Cummins QSK19, QSK23, QSK38, QSK45, QSK50, QSK60, QSK78 & K19, K38, K50 Engines Service Repair Manual
Complete service repair manual with Electrical Wiring Diagrams for Cummins QSK19, QSK23, QSK38, QSK45, QSK50, QSK60, QSK78 & K19, K38, K50 Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Cummins QSK19, QSK23, QSK38, QSK45, QSK50, QSK60, QSK78 & K19, K38, K50 Diesel Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
3666098 - QSK19 (QUANTUM System K19 Series Engines) Troubleshooting & Repair Manual.pdf
3666113 - QSK19, QSK23, QSK45, QSK60 & QSK78 Electronic Control System Troubleshooting & Repair Manual.exe
3666120 - QSK19, QSK19 CM850 MCRS & QSK19 CM2150 MCRS Operation & Maintenance Manual.exe
3666232 - QSK19 Series Engines Shop Manual.pdf
3666410 - QSK45 & QSK60 CENSE System Troubleshooting & Repair Manual.exe
3810307 - K19 Engines Troubleshooting & Repair Manual.pdf
3810497 - K38, K50, QSK38 & QSK50 Operation & Maintenance Manual.exe
4021375 - QSK23 Troubleshooting & Repair Manual.pdf
4021419 - QSX15, QSK23, QSK45, QSK60, QSK78 Power Generation Control Systems Troubleshooting & Repair Manual.exe
4021520 - QSK50 CM850 Industrial Modular Common Rail System Wiring Diagram.exe
4021528 - K38, K50, QSK38 & QSK50 Service Manual.exe
4021528 - K38, K50, QSK38 & QSK50 Service Manual Vol. 3.pdf
4021530 - QSK45 & QSK60 Service Repair Manual.exe
4021533 - Troubleshooting and Repair Manual - Electronic Control System, QSK50 and QSK60, CM850 - Modular Common Rail System Series Engines - Volume 1.pdf
4021533 - Troubleshooting and Repair Manual - Electronic Control System, QSK50 and QSK60, CM850 - Modular Common Rail System Series Engines - Volume 2.pdf
4021533 - Troubleshooting and Repair Manual - Electronic Control System, QSK50 and QSK60, CM850 - Modular Common Rail System Series Engines - Volume 3.pdf
4021592 - QSK19, QSK19 CM850 MCRS & QSK19 CM2150 MCRS Service Manual.exe
33152954 - Parts Catalog [Content For Engine Serial Number ESN33152954].exe
33184373 - Parts Catalog [Content For Engine Serial Number ESN33184373].exe
33184412 - Parts Catalog [Content For Engine Serial Number ESN33184412].exe
33184413 - Parts Catalog [Content For Engine Serial Number ESN33184413].exe
33184414 - Parts Catalog [Content For Engine Serial Number ESN33184414].exe
33184415 - Parts Catalog [Content For Engine Serial Number ESN33184415].exe
33184417 - Parts Catalog [Content For Engine Serial Number ESN33184417].exe
Cummins QSK19 Fuel System Familiarisation.pdf
PRODUCT DETAILS:
Total Pages / Size : 6,313 pages / 2.4 GB
File Format: PDF / EXE
Language: English
TABLE OF CONTENTS
3666098 - QSK19 (QUANTUM System K19 Series Engines) Troubleshooting & Repair Manual...1
3666232 - QSK19 Series Engines Shop Manual...691
TABLE OF CONTENTS...693
INTRODUCTION...694
ABOUT THE MANUAL...695
GENERAL CLEANING INSTRUCTIONS...703
GLASS OR PLASTIC BEAD CLEANING...703
SOLVENT AND ACID CLEANING...703
STEAM CLEANING...703
GENERAL REPAIR INSTRUCTIONS...702
WELDING ON A VEHICLE WITH ELECTRONIC COMPONENTS...702
GENERAL SAFETY INSTRUCTIONS...694
IMPORTANT SAFETY NOTICE...694
HOW TO USE THE MANUAL...695
ILLUSTRATIONS...700
SYMBOLS...696
ENGINE IDENTIFICATION...705
ENGINE DIAGRAMS...711
ENGINE VIEWS...711
ENGINE IDENTIFICATION...706
CUMMINS ENGINE NOMENCLATURE...706
ECM DATAPLATE...706
ENGINE DATAPLATE...706
SPECIFICATIONS...707
AIR INTAKE SYSTEM...707
BATTERIES (SPECIFICATION GRAVITY)...710
COOLING SYSTEM...709
ELECTRICAL SYSTEM...707
EXHAUST SYSTEM...709
FUEL SYSTEM...707
GENERAL SPECIFICATIONS...707
LUBRICATING OIL SYSTEM...708
COMPLETE ENGINE - GROUP 00...714
ENGINE ASSEMBLY...772
ASSEMBLE...772
ENGINE DIASSEMBLY...722
DISASSEMBLE...723
GENERAL INFORMATION...722
ASSEMBLY...722
DISASSEMBLY...722
SERVICE TOOLS...715
ENGINE DISASSEMBLY AND ASSEMBLY...715
CYLINDER BLOCK - GROUP 01...869
BEARINGS, CONNECTING ROD...875
CLEAN...875
INSPECTION FOR REUSE...875
BEARINGS, MAIN...875
CLEAN...875
INSPECT FOR REUSE...876
MEASURE...876
BEARINGS, THRUST ...876
ASSEMBLE...877
INSPECT FOR REUSE...876
CAMSHAFT...877
CLEAN...877
INSPECT FOR REUSE...877
MAGNETIC CRACK INSPECTION...878
CAMSHAFT BUSHINGS...885
INSPECT FOR REUSE...886
INSTALL...886
REMOVE...885
CAMSHAFT GEAR (CAMSHAFT REMOVED)...880
INSPECT FOR REUSE...881
INSTALL...884
MAGNETIC CRACK INSPECT...882
REMOVE...880
CONNECTING ROD...888
CLEAN...888
INSPECT FOR REUSE...888
MAGNETIC CRACK INSPECT...894
CRANKSHAFT...895
BEND AND TWIST INSPECTION...899
CLEAN...895
