Cummins K19 Engine - Service Manual - Repair Manual

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CUMMINS K19 ENGINE - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual / Repair Manual, for Cummins K19 Engine.
 

CONTENTS:

SECTION I - INTRODUCTION
- About The Manual
- How To Use The Manual
- Symbols
- Simbolos
- Symbole
- Symboles
- Illustrations
- General Safety Instructions
- General Repair Instructions
- General Cleaning Instructions
- Definition Of Terms
SECTION E - ENGINE AND COMPONENT IDENTIFICATION
- Engine Identification
- General Specifications
- External Engine Components
SECTION T - TROUBLESHOOTING
- Procedures And Techniques
- Troubleshooting Charts (Alphabetical Listing)
- Troubleshooting Charts (By System)
- Coolant Temperature Above Normal
- Coolant Temperature Below Normal
- Coolant Loss
- Fuel In Coolant
- Lubricating Oil Pressure Low
- Lubricating Oil Pressure High
- Lubricating Oil Temperature Above Normal
- Lubricating Or Hydraulic Oil In The Coolant
- Lubricating Oil Consumption Excessive
- Lubricating Oil Sludge In The Engine Crankcase Excessive
- Coolant In The Lubricating Oil
- Fuel In The Lubricating Oil
- Turbocharger Noise
- Turbocharger Boost Pressure Low
- Turbocharger Leaks (Engine Oil Or Fuel)
- Air Compressor Slow Air Pressure Rise
- Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously)
- Air Compressor Pumping Excessive Lubricating Oil
- Air Compressor Will Not Pump
- Air Compressor Will Not Stop Pumping
- Air Compressor Noise Excessive
- Engine Cranks But Will Not Start (No Smoke From Exhaust)
- Engine Hard To Start Or Will Not Start (Exhaust Smoke Present)
- Engine Starts But Will Not Keep Running
- Engine Runs Rough Or Misfires (Warm Engine)
- Idle Rough
- Engine Surges At Low Idle
- Engine Will Not Reach Rated Rpm When Loaded
- Engine Power Output Low
- Performance Measurement
- Exhaust Smoke Excessive Under Load
- Engine Will Not Shut Off
- Engine Decelerates Poorly
- Engine Surges Under Load
- Engine Surges At High Idle
- Throttle Response Slow (Engine Dies Going Down Hill)
- Fuel Consumption Excessive
- Engine Will Not Crank Or Cranks Slowly (Air Starter)
- Engine Will Not Crank Or Cranks Slowly (Electric Starter)
- Alternator Malfunctioning
- Crankcase Gases (Blowby) Excessive
- Engine Vibration Excessive
- Engine Noise - Diagnostic Procedures
- Engine Noise Excessive
- Exhaust Smoke (White) At Idle Excessive (Warm Engine)
SECTION 1 - COOLING SYSTEM
- Service Tools (01-00)
- General Information (01-01)
- Cooling System Specifications (01-02)
- Cooling System Flow Charts (01-03)
- Cooling System Venting (01-04)
- Cooling System - Maintenance (01-05)
- Cooling System - Drain (01-06)
- Cooling System - Fill (01-07)
- Coolant Filter - Replace (01-08)
- Diesel Coolant Additives (Dca4) (01-09)
- Cooling System - Clean (01-10)
- Cooling System - Test For Air Or Combustion Gases (01-11)
- Cracked Or Porous Cylinder Liner
- Defective Air Control Valve
- Air Compressor Check
- Cooling System - Pressure Test (01-12)
- Hoses - Check (01-13)
