following parts of gas engine in back views:
 Air box

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 Fuel control valve
 Gas mass flow sensor
 Fuel inlet
 Coil on plug
 AC terminal box
 Frame rail
 Oil pan
 DC terminal box
 Emergency stop
Caution
 Do not idle for extended periods of time. Excessive idle time can cause poor engine
performance.
 Cold weather
 Ambient temperature
 0 to -32 OC [32 to-25 OF]
Use 50-percent ethylene glycol antifreeze and 50-percent water foe the engine
coolant mixture. Refer to maintenance specifications (section V) lubricating oil
recommendations for the correct.
 -32 to 54 OC [-25 to -65 OF]
Use 60-percent ethylene glycol antifreeze and 40-percent water foe the engine
coolant mixture. Refer to maintenance specifications (section V) lubricating oil
recommendations for the correct.
The following cold weather operating aids are required for cold weather operations.
Winter fronts and Shutters
It can be used on a vehicle or equipment to reduce air flow through the radiator core into the
engine compartment. This can reduce the time required to warm the engine and help maintain the
engine coolant temperature. The engine coolant temperature specifications are in the
maintenance specification (section V).
Engine Shutdown
Allow the engine to idle 3 to 5 minutes before shutting it off after a full load operation. This
allows adequate cool down of piston, cylinders, bearings and turbocharger components.
Turn the ignition switch to the OFF position. If the engine does not shut down, refer to
troubleshooting symptom (section TS).

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Electronic Components
There are two CM558 modules.
The CM558 sub system modules:
 Solid state fully encapsulated and can connect with nine cylinders.
 Non –serviceable
 Module has two 50 pin Deutsch connection.
The CM558 sub system modules monitor for:
 Engine speed/position
 Throttle position sensor
 Knock sensor
 Intake manifold pressure sensor
Operating Instructions
The gas mass flow sensor mounted on the outside of the fuel control valve measures the amount
of fuel being fixed with the intake air. The sensor is a hot wire thermometer that measures the
amount of power required to keep an electrically heated wire at a constant temperature. The wire
requires more power to maintain a constant temperature as more fuel flows by the wire. The
sensor has a built in circuit board that controls the sensor.
The CM558 supplies the sensor with 14 VDC and a return. The sensor provides a signal between
0 and 5 VDC that proportional to the gas mass flow. It uses this input for fuel control.
 The fuel inlet pressure sensor
 The fuel outlet pressure sensor
 The intake manifold temperature sensor
 The compressor outlet pressure sensor
 The heated oxygen sensor
 The exhaust back pressure sensor
QSK60G ENGINE
Lubricating Parts
 Oil suction tube
 Oil pump discharge
 High pressure relief valve

10. 10
 Oil pump transfer tube
 Block connection
 Oil flow to filter head
 Oil filters
 Oil flow from filter head
 Oil filters
 Oil supply to oil coolers
 Oil cooler
 Cooled oil to flywheel housing
 Main oil riffle
 Oil supply to main bearings
 Sensing riffle to pressure regulator
 Pressure regulator valve
Piston Cooling
 Oil flow from oil cooler
 Oil supply to main oil riffle
 Oil supply to left bank overhead
 Oil supply to right bank overhead
 Oil supply to rocker levers
 Left bank piston cooling nozzle regulator
 Piston cooling nozzle
 Right bank piston cooling nozzle regulator
 Oil supply to Right bank piston cooling nozzle
 Oil supply to turbochargers
 Turbocharger oil drain to sump
Front Side View
 Main oil supply
 Oil supply to idler gear
 Oil supply to accessory drive
 Oil supply to gear cover
 Oil supply to Rockford fan clutch
 Oil supply to water pumps drive.
Full-Flow Oil Filter Head
 Oil supply from lubricating oil pump
 Oil supply through filter head to oil filters
 Lubricating oil filters
 Bypass valve – open position
 Oil supply from oil filter

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 Oil supply oil coolers
 Bypass valve – closed position
Cooling System
 LTA coolant flow from LTA radiator
 LTA water pump
 LTA coolant flow to after cooler
 After cooler
 LTA return to thermostat housing
 Thermostat housing
 LTA coolant return to LTA lamp
 LTA coolant return to LTA radiator
 Coolant inlet to water pump
 Coolant return from after cooler
 Coolant return from turbocharger
 Turbocharger coolant supply
 Water pump to after cooler
 Coolant bypass return to water pump
 Coolant return to radiator
Thermostat Housing Flow- LTA (Two Pump-Two Loop)
 Right bank coolant to thermostat housing
 Left bank coolant to thermostat housing
 Coolant bypass to water pump
 Coolant filters
 Coolant return to engine radiators
 LTA coolant from after cooler
 LTA thermostat open
 LTA coolant return to low temperature after cooler radiator
 LTA thermostat closed
 LTA coolant to low temperature after cooler coolant pump.
Air Fuel Mix
 Intake air
 Fuel supply
 Fuel/air mixer
 Turbocharger compressor
 Air/fuel mixture flow to after cooler
 Throttle actuator
 Thermostat housing
 Cylinder head intake port

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 Intake manifold
Exhaust System
 Exhaust port
 Exhaust manifold
 Turbocharger exhaust outlet