INSPECT FOR REUSE...896
MAGNETIC CRACK INSPECT...897
CRANKSHAFT GEAR, FRONT (CRANKSHAFT INSTALLED)...904
INSPECT FOR REUSE...905
INSTALL...905
REMOVE...904
CRANKSHAFT GEAR, REAR (CRANKSHAFT INSTALLED)...906
INSTALL...906
CRANKSHAFT PULLEY...906
CLEAN...906
INSPECT FOR REUSE...907
CYLINDER BLOCK...908
CLEAN...909
INSPECT FOR REUSE...911
MAGNETIC CRACK INSPECT...915
WORKSHEET...908
CYLINDER BLOCK - GENERAL INFORMATION...871
GENERAL INFORMATION...871
CYLINDER BLOCK AND LINER SEATS...917
GENERAL INFORMATION...917
INSPECT FOR REUSE...917
LEAK TEST...921
MEASURE...919
CYLINDER BLOCK COUNTERBORE...935
MACHINE...935
CYLINDER LINER...921
CLEAN...921
INSPECT FOR REUSE...922
CYLINDER LINER PROTRUSION...949
ADJUST...949
GEAR COVER ACCESSORY DRIVE BUSHING ...950
INSTALL...950
REMOVE...950
GEAR COVER, FRONT...925
CLEAN...925
INSPECT FOR REUSE...926
MEASURE...927
GEAR COVER SPACER PLATE...925
CLEAN...925
INSPECT FOR REUSE...925
IDLER GEAR, CAMSHAFT...927
CLEAN...927
INSPECT FOR REUSE...927
MAGNETIC CRACK INSPECT...928
IDLER GEAR, HYDRAULIC PUMP...929
CLEAN...929
INSPECT FOR REUSE...930
IDLER GEAR, WATER PUMP...930
CLEAN...930
INSPECT FOR REUSE...930
PISTON...930
CLEAN...930
INSPECT FOR REUSE...931
SERVICE TOOLS...872
CYLINDER BLOCK...872
VIBRATION DAMPER...933
CLEAN...933
INSPECT FOR REUSE...933
CYLINDER HEAD - GROUP 02...951
CROSSHEAD...955
CLEAN...955
INSPECT FOR REUSE...955
CYLINDER HEAD...956
ASSEMBLE...965
CLEAN...957
DISASSEMBLE...964
EXPLODED VIEW...956
INSPECT FOR REUSE...957
PRESSURE TEST...959
VACUUM TEST...961
CYLINDER HEAD - GENERAL INFORMATION...952
GENERAL INFORMATION...952
CYLINDER HEAD INJECTOR BORE...966
ADJUST...968
INSPECT FOR REUSE...966
SERVICE TOOLS...953
CYLINDER HEAD...953
VALVE, CYLINDER HEAD...973
GRIND...975
INSPECT FOR REUSE...974
INSTALL...977
LAP...977
MAGNETIC CRACK INSPECT...974
REMOVE...973
VALVE GUIDE, CYLINDER HEAD...969
CLEAN...969
INSPECT...970
INSPECT FOR REUSE...969
INSTALL...970
REMOVE...969
VALVE SEAT BORE...971
INITIAL CHECK...971
VALVE SEAT INSERT, CYLINDER HEAD...971
GRIND...972
INSTALL...972
REMOVE...971
ROCKER LEVERS - GROUP - 03...980
CRANKCASE BREATHER (EXTERNAL)...984
CLEAN...985
INSTALL...986
REMOVE...984
ROCKER LEVER...987
ASSEMBLE...989
DISASSEMBLE...987
MAGNETIC CRACK INSPECT...988
ROCKER LEVER ASSEMBLY...990
ASSEMBLE...994
CLEAN...992
DISASSEMBLE...993
EXPLODED VIEW...990
INSPECT FOR REUSE...992
ROCKER LEVER BUSHINGS...994
INSTALL...994
REMOVE...994
ROCKER LEVER COVER...995
CLEAN...995
INSPECT FOR REUSE...995
ROCKER LEVER HOUSING...995
ASSEMBLE...996
CLEAN...995
INSPECT FOR REUSE...996
ROCKER LEVERS - GENERAL INFORMATION...981
GENERAL INFORMATION...981
SERVICE TOOLS...982
ROCKER LEVERS...982
CAM FOLLOWERS/TAPPETS - GROUP 04...997
CAM FOLLOWER ASSEMBLY...999
ASSEMBLE...1002
CLEAN...1000
DISASSEMBLE...1000
EXPLODED VIEW...999
INSPECT FOR REUSE...1001
CAM FOLLOWER COVER...1003
CLEAN...1003
GENERAL INFORMATION...1003
INSPECT FOR REUSE...1003
CAM FOLLOWERS/TAPPETS - GENERAL INFORMATION...998
PUSH RODS OR TUBES...1004
CLEAN...1004
GENERAL INFORMATION...1004
INSPECT FOR REUSE...1004
FUEL SYSTEM - GROUP 05...1006
FUEL PUMP...1012
CALIBRATE...1013
CLEAN...1012
INSPECT FOR REUSE...1012
FUEL SHUTOFF VALVE (FSOV)...1015
CLEAN...1016
INSPECT FOR REUSE...1016
INSTALL...1017
REMOVE...1015
FUEL SYSTEM - GENERAL INFORMATION...1007
GENERAL INFORMATION...1007
SERVICE TOOLS...1010
FUEL SYSTEM...1010
INJECTORS AND FUEL LINES - GROUP 06...1019
FUEL FILTER HEAD...1021
INSTALL...1021
REMOVE...1021
FUEL MANIFOLD (SUPPLY)...1022
CLEAN...1022
INSPECT FOR REUSE...1023
FUEL SUPPLY LINES...1023
CLEAN...1023
INSPECT FOR REUSE...1024
FUEL CONTROL SUPPLY LINE...1024
FUEL INLET LINE...1025
FUEL RAIL SUPPLY LINE...1024
FUEL TANK-TO-FUEL FILTER...1024
FUEL TIMING SUPPLY LINE...1024
INJECTOR...1025
CLEAN...1025
INSPECT FOR REUSE...1025
INJECTORS AND FUEL LINES - GENERAL INFORMATION...1020
GENERAL INFORMATION...1020
LUBRICATING OIL SYSTEM - GROUP 7...1028
LUBRICATING OIL COOLER...1031
CLEAN...1032
EXPLODED VIEW...1031
GENERAL INFORMATION...1032
INSPECT FOR REUSE...1032
LUBRICATING OIL FILTER HEAD...1033
ASSEMBLE...1038
CLEAN...1037
DISASSEMBLE...1036
EXPLODED VIEW...1034
GENERAL INFORMATION...1033
INSPECT FOR REUSE...1037
LUBRICATING OIL FILTER HEAD ADAPTER...1041
CLEAN...1041
GENERAL INFORMATION...1041
INSPECT FOR REUSE...1041
LUBRICATING OIL FILTER HEAD (REMOTE-MOUNTED)...1039
ASSEMBLE...1040
CLEAN...1040
DISASSEMBLE...1039
INSPECT FOR REUSE...1040