- Coolant Temperature Gauge - Check (01-14)
- Radiator Pressure Cap - Check (01-15)
- Radiator Fins - Inspect (01-16)
- Radiator Baffle Leakage - Check (01-17)
- Radiator - Check For Reverse Flow (01-18)
- Radiator - Check For Obstruction (01-19)
- Shutter Operation - Check (01-20)
- Fan, And Fan Shroud - Inspect (01-21)
- Fan - Replace (01-22)
- Fan Drive Belt - Replace (01-23)
- Fan Clutch - Check Operation (01-24)
- Fan Rpm - Check (01-25)
- Fan Hub (Belt Driven) - Replace (01-26)
- Fan Hub (Gear Driven) - Replace (01-27)
- Fan Hub Idler And Shock Absorber (Or Turnbuckle) - Replace (01-28)
- Water Pump Block Pressure - Check (01-29)
- Water Pump - Replace (01-30)
- Water Pump - Check For Reuse (01-31)
- Thermostat - Test (Thermostat In Chassis) (01-32)
- Thermostat - Replace (01-33)
- Thermostat - Check Operating Temperature (01-34)
- Thermostat Housing - Replace (01-35)
- Check For Coolant Leaks At Counterbore (01-36)
SECTION 2 - LUBRICATION OIL SYSTEM
- Service Tools (01-00)
- General Information (02-01)
- Specifications (02-02)
- Flow Diagrams (02-03)
- Internal Engine Damage - Check (02-04)
- Oil Leaks (External) - Checks (02-05)
- Oil System - Leak Check Using Dye (02-06)
- Oil Pressure Gauge - Check (02-07)
- Oil Temperature Gauge - Check (02-08)
- Drain Oil (02-09)
- Oil Pan - Fill (02-10)
- Oil Filters (Full Flow And Bypass) - Replace (02-11)
- Oil Filter (Full Flow) - Measure Pressure Drop (02-12)
- Crankcase Breather And Tube - Replace (02-13)
- Dipstick Tube - Replace (02-14)
- Dipstick - Calibrate (02-15)
- Oil Pan - Replace (02-16)
- Oil Pan Adapter - Replace (02-17)
- Oil Filter Head - Replace (02-18)
- Oil Cooler - Measure Pressure Drop (02-19)
- Oil Cooler Cover - Replace (02-20)
- Torque Converter Cooler - Replace (02-21)
- Oil Cooler Core - Replace (02-22)
- Oil Cooler Core - Check For Reuse (02-23)
- Torque Converter Cooler - Pressure Test (02-24)
- Oil Cooler Housing - Replace (02-25)
- Main Oil Pressure Regulator - Replace (02-26)
- Oil Pump - Replace (02-27)
- Lubricating Oil Pump - Check For Reuse (02-28)
SECTION 3 - COMBUSTION AIR SYSTEM
- General Information (03-01)
- Specifications (03-02)
- Flow Diagrams (03-03)
- Service Tools (03-04)
- Turbocharger Turbine Seal Leaks - Check (03-05)
- Compressor Seal Leakage - Check (03-06)
- Correct Turbocharger Installed - Check (03-07)
- Intake Air Restriction - Check (03-08)
- Exhaust Restriction - Check (03-09)
- Air Leaks - Check (03-10)
- Turbocharger Blade Damage - Check (03-11)
- Turbocharger Axial And Radial Clearance - Check (03-12)
- Turbocharger - Replace (03-13)
- Series Turbocharger - Replace (03-14)
- Exhaust Manifold - Replace (03-15)
- Exhaust Manifold - Check (03-16)
- Aftercooler - Replace (03-17)
- Aftercooler Element - Replace (03-18)
- Aftercooler Element - Test (03-19)
- Intake Manifold Pressure - Check (03-20)
SECTION 4 - COMPRESSED AIR SYSTEM
- General Information (04-01)
- Specifications (04-02)
- Flow Diagrams (04-03)
- Service Tools (04-04)
- Carbon Buildup, Air Compressor - Check (04-05)
- Gasket Leaks, Air Compressor - Check (04-06)