LUBRICATING OIL PAN...1043
GENERAL INFORMATION...1043
OIL PAN CAPACITY...1043
LUBRICATING OIL PAN ADAPTER...1044
CLEAN...1044
INSPECT FOR REUSE...1044
LUBRICATING OIL PUMP...1045
ASSEMBLE...1050
CLEAN...1047
DISASSEMBLE...1047
EXPLODED VIEW...1046
GENERAL INFORMATION...1045
INSPECT FOR REUSE...1048
LUBRICATING OIL SYSTEM - GENERAL INFORMATION...1029
GENERAL INFORMATION...1029
OIL TRANSFER CONNECTION...1051
ASSEMBLE...1052
CLEAN...1051
DISASSEMBLE...1051
INSPECT FOR REUSE...1051
SERVICE TOOLS...1030
LUBRICATING OIL SYSTEM...1030
COOLING SYSTEM - GROUP 08...1053
COOLANT THERMOSTAT...1057
INSTALL...1059
CONVENTIONAL AFTERCOOLING...1059
LOW TEMPERATURE AFTERCOOLING...1060
REMOVE...1057
TEST...1061
ENGINE THEMOSTATS...1061
LOW TEMPERATURE AFTERCOOLING THERMOSTAT...1062
COOLANT THERMOSTAT HOUSING SUPPORT...1063
GENERAL INFORMATION...1063
LTA COOLING SYSTEM...1063
THERMOSTAT...1063
THERMOSTAT SEAL...1063
THERMOSTAT SUPPORT...1063
COOLING SYSTEM - GENERAL INFORMATION...1054
GENERAL INFORMATION...1054
FAN, COOLING...1071
GENERAL INFORMATION...1071
FAN DRIVE IDLER ARM ASSEMBLY...1064
ASSEMBLE...1065
CLEAN...1064
DISASSEMBLE...1064
INSPECT FOR REUSE...1064
FAN DRIVE IDLER PULLEY ASSEMBLY...1065
CLEAN...1065
INSPECT FOR REUSE...1066
FAN HUB, BELT DRIVEN...1067
ASSEMBLE...1069
CLEAN...1068
GENERAL INFORMATION...1067
INSPECT FOR REUSE...1068
SERVICE TOOLS...1056
COOLING SYSTEM...1056
TORQUE CONVERTER COOLER...1079
ASSEMBLE...1080
CLEAN...1081
DISASSEMBLE...1081
EXPLODED VIEW...1079
GENERAL INFORMATION...1079
INSPECT FOR REUSE...1080
WATER PUMP...1072
ASSEMBLE...1075
CLEAN...1074
DISASSEMBLE...1072
INSPECT...1074
INSPECT FOR REUSE...1072
WATER PUMP BEARINGS ...1081
INSTALL...1082
MEASURE...1081
REMOVE...1081
DRIVE UNITS - GROUP 09...1084
ACCESSORY DRIVE PULLEY...1088
INSPECT FOR REUSE...1088
INSTALL...1088
REMOVE...1088
DRIVE UNITS - GENERAL INFORMATION...1086
GENERAL INFORMATION...1086
FUEL PUMP DRIVE...1090
ASSEMBLE...1095
CLEAN...1092
DISASSEMBLE...1094
EXPLODED VIEW...1091
GENERAL INFORMATION...1090
INSPECT FOR REUSE...1092
FUEL PUMP DRIVE GEAR AND SHAFT...1096
ASSEMBLE...1097
DISASSEMBLE...1096
HYDRAULIC PUMP DRIVE...1099
ASSEMBLE ...1101
CLEAN...1100
DISASSEMBLE...1100
EXPLODED VIEW...1099
GENERAL INFORMATION...1099
INSPECT FOR REUSE...1100
HYDRAULIC PUMP DRIVE GEAR AND SHAFT...1102
ASSEMBLE...1103
DISASSEMBLE...1102
HYDRAULIC PUMP SUPPORT BUSHING...1142
INSPECT FOR REUSE...1143
INSTALL...1143
REMOVE...1142
OUTER HYDRAULIC PUMP SUPPORT DRIVE...1138
ASSEMBLE...1141
DISASSEMBLE...1138
INSPECT FOR REUSE...1139
INSTALL...1140
REAR GEAR DRIVE (LOWER ASSEMBLY)...1103
ASSEMBLE...1111
DISASSEMBLE...1110
EXPLODED VIEW...1108
INSPECT FOR REUSE...1111
INSTALL...1114
REMOVE...1103
REAR GEAR DRIVE (UPPER ASSEMBLY)...1120
ASSEMBLE...1127
DISASSEMBLE...1122
EXPLODED VIEW...1120
INSPECT FOR REUSE...1125
SERVICE TOOLS...1087
DRIVE UNITS...1087
WATER PUMP DRIVE BUSHING...1137
ASSEMBLE...1137
DISASSEMBLE...1137
WATER PUMP DRIVER GEAR AND SHAFT...1136
ASSEMBLE...1137
DISASSEMBLE...1136
WATER PUMP DRIVE PULLEY...1137
CLEAN...1137
INSPECT FOR REUSE...1138
AIR INTAKE SYSTEM - GROUP 10...1144
AFTERCOOLER ASSEMBLY...1147
ASSEMBLE...1149
CLEAN...1148
DISASSEMBLE...1148
EXPLODED VIEW...1147
INSPECT FOR REUSE...1148
AFTERCOOLER COOLANT TUBE...1150
CLEAN...1150
INSPECT FOR REUSE...1150
AIR CROSSOVER...1151
CLEAN...1151
INSPECT FOR REUSE...1151
AIR INTAKE SYSTEM - GENERAL INFORMATION...1145
PREPARATORY...1145
CHARGE AIR COOLER (CAC)...1152
CLEAN...1152
INSPECT FOR REUSE...1152
LEAK TEST...1153
SERVICE TOOLS...1146
AIR INTAKE SYSTEM...1146
TURBOCHARGER HEAT SHIELD...1155
CLEAN...1155
MARINE APLICATIONS...1155
INSPECT FOR REUSE...1155
MARINE APPLICATIONS...1155
INSTALL ...1155
MARINE APPLICATIONS...1155
REMOVE...1155
MARINE APPLICATIONS...1155
TURBOCHARGER, WATER-COOLED...1154
CLEAN...1154
INSPECT FOR REUSE...1154
EXHAUST SYSTEM - GROUP 11...1157
EXHAUST MANIFOLD, DRY...1158
ASSEMBLE...1160
CLEAN...1158
MARINE APPLICATIONS...1159
DISASSEMBLE...1159
INSPECT FOR REUSE...1159
MARINE APPLICATIONS...1160
EXHAUST MANIFOLD HEAT SHIELD...1160
CLEAN...1160
INSPECT FOR REUSE...1161
EXHAUST SYSTEM - GENERAL INFORMATION...1158
GENERAL INFORMATION...1158
COMPRESSED AIR SYSTEM - GROUP 12...1162
COMPRESSED AIR SYSTEM - GENERAL INFORMATION...1163
GENERAL INFORMATION...1163
ELECTRICAL EQUIPMENT - GROUP 13...1165
ALTERNATOR ADJUSTING LINK...1169
CLEAN...1169
INSPECT FOR REUSE...1169
ALTERNATOR BRACKET...1167
CLEAN...1167
INSPECT FOR REUSE...1167
DRIVE BELT, ALTERNATOR...1167
ADJUST...1167
ELECTRICAL EQUIPMENT - GENERAL INFORMATION...1166
GENERAL INFORMATION...1166
STARTING MOTOR...1168
CLEAN...1168
INSPECT FOR REUSE...1169
ENGINE TESTING - GROUP 14...1170
DYNAMOMETER WORKSHEET...1180
WORKSHEET...1180
ENGINE RUN-IN (CHASSIS DYNAMOMETER)...1193
GENERAL INFORMATION...1193
ENGINE THROTTLE CONTROL...1194
RUN-IN INSTRUCTIONS...1196
ENGINE RUN-IN (ENGINE DYNAMOMETER)...1212
GENERAL INFORMATION...1212
RUN-IN INSTRUCTIONS...1214
ENGINE RUN-IN (WITHOUT DYNAMOMETER)...1198
PREPARATORY...1198
GENERAL ENGINE TEST PROCEDURES...1198
RUN-IN INSTRUCTIONS...1200
GENERATOR SET...1200
OFF-HIGHWAY...1200
ENGINE TESTING - GENERAL INFORMATION...1171
FUEL FLOW MEASUREMENT ON ENGINE OR CHASSIS DYNAMOMETER...1172
INSTALLATION...1172
OPERATION...1173
GENERAL INFORMATION...1171
ENGINE TESTING (CHASSIS DYNAMOMETER)...1181
SETUP...1181
TEST...1184
ENGINE TESTING (ENGINE DYNAMOMETER)...1201
INSTALL...1201
TEST...1204
ENGINE TESTING (IN CHASSIS)...1217
STALL SPEED CHECK...1217
TIME SPEED CHECK...1220
SERVICE TOOLS...1178
ENGINE TESTING...1178
SPECIFICATIONS...1176
COOLING SYSTEM...1177
ENGINE TESTING...1176
EXHAUST SYSTEM...1177
LUBRICATING OIL SYSTEM...1177
MOUNTING ADAPTATIONS - GROUP 16...1225
ENGINE SUPPORT BRACKET, FRONT...1229
CLEAN...1229
INSPECT FOR REUSE...1229
FLYWHEEL...1229
CLEAN...1229
INSPECT FOR REUSE...1230
FLYWHEEL HOUSING...1231
CLEAN...1231
INSPECT FOR REUSE...1231
REDOWEL...1232
FLYWHEEL RING GEAR...1235
ASSEMBLE...1236
DISASSEMBLE...1235
MOUNTING ADAPTATIONS - GENERAL INFORMATIONBGENERAL INFORMATION...1226
GENERAL INFORMATION...1226
SERVICE TOOLS...1228
MOUNTING ADAPTATIONS...1228
ELECTRONIC ENGINE CONTROLS - GROUP 19...1238
ELECTRONIC ENGINE CONTROLS - GENERAL INFORMATION...1239
GENERAL INFORMATION...1239
CONNECTOR PINS - CHECKING...1241
CONTINUITY CHECK...1245
HOW TO FIND THE INTERNAL RESISTANCE OF THE METER...1240
HOW TO MEASURE CURRENT...1239
HOW TO MEASURE RESISTANCE...1240
HOW TO MEASURE VOLTAGE...1240
HOW TO TEST FOR CONTINUITY...1240
HOW TO USE A DIGITAL VOLT/OHM METER...1239
POLARITY CHECK...1244
RESISTANCE CHECK - COIL...1246
SHORT CIRCUIT FROM PIN TO PIN - CHECK...1243
SHORT CIRCUIT TO GROUND - CHECK...1242
USE OF SPECIAL TEST LEADS...1239
VOLTAGE CHECKING...1243
ENGINE WIRING HARNESS...1246
INSPECT FOR REUSE...1246
OEM INTERFACE HARNESS...1247
GENERAL INFORMATION...1247
OEM WIRING HARNESS...1247
GENERAL INFORMATION...1247
SERVICE LITERATURE...1249
ADDITIONAL SERVICE LITERATURE...1250
LITERATURE ORDER FORM...1252
SERVICE LITERATURE ORDERING LOCATION...1251
COMPONENT MANUFACTURERS...1254
COMPONENT MANUFACTURERS' ADDRESSES...1255
AIR COMPRESSORS...1255
AIR CYLINDERS...1255
AIR HEATERS...1255
AIR STARTING MOTORS...1255
ALTERNATORS...1255
AUXILIARY BRAKES...1255
BELTS...1255
CATALYTIC CONVERTERS...1255
CLUTCHES...1255
COOLANT HEATERS ...1256
COOLANT LEVEL SWITCHES...1255
DRIVE PLATES...1256
ELECTRIC STARTING MOTORS...1256
ELECTRONIC SWITCHES...1256
ENGINE PROTECTION CONTROLS...1256
FAN CLUTCHES...1256
FANS...1256
FAULT LAMPS...1256
FILTERS...1256
FLEXPLATES...1256
FUEL COOLERS...1256
FUEL WARMERS...1256
GAUGES...1256
GOVERNORS...1257
HEAT SLEEVES...1257
HYDRAULIC AND POWER STEERING PUMPS...1257
IN-LINE CONNECTORS...1257
OIL HEATERS...1257
PRELUBRICATIONS SYSTEMS...1257
RADIATORS...1257
THROTTLE ASSEMBLIES...1257
TORQUE CONVERTERS...1257
SPECIFICATIONS...1259
AIR INTAKE SYSTEM - SPECIFICATIONS...1302
AFTERCOOLER ASSEMBLY...1302
TURBOCHARGER, WATER-COOLED...1302
AIR INTAKE SYSTEM - TORQUE VALUES...1303
AFTERCOOLER ASSEMBLY...1303
TURBOCHARGER HEAT SHIELD...1303
CAM FOLLOWERS/TAPPETS - SPECIFICATIONS...1284
CAM FOLLOWER ASSEMBLY...1284
CAPSCREW MARKINGS AND TORQUE VALUES...1308
CAPSCREW MARKINGS AND TORQUE VALUES - METRIC...1309
CAPSCREW MARKINGS AND TORQUE VALUES - U.S. CUSTOMARY...1310
COMPLETE ENGINE - SPECIFICATIONS...1261
ENGINE ASSEMBLY...1261
COMPLETE ENGINE - TORQUE VALUES...1263
ENGINE ASSEMBLY...1263
ENGINE DISASSEMBLY...1263
COOLING SYSTEM - SPECIFICATIONS...1291
FAN DRIVE IDLER PULLEY ASSEMBLY...1291
FAN HUB, BELT DRIVEN...1291
TORQUE CONVERTER COOLER...1291
WATER PUMP...1291
WATER PUMP BEARINGS...1292
COOLING SYSTEM - TORQUE VALUES...1293
COOLANT THERMOSTAT...1293
FAN HUB, BELT DRIVEN...1293
TORQUE CONVERTER COOLER...1294
WATER PUMP...1294
CYLINDER BLOCK - SPECIFICATIONS...1273
BEARINGS, MAIN...1273
CAMSHAFT...1273
CAMSHAFT BUSHINGS...1273