- Air Governor - Check (Air Compressor Not Pumping) (04-07)
- Air Governor - Check (Air Compressor Pumps Continuously) (04-08)
- Lubricating Oil Usage, Air Compressor - Check (04-09)
- Unloader Valve, Air Compressor - Replace (04-10)
- Unloader Valve - Check (04-11)
- Intake/Exhaust Valves, Air Compressor - Check (04-12)
- Cylinder Head, Air Compressor - Rebuild On Engine (04-13)
- Cylinder Head, Air Compressor - Replace (04-14)
- Air Compressor (Single Cylinder) - Replace (04-15)
- Air Compressor (Two Cylinder) - Replace (04-16)
- Air Compressor - Check For Reuse (04-17)
SECTION 5 - FUEL SYSTEM
- General Information (05-01)
- Specifications 05-02)
- Flow Diagrams (05-03)
- Service Tools (05-04)
- Idle Speed - Check And Adjust (05-05)
- Horsepower - Measure Engine Performance (05-06)
- Fuel Rate - Adjust (05-07)
- Afc No-Air Valve Setting - Check And Adjust (05-08)
- Injectors - Replace (05-09)
- Injectors - Clean Exterior For Reuse (05-10)
- Fuel Pump - Replace (05-11)
- Throttle Travel - Check (05-12)
- Fuel System Maintenance (05-13)
- Gear Pump Check Valve - Replace (05-14)
- Variable Speed (Vs) Governor Leaking Fuel (05-15)
- Fuel Shutoff Valve - Check (05-16)
- Fuel Pump - Flow Check And Prime (05-17)
- Fuel Pump Rotation Check (05-18)
- Air Leaks (05-19)
- Afc - Check For Air Leak (05-20)
- Cylinder Misfire (05-21)
- Engine Oil Dilution By Fuel (05-22)
- Fuel Line Restriction (Suction) - Check (05-23)
- Fuel Drain Restriction - Check (05-24)
- Stc Oil Control Valve - Check (05-25)
- Stc Fuel Pressure Switch - Check (05-26)
- Stc Wiring Harness - Check For Reuse (05-27)
- Stc Oil Control Valve - Replace (05-28)
- Stc Wiring Harness - Replace (05-29)
- Fuel Consumption Check (05-30)
- Low Power Check (05-31)
- Engine Stall Speed And Time Check (05-32)
- Fuel Manifold - Replace (05-33)
- Stc Oil Manifold - Replace (05-34)
- Stall Speed Check List (05-35)
- Driveability - Low Power Check List (05-36)
- Fuel Consumption Check List (05-37)
SECTION 6 - ELECTRICALSYSTEM
- General Information (06-01)
- Specifications (06-02)
- Service Tools (06-03)
- Battery Terminal Connections - Check (06-04)
- Batteries - Check (06-05)
- Starting Circuit - Check (06-06)
- Alternator Belt - Adjust (06-07)
- Alternator - Output Test (06-08)
- Alternator - Replace (06-09)
- Accessory/Alternator Drive Pulley - Check For Reuse (06-10)
- Starting Motor - Replace (06-11)
- Starter Motor - Check For Reuse (06-12)
SECTION 7 - BASE ENGINE COMPONENTS
- Service Tools (07-01)
- General Information (07-02)
- Crankcase Gas (Blowby) - Check (07-03)
- Rocker Lever Cover - Replace (07-04)
- Check/Adjust Valves And Injectors (07-05)
- Jacobs Engine Brake - Adjust (07-06)
- Jacobs Engine Brake - Replace (07-07)
- Push Rod - Replace (07-08)
- Rocker Lever Assembly - Replace (07-09)
- Rocker Lever Assembly - Clean And Check For Reuse (07-10)
- Rocker Lever Housing - Replace (07-11)
- Check Cylinder Head Gasket For Combustion, Coolant, Or Oil Leak (07-12)
- Power Cylinder - Locate Failed Cylinder (07-13)
- Cylinder Head Gasket - Replace (07-14)