CAMSHAFT GEAR (CAMSHAFT REMOVED)...1273
CONNECTING ROD...1274
CRANKSHAFT...1275
CRANKSHAFT GEAR, FRONT (CRANKSHAFT INSTALLED)...1275
CRANKSHAFT PULLEY...1275
CYLINDER BLOCK...1275
CYLINDER BLOCK AND LINER SEATS...1275
CYLINDER BLOCK COUNTERBORE...1278
CYLINDER LINER...1276
GEAR COVER ACCESSORY DRIVE BUSHING...1278
GEAR COVER, FRONT...1277
GEAR COVER SPACER PLATE...1277
IDLER GEAR, CAMSHAFT...1277
MEASURE THE CONNECTING ROD BEND (BORE ALIGHNMENT)...1274
MEASURE THE CONNECTING ROD TWIST...1275
PISTON...1277
CYLINDER BLOCK - TORQUE VALUES...1279
CONNECTING ROD...1279
CRANKSHAFT PULLEY...1279
CYLINDER BLOCK...1279
CYLINDER BLOCK COUNTERBORE...1279
CYLINDER HEAD - SPECIFICATIONS...1280
CYLINDER HEAD ...1280
CYLINDER HEAD INJECTOR BORE...1280
VALVE, CYLINDER HEAD...1281
VALVE GUIDE, CYLINDER HEAD...1280
VALVE SEAT BORE...1281
VALVE SEAT INSERT, CYLINDER HEAD...1281
DRIVE BELT TENSION...1307
DRIVE UNITS - SPECIFICATIONS...1295
FUEL PUMP DRIVE...1295
FUEL PUMP DRIVE GEAR AND SHAFT...1296
HYDRAULIC PUMP DRIVE...1296
HYDRAULIC PUMP SUPPORT BUSHING...1299
OUTER HYDRAULIC PUMP SUPPORT DRIVE...1298
REAR GEAR DRIVE (LOWER ASSEMBLY)...1296
REAR GEAR DRIVE (UPPER ASSEMBLY)...1297
WATER PUMP DRIVE...1298
DRIVE UNITS - TORQUE VALUES...1300
OUTER HYDRUALIC PUMP SUPPORT DRIVE...1301
REAR GEAR DRIVE (LOWER ASSEMBLY)...1300
REAR GEAR DRIVE (UPPER ASSEMBLY)...1300
ELECTRICAL EQUIPMENT - SPECIFICATIONS...1305
DRIVE BELT, ALTERNATOR...1305
ENGINE TESTING - SPECIFICATIONS...1306
ENGINE TESTING (CHASSIS DYNAMOMETER)...1306
ENGINE TESTING (ENGINE DYNAMOMETER)...1306
EXHAUST SYSTEM - SPECIFICATIONS...1304
EXHAUST MANIFOLD, DRY...1304
FRACTION, DECIMAL, MILLIMETER CONVERSIONS...1311
FUEL SYSTEM - TORQUE VALUES...1285
FUEL SHUTOFF VALVE (FSOV)...1285
INJECTORS AND FUEL LINES - TORQUE VALUES...1286
FUEL MANIFOLD(SUPPLY)...1286
LUBRICATING OIL SYSTEM - SPECIFICATIONS...1287
LUBRICATING OIL FITER HEAD...1287
LUBRICATING OIL FILTER HEAD (LF670)...1287
LUBRICATING OIL FILTER HEAD (REMOTE-MOUNTED)...1287
LUBRICATING OIL PAN...1287
LUBRICATING OIL PUMP...1287
OIL TRANSFER CONNECTION...1288
LUBRICATING OIL SYSTEM - TORQUE VALUES...1289
LUBRICATING OIL COOLER...1289
LUBRICATING OIL FILTER HEAD...1289
LUBRICATING OIL FILTER HEAD (REMOTE-MOUNTED)...1289
LUBRICATING OIL PUMP...1289
OIL TRANSFER CONNECTION...1290
NEWTON-METER TO FOOT-POUND CONVERSION CHART...1312
PIPE PLUG TORQUE VALUES...1313
ROCKER LEVERS - SPECIFICATIONS...1283
ROCKER LEVER...1283
ROCKER LEVER ASSEMBLY...1283
ROCKER LEVER BUSHINGS...1283
TAP-DRILL CHART - U.S. CUSTOMARY AND METRIC...1314
WEIGHTS AND MEASURES - CONVERSION FACTORS...1315
INDEX...1317
3810307 - K19 Engines Troubleshooting & Repair Manual...1325
COVER PAGE...1325
FOREWORD...1327
TABLE OF CONTENTS...1328
SECTION I - INTRODUCTION...1330
ABOUT THE MANUAL...1331
HOW TO USE THE MANUAL...1331
SYMBOLS...1332
SIMBOLOS...1333
SYMBOLE...1334
SYMBOLES...1335
ILLUSTRATIONS...1336
GENERAL SAFETY INSTRUCTIONS...1337
IMPORTANT SAFETY NOTICE...1337
GENERAL REPAIR INSTRUCTIONS...1338
GENERAL CLEANING INSTRUCTIONS...1339
SOLVENT AND ACID CLEANING...1339
STEAM CLEANING...1339
GLASS OR PLASTIC BEAD CLEANING...1339
DEFINITION OF TERMS...1340
SECTION E - ENGINE AND COMPONENT IDENTIFICATION...1344
ENGINE IDENTIFICATION...1345
CUMMINS ENGINE NOMENCLATURE...1345
ENGINE DATAPLATE...1345
FUEL PUMP DATAPLATE...1345
GENERAL SPECIFICATIONS...1346
GENERAL ENGINE DATA...1347
AIR INDUCTION SYSTEM...1348
LUBRICATING OIL SYSTEM...1348
COOLING SYSTEM...1348
EXHAUST SYSTEM...1348
FUEL SYSTEM...1349
ELECTRICAL SYSTEM...1349
EXTERNAL ENGINE COMPONENTS...1350
SECTION T - TROUBLESHOOTING...1352
PROCEDURES AND TECHNIQUES...1352
TROUBLESHOOTING CHARTS (ALPHABETICAL LISTING)...1353
TROUBLESHOOTING CHARTS (BY SYSTEM)...1355
COOLANT TEMPERATURE ABOVE NORMAL...1357
COOLANT TEMPERATURE BELOW NORMAL...1359
COOLANT LOSS...1360
FUEL IN COOLANT...1361
LUBRICATING OIL PRESSURE LOW...1362
LUBRICATING OIL PRESSURE HIGH...1364
LUBRICATING OIL TEMPERATURE ABOVE NORMAL...1365
LUBRICATING OR HYDRAULIC OIL IN THE COOLANT...1366
LUBRICATING OIL CONSUMPTION EXCESSIVE...1367
LUBRICATING OIL SLUDGE IN THE ENGINE CRANKCASE EXCESSIVE...1369
COOLANT IN THE LUBRICATING OIL...1370
FUEL IN THE LUBRICATING OIL...1371
TURBOCHARGER NOISE...1372
TURBOCHARGER BOOST PRESSURE LOW...1373
TURBOCHARGER LEAKS (ENGINE OIL OR FUEL)...1374
AIR COMPRESSOR SLOW AIR PRESSURE RISE...1375
AIR COMPRESSOR WILL NOT MAINTAIN ADEQUATE AIR PRESSURE (NOT PUMPING CONTINUOUSLY)...1376
AIR COMPRESSOR PUMPING EXCESSIVE LUBRICATING OIL...1377
AIR COMPRESSOR WILL NOT PUMP...1378
AIR COMPRESSOR WILL NOT STOP PUMPING...1379
AIR COMPRESSOR NOISE EXCESSIVE...1380
ENGINE CRANKS BUT WILL NOT START (NO SMOKE FROM EXHAUST)...1381
ENGINE HARD TO START OR WILL NOT START (EXHAUST SMOKE PRESENT)...1383
ENGINE STARTS BUT WILL NOT KEEP RUNNING...1384
ENGINE RUNS ROUGH OR MISFIRES (WARM ENGINE)...1386
IDLE ROUGH...1388
ENGINE SURGES AT LOW IDLE...1389
ENGINE WILL NOT REACH RATED RPM WHEN LOADED...1390
ENGINE POWER OUTPUT LOW...1391
APPLICATION SPECIFIC PROBLEM - CONSTRUCTION...1393
APPLICATION SPECIFIC PROBLEM - GENSET ...1393
APPLICATION SPECIFIC PROBLEM - MARINE...1394
PERFORMANCE MEASUREMENT...1395
EXHAUST SMOKE EXCESSIVE UNDER LOAD...1397
ENGINE WILL NOT SHUT OFF...1398
ENGINE DECELERATES POORLY...1399
ENGINE SURGES UNDER LOAD...1400
ENGINE SURGES AT HIGH IDLE...1401
THROTTLE RESPONSE SLOW (ENGINE DIES GOING DOWN HILL)...1402
FUEL CONSUMPTION EXCESSIVE...1403
ENGINE WILL NOT CRANK OR CRANKS SLOWLY (AIR STARTER)...1404
ENGINE WILL NOT CRANK OR CRANKS SLOWLY (ELECTRIC STARTER)...1405
ALTERNATOR MALFUNCTIONING...1407
CRANKCASE GASES (BLOWBY) EXCESSIVE...1408
ENGINE VIBRATION EXCESSIVE...1409
ENGINE NOISE - DIAGNOSTIC PROCEDURES...1410
MAIN BEARING NOISE...1410
CONNECTING ROD BEARING NOISE...1410
PISTON NOISE...1410
ENGINE NOISE EXCESSIVE...1411
EXHAUST SMOKE (WHITE) AT IDLE EXCESSIVE (WARM ENGINE)...1413
SECTION 1 - COOLING SYSTEM...1416
SERVICE TOOLS (01-00)...1417
GENERAL INFORMATION (01-01)...1418
COOLING SYSTEM SPECIFICATIONS (01-02)...1419
COOLING SYSTEM FLOW CHARTS (01-03)...1424
COOLING SYSTEM VENTING (01-04)...1426
COOLING SYSTEM - MAINTENANCE (01-05)...1427
COOLING SYSTEM - DRAIN (01-06)...1428
COOLING SYSTEM - FILL (01-07)...1429
COOLANT FILTER - REPLACE (01-08)...1431
DIESEL COOLANT ADDITIVES (DCA4) (01-09)...1432
COOLING SYSTEM - CLEAN (01-10)...1436
COOLING SYSTEM - TEST FOR AIR OR COMBUSTION GASES (01-11)...1436
CRACKED OR POROUS CYLINDER LINER...1438
DEFECTIVE AIR CONTROL VALVE...1440
AIR COMPRESSOR CHECK...1440
COOLING SYSTEM - PRESSURE TEST (01-12)...1441
HOSES - CHECK (01-13)...1444
COOLANT TEMPERATURE GAUGE - CHECK (01-14)...1444
RADIATOR PRESSURE CAP - CHECK (01-15)...1445
RADIATOR FINS - INSPECT (01-16)...1445
RADIATOR BAFFLE LEAKAGE - CHECK (01-17)...1446
RADIATOR - CHECK FOR REVERSE FLOW (01-18)...1446
RADIATOR - CHECK FOR OBSTRUCTION (01-19)...1447
SHUTTER OPERATION - CHECK (01-20)...1448
FAN, AND FAN SHROUD - INSPECT (01-21)...1450
FAN - REPLACE (01-22)...1451
FAN DRIVE BELT - REPLACE (01-23)...1452
FAN CLUTCH - CHECK OPERATION (01-24)...1454
FAN RPM - CHECK (01-25)...1457
FAN HUB (BELT DRIVEN) - REPLACE (01-26)...1459
FAN HUB (GEAR DRIVEN) - REPLACE (01-27)...1460
FAN HUB IDLER AND SHOCK ABSORBER (OR TURNBUCKLE) - REPLACE (01-28)...1462
WATER PUMP BLOCK PRESSURE - CHECK (01-29)...1464
WATER PUMP - REPLACE (01-30)...1466
WATER PUMP - CHECK FOR REUSE (01-31)...1470
THERMOSTAT - TEST (THERMOSTAT IN CHASSIS) (01-32)...1471
THERMOSTAT - REPLACE (01-33)...1473
THERMOSTAT - CHECK OPERATING TEMPERATURE (01-34)...1477
THERMOSTAT HOUSING - REPLACE (01-35)...1478
CHECK FOR COOLANT LEAKS AT COUNTERBORE (01-36)...1481
SECTION 2 - LUBRICATION OIL SYSTEM...1483
SERVICE TOOLS (01-00)...1484
GENERAL INFORMATION (02-01)...1486
SPECIFICATIONS (02-02)...1487
FLOW DIAGRAMS (02-03)...1488
INTERNAL ENGINE DAMAGE - CHECK (02-04)...1491
OIL LEAKS (EXTERNAL) - CHECKS (02-05)...1492
OIL SYSTEM - LEAK CHECK USING DYE (02-06)...1493
OIL PRESSURE GAUGE - CHECK (02-07)...1494
OIL TEMPERATURE GAUGE - CHECK (02-08)...1494
DRAIN OIL (02-09)...1495
OIL PAN - FILL (02-10)...1496
OIL FILTERS (FULL FLOW AND BYPASS) - REPLACE (02-11)...1497
OIL FILTER (FULL FLOW) - MEASURE PRESSURE DROP (02-12)...1498
CRANKCASE BREATHER AND TUBE - REPLACE (02-13)...1499
DIPSTICK TUBE - REPLACE (02-14)...1501
DIPSTICK - CALIBRATE (02-15)...1501
OIL PAN - REPLACE (02-16)...1503
OIL PAN ADAPTER - REPLACE (02-17)...1505
OIL FILTER HEAD - REPLACE (02-18)...1512
OIL COOLER - MEASURE PRESSURE DROP (02-19)...1514
OIL COOLER COVER - REPLACE (02-20)...1515
TORQUE CONVERTER COOLER - REPLACE (02-21)...1519
OIL COOLER CORE - REPLACE (02-22)...1524
OIL COOLER CORE - CHECK FOR REUSE (02-23)...1525
TORQUE CONVERTER COOLER - PRESSURE TEST (02-24)...1525
OIL COOLER HOUSING - REPLACE (02-25)...1526
MAIN OIL PRESSURE REGULATOR - REPLACE (02-26)...1529