- Cylinder Head - Clean And Check For Reuse (07-15)
- Pressure Test Cylinder Head - Head Removed (07-16)
- Cam Follower Assembly - Replace (07-17)
- Cam Follower Assembly - Clean And Check For Reuse (07-18)
- Injection Timing - General Information (07-19)
- Measure The Injection Timing (07-20)
- Piston Cooling Nozzle - Replace (07-21)
- Main Crankshaft Bearing - Replace (07-22)
- Connecting Rod Bearing - Replace (07-23)
- Piston And Rod Assembly - Replace (07-24)
- Piston - Clean And Check For Reuse (07-25)
- Cylinder Liner - Remove (07-26)
- Check Liner Protrusion (07-27)
- Accessory Drive Pulley - Replace (07-28)
- Wear Sleeve, Accessory Drive Pulley - Replace (07-29)
- Accessory Drive Seal - Replace (07-30)
- Accessory Drive Assembly - Replace (07-31)
- Fuel Pump/Compressor Drive - Clean And Check For Reuse (07-32)
- Vibration Damper - Replace (07-33)
- Viscous Vibration Damper - Clean And Check For Reuse (07-34)
- Rubber Vibration Damper - Clean And Check For Reuse (07-35)
- Crankshaft Front Seal - Replace (07-36)
- Water Pump Drive - Replace (07-37)
- Water Pump Drive - Clean And Check For Reuse (07-38)
- Gear Cover (One Piece) - Replace (07-39)
- Camshaft Gear - Replace (Camshaft Installed) (07-40)
- Gear Cover Plate (Spacer Plate) - Replace (07-41)
- Gear Cover (Two Piece) - Replace (07-42)
- Gear Housing (Two Piece Design) - Replace (07-43)
- Check Gear Train Backlash (07-44)
- Idler Shaft (Press-In) - Replace (07-45)
- Front Engine Support - Replace (07-46)
- Crankshaft Gear - Remove And Install (07-47)
- Camshaft - Replace (07-48)
- Camshaft Gear - Remove And Install (07-49)
- Cylinder Block - Replace Camshaft Bushings (07-50)
- Camshaft Rear Cover - Replace (07-51)
- Flywheel - Replace (07-52)
- Crankshaft Seal, Rear - Replace (07-53)
- Flywheel Housing - Replace (07-54)
- Flywheel Housing Redowel To Cylinder Block (07-55)
- Pipe Plugs And Cup Plugs - Replace (07-56)
SECTION 8 - ENGINE TESTING ("IN-CHASSIS")
- Specifications And Procedures (08-01)
- General Engine Test Procedures (08-01)
- Chassis Dynamometer Operation (08-02)
- Engine Run-In Procedure (Chassis Dynamometer) (08-03)
- Engine Run-In Procedure "In-Chassis" (On And Off-Highway Vehicles) (08-04)
- Engine Configurations And Models (08-05)
SECTION 9 - ENGINE REMOVE AND INSTALL
- General Information (09-01)
- Service Tools (09-02)
- Engine - Remove (09-03)
- Engine Mount - Inspect (09-04)
- Engine - Install (09-05)
SECTION 10 - ENGINE COMPONENT SPECIFICATIONS
- General Information (10-01)
- Conversion Factors (10-02)
- Pipe Plug Torque Values (10-03)
- Capscrew Markings And Torque Values (10-04)
- Decimal And Metric Equivalents (10-05)
- Cooling System (10-06)
- Lubricating Oil System (10-07)
- Combustion Air System (10-08)
- Compressed Air System (10-09)
- Fuel System (10-10)
- Electrical System (10-11)
- Base Engine Components (10-12)
SECTION 11 - INDEX - TROUBLESHOOTING AND REPAIR
SECTION 12 - SERVICE LITERATURE
- Service Literature Ordering Location
- Service Literature Order Form
SECTION 13 - COMPONENT MANUFACTURERS