OIL PUMP - REPLACE (02-27)...1531
LUBRICATING OIL PUMP - CHECK FOR REUSE (02-28)...1533
SECTION 3 - COMBUSTION AIR SYSTEM...1535
GENERAL INFORMATION (03-01)...1536
SPECIFICATIONS (03-02)...1537
FLOW DIAGRAMS (03-03)...1538
SERVICE TOOLS (03-04)...1540
TURBOCHARGER TURBINE SEAL LEAKS - CHECK (03-05)...1541
COMPRESSOR SEAL LEAKAGE - CHECK (03-06)...1543
CORRECT TURBOCHARGER INSTALLED - CHECK (03-07)...1545
INTAKE AIR RESTRICTION - CHECK (03-08)...1545
EXHAUST RESTRICTION - CHECK (03-09)...1547
AIR LEAKS - CHECK (03-10)...1548
TURBOCHARGER BLADE DAMAGE - CHECK (03-11)...1550
TURBOCHARGER AXIAL AND RADIAL CLEARANCE - CHECK (03-12)...1551
TURBOCHARGER - REPLACE (03-13)...1552
SERIES TURBOCHARGER - REPLACE (03-14)...1558
EXHAUST MANIFOLD - REPLACE (03-15)...1566
EXHAUST MANIFOLD - CHECK (03-16)...1571
AFTERCOOLER - REPLACE (03-17)...1572
AFTERCOOLER ELEMENT - REPLACE (03-18)...1578
AFTERCOOLER ELEMENT - TEST (03-19)...1582
INTAKE MANIFOLD PRESSURE - CHECK (03-20)...1583
SECTION 4 - COMPRESSED AIR SYSTEM...1585
GENERAL INFORMATION (04-01)...1586
SPECIFICATIONS (04-02)...1587
FLOW DIAGRAMS (04-03)...1589
SERVICE TOOLS (04-04)...1590
CARBON BUILDUP, AIR COMPRESSOR - CHECK (04-05)...1591
GASKET LEAKS, AIR COMPRESSOR - CHECK (04-06)...1593
AIR GOVERNOR - CHECK (AIR COMPRESSOR NOT PUMPING) (04-07)...1593
AIR GOVERNOR - CHECK (AIR COMPRESSOR PUMPS CONTINUOUSLY) (04-08)...1594
LUBRICATING OIL USAGE, AIR COMPRESSOR - CHECK (04-09)...1596
UNLOADER VALVE, AIR COMPRESSOR - REPLACE (04-10)...1597
UNLOADER VALVE - CHECK (04-11)...1600
INTAKE/EXHAUST VALVES, AIR COMPRESSOR - CHECK (04-12)...1601
CYLINDER HEAD, AIR COMPRESSOR - REBUILD ON ENGINE (04-13)...1603
CYLINDER HEAD, AIR COMPRESSOR - REPLACE (04-14)...1607
AIR COMPRESSOR (SINGLE CYLINDER) - REPLACE (04-15)...1611
AIR COMPRESSOR (TWO CYLINDER) - REPLACE (04-16)...1614
AIR COMPRESSOR - CHECK FOR REUSE (04-17)...1618
SECTION 5 - FUEL SYSTEM...1621
GENERAL INFORMATION (05-01)...1622
SPECIFICATIONS 05-02)...1623
FLOW DIAGRAMS (05-03)...1628
SERVICE TOOLS (05-04)...1634
IDLE SPEED - CHECK AND ADJUST (05-05)...1639
HORSEPOWER - MEASURE ENGINE PERFORMANCE (05-06)...1642
FUEL RATE - ADJUST (05-07)...1648
AFC NO-AIR VALVE SETTING - CHECK AND ADJUST (05-08)...1650
INJECTORS - REPLACE (05-09)...1654
INJECTORS - CLEAN EXTERIOR FOR REUSE (05-10)...1659
FUEL PUMP - REPLACE (05-11)...1659
THROTTLE TRAVEL - CHECK (05-12)...1663
FUEL SYSTEM MAINTENANCE (05-13)...1664
GEAR PUMP CHECK VALVE - REPLACE (05-14)...1667
VARIABLE SPEED (VS) GOVERNOR LEAKING FUEL (05-15)...1668
FUEL SHUTOFF VALVE - CHECK (05-16)...1671
FUEL PUMP - FLOW CHECK AND PRIME (05-17)...1673
FUEL PUMP ROTATION CHECK (05-18)...1675
AIR LEAKS (05-19)...1676
AFC - CHECK FOR AIR LEAK (05-20)...1680
CYLINDER MISFIRE (05-21)...1684
ENGINE OIL DILUTION BY FUEL (05-22)...1685
FUEL LINE RESTRICTION (SUCTION) - CHECK (05-23)...1689
FUEL DRAIN RESTRICTION - CHECK (05-24)...1691
STC OIL CONTROL VALVE - CHECK (05-25)...1693
STC FUEL PRESSURE SWITCH - CHECK (05-26)...1695
STC WIRING HARNESS - CHECK FOR REUSE (05-27)...1696
STC OIL CONTROL VALVE - REPLACE (05-28)...1697
STC WIRING HARNESS - REPLACE (05-29)...1699
FUEL CONSUMPTION CHECK (05-30)...1699
LOW POWER CHECK (05-31)...1704
ENGINE STALL SPEED AND TIME CHECK (05-32)...1706
FUEL MANIFOLD - REPLACE (05-33)...1710
STC OIL MANIFOLD - REPLACE (05-34)...1712
STALL SPEED CHECK LIST (05-35)...1713
DRIVEABILITY - LOW POWER CHECK LIST (05-36)...1715
FUEL CONSUMPTION CHECK LIST (05-37)...1718
SECTION 6 - ELECTRICALSYSTEM...1721
GENERAL INFORMATION (06-01)...1722
SPECIFICATIONS (06-02)...1723
SERVICE TOOLS (06-03)...1724
BATTERY TERMINAL CONNECTIONS - CHECK (06-04)...1725
BATTERIES - CHECK (06-05)...1725
STARTING CIRCUIT - CHECK (06-06)...1726
ALTERNATOR BELT - ADJUST (06-07)...1732
ALTERNATOR - OUTPUT TEST (06-08)...1734
ALTERNATOR - REPLACE (06-09)...1735
ACCESSORY/ALTERNATOR DRIVE PULLEY - CHECK FOR REUSE (06-10)...1738
STARTING MOTOR - REPLACE (06-11)...1738
STARTER MOTOR - CHECK FOR REUSE (06-12)...1739
SECTION 7 - BASE ENGINE COMPONENTS...1741
SERVICE TOOLS (07-01)...1743
GENERAL INFORMATION (07-02)...1749
CRANKCASE GAS (BLOWBY) - CHECK (07-03)...1749
ROCKER LEVER COVER - REPLACE (07-04)...1753
CHECK/ADJUST VALVES AND INJECTORS (07-05)...1757
JACOBS ENGINE BRAKE - ADJUST (07-06)...1766
JACOBS ENGINE BRAKE - REPLACE (07-07)...1769
PUSH ROD - REPLACE (07-08)...1771
ROCKER LEVER ASSEMBLY - REPLACE (07-09)...1773
ROCKER LEVER ASSEMBLY - CLEAN AND CHECK FOR REUSE (07-10)...1775
ROCKER LEVER HOUSING - REPLACE (07-11)...1777
CHECK CYLINDER HEAD GASKET FOR COMBUSTION, COOLANT, OR OIL LEAK (07-12)...1783
POWER CYLINDER - LOCATE FAILED CYLINDER (07-13)...1785
CYLINDER HEAD GASKET - REPLACE (07-14)...1787
CYLINDER HEAD - CLEAN AND CHECK FOR REUSE (07-15)...1798
PRESSURE TEST CYLINDER HEAD - HEAD REMOVED (07-16)...1800
CAM FOLLOWER ASSEMBLY - REPLACE (07-17)...1804
CAM FOLLOWER ASSEMBLY - CLEAN AND CHECK FOR REUSE (07-18)...1808
INJECTION TIMING - GENERAL INFORMATION (07-19)...1809
MEASURE THE INJECTION TIMING (07-20)...1811
PISTON COOLING NOZZLE - REPLACE (07-21)...1820
MAIN CRANKSHAFT BEARING - REPLACE (07-22)...1820
CONNECTING ROD BEARING - REPLACE (07-23)...1828
PISTON AND ROD ASSEMBLY - REPLACE (07-24)...1833
PISTON - CLEAN AND CHECK FOR REUSE (07-25)...1845
CYLINDER LINER - REMOVE (07-26)...1848
CHECK LINER PROTRUSION (07-27)...1859
ACCESSORY DRIVE PULLEY - REPLACE (07-28)...1860
WEAR SLEEVE, ACCESSORY DRIVE PULLEY - REPLACE (07-29)...1861
ACCESSORY DRIVE SEAL - REPLACE (07-30)...1863
ACCESSORY DRIVE ASSEMBLY - REPLACE (07-31)...1865
FUEL PUMP/COMPRESSOR DRIVE - CLEAN AND CHECK FOR REUSE (07-32)...1869
VIBRATION DAMPER - REPLACE (07-33)...1869
VISCOUS VIBRATION DAMPER - CLEAN AND CHECK FOR REUSE (07-34)...1872
RUBBER VIBRATION DAMPER - CLEAN AND CHECK FOR REUSE (07-35)...1873
CRANKSHAFT FRONT SEAL - REPLACE (07-36)...1874
WATER PUMP DRIVE - REPLACE (07-37)...1877
WATER PUMP DRIVE - CLEAN AND CHECK FOR REUSE (07-38)...1881
GEAR COVER (ONE PIECE) - REPLACE (07-39)...1881
CAMSHAFT GEAR - REPLACE (CAMSHAFT INSTALLED) (07-40)...1895
GEAR COVER PLATE (SPACER PLATE) - REPLACE (07-41)...1900
GEAR COVER (TWO PIECE) - REPLACE (07-42)...1906
GEAR HOUSING (TWO PIECE DESIGN) - REPLACE (07-43)...1916
CHECK GEAR TRAIN BACKLASH (07-44)...1928
IDLER SHAFT (PRESS-IN) - REPLACE (07-45)...1928
FRONT ENGINE SUPPORT - REPLACE (07-46)...1931
CRANKSHAFT GEAR - REMOVE AND INSTALL (07-47)...1933
CAMSHAFT - REPLACE (07-48)...1935
CAMSHAFT GEAR - REMOVE AND INSTALL (07-49)...1944
CYLINDER BLOCK - REPLACE CAMSHAFT BUSHINGS (07-50)...1947
CAMSHAFT REAR COVER - REPLACE (07-51)...1949
FLYWHEEL - REPLACE (07-52)...1950
CRANKSHAFT SEAL, REAR - REPLACE (07-53)...1953
FLYWHEEL HOUSING - REPLACE (07-54)...1954
FLYWHEEL HOUSING REDOWEL TO CYLINDER BLOCK (07-55)...1963
PIPE PLUGS AND CUP PLUGS - REPLACE (07-56)...1967
SECTION 8 - ENGINE TESTING ("IN-CHASSIS")...1971
SPECIFICATIONS AND PROCEDURES (08-01)...1972
GENERAL ENGINE TEST PROCEDURES (08-01)...1973
CHASSIS DYNAMOMETER OPERATION (08-02)...1975
ENGINE RUN-IN PROCEDURE (CHASSIS DYNAMOMETER) (08-03)...1977
ENGINE RUN-IN PROCEDURE "IN-CHASSIS" (ON AND OFF-HIGHWAY VEHICLES) (08-04)...1980
ENGINE CONFIGURATIONS AND MODELS (08-05)...1982
SECTION 9 - ENGINE REMOVE AND INSTALL...1985
GENERAL INFORMATION (09-01)...1986
SERVICE TOOLS (09-02)...1987
ENGINE - REMOVE (09-03)...1988
ENGINE MOUNT - INSPECT (09-04)...1991
ENGINE - INSTALL (09-05)...1991
SECTION 10 - ENGINE COMPONENT SPECIFICATIONS...1995
GENERAL INFORMATION (10-01)...1996
CONVERSION FACTORS (10-02)...1997
PIPE PLUG TORQUE VALUES (10-03)...1998
CAPSCREW MARKINGS AND TORQUE VALUES (10-04)...1998
DECIMAL AND METRIC EQUIVALENTS (10-05)...2000
COOLING SYSTEM (10-06)...2001
LUBRICATING OIL SYSTEM (10-07)...2004
COMBUSTION AIR SYSTEM (10-08)...2006
COMPRESSED AIR SYSTEM (10-09)...2008
FUEL SYSTEM (10-10)...2010
ELECTRICAL SYSTEM (10-11)...2011
BASE ENGINE COMPONENTS (10-12)...2012
SECTION 11 - INDEX - TROUBLESHOOTING AND REPAIR...2021
SECTION 12 - SERVICE LITERATURE...2030
SERVICE LITERATURE ORDERING LOCATION...2031
SERVICE LITERATURE ORDER FORM...2032
SECTION 13 - COMPONENT MANUFACTURERS...2034
4021375 - QSK23 Troubleshooting & Repair Manual...2038
4021528 - K38, K50, QSK38 & QSK50 Service Manual Vol. 3...3037
4021533 - Troubleshooting and Repair Manual - Electronic Control System, QSK50 and QSK60, CM850 - Modular Common Rail System Series Engines - Volume 1...3891
4021533 - Troubleshooting and Repair Manual - Electronic Control System, QSK50 and QSK60, CM850 - Modular Common Rail System Series Engines - Volume 2...4819
4021533 - Troubleshooting and Repair Manual - Electronic Control System, QSK50 and QSK60, CM850 - Modular Common Rail System Series Engines - Volume 3...5533
Cummins QSK19 Fuel System Familiarisation...6339
Cummins QSK19, QSK23, QSK38, QSK45, QSK50, QSK60, QSK78 & K19, K38, K50 Engines Service Repair Manual
