Руководство по эксплуатации qsk19

(Ocr-Read Summary of Contents of some pages of the CUMMINS QSK19 Document (Main Content), UPD: 25 July 2023)

  • 2, To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com Troubleshooting and Repair Manual Electronic Control System QSK19 CM850 Modular Common Rail System Series Engine Volume 1 Copyright© 2018 Bulletin 4021493 Cummins Inc. Printed 17-JULY-2018 All rights reserved Find manuals at https://best-manuals.com
    …

  • 34, QSK19 CM850 Acronyms and Abbreviations Section i — Introduction Page i-27 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com Acronyms and Abbreviations General Information The following list contains some of the acronyms and abbreviations used in this manual. ANSI American National Standards Institute API American Petroleum Institute ASTM American Society of Tes…

  • 22, QSK19 CM850 General Safety Instructions Section i — Introduction Page i-15 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com Liquid Nitrogen • Work in a well-ventilated area. • Protect eyes. In case of contact with eyes, flush with water for a minimum of 15 minutes. Receive medical attention immediately. • Protect skin. In case of contact with skin, receive medical attention …

  • 3, CUMMINS QSK19 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com Foreword Thank you for depending on Cummins® products. If you have any questions about this product, please contact your Cummins® Authorized Repair Location. You can also visit cumminsengines.com or quickserve.cummins.com for more information, or go to locator.cummins.com for Cummins…

  • 36, QSK19 CM850 Section E — Engine and System Identification Page E-a To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com Section E — Engine and System Identification Section Contents Page Engine Diagrams …………………………………………………………………………………………………………………………………….. E-2 Engine Views……………………..…

  • 14, CUMMINS QSK19 QSK19 CM850 Illustrations Section i — Introduction Page i-7 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com Illustrations General Information Some of the illustrations throughout this manual are generic and will not look exactly like the engine or parts used in your application. The illustrations can contain s…

  • 13, Symbols QSK19 CM850 Page i-6 Section i — Introduction To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com Refer to another location in this manual or another publication for additional information. The component weighs 23kg [50 lbs] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift the component.
    …

  • 47, Electronic Controlled Fuel System QSK19 CM850 Page F-2 Section F — Familiarization To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com The lights will remain off until a fault code is recorded. If a stop (red) light comes on while the engine is in operation, the fault can disable the engine. Stop the engine in a safe manner as soon as possible. If the warning (amber) light illuminates, the engine can still…

  • 50, QSK19 CM850 Service Tools and Hardware — Overview Section F — Familiarization Page F-5 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com Service Tools and Hardware — Overview General Information Cummins Inc. produces many engines that are electronically controlled. These engines have special diagnostic requirements for the engine control module (ECM) in the system. To…

  • 37, QSK19 CM850 Page E-b Section E — Engine and System Identification This Page Left Intentionally Blank
    …

  • 46, CUMMINS QSK19 QSK19 CM850 Electronic Controlled Fuel System Section F — Familiarization Page F-1 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com Electronic Controlled Fuel System (101-007) QSK System Description The QSK fuel system is an electronic engine control system designed to optimize engine control and reduce exhaust emissions. The QSK fuel system controls eng…

  • 1, Troubleshooting and Repair Manual Electronic Control System QSK19 CM850 Modular Common Rail System Series Engine Volume 1 Troubleshooting and Repair Manual Electronic Control System QSK19 CM850 Modular Common Rail System Series Engine Volume 1 Bulletin 4021493 Printed in U.S.A. 17-JULY-2018 Cummins Inc. Box 3005 Columbus, Indiana, U.S.A., 47202 www.cummins.com Copyright © 2018 Cummins Inc. 383843_Cummins_4021493v1.indd 1 8/17/2018…

  • 8, QSK19 CM850 About the Manual Section i — Introduction Page i-1 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com About the Manual General Information Cummins Inc. manuals are created to support Cummins® products. For information on components or fault codes not supplied by Cummins Inc., contact the original equipment manufacturer or supplier. The content of this manual is based on t…

  • 4, To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com Table of Contents Section Introduction …………………………………………………………………………………………………………………………………….. i Engine and System Identification …………………………………………………………………………………………………….. E Familiarization .…

  • 17, General Safety Instructions QSK19 CM850 Page i-10 Section i — Introduction To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com When working around operating equipment, appropriately rated hearing protection should be worn. Types of hearing protection to consider are listed below. • Single use ear plugs. • Pre-formed ear plugs. • Ear muffs. Protective Clothing Wear approp…

  • 33, CUMMINS QSK19 General Cleaning Instructions QSK19 CM850 Page i-26 Section i — Introduction To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com is 76 microns [0.003 in] in diameter. One micron measures 0.001 mm [0.00004 in.]. The contaminants being filtered out are smaller than can be seen with the human eye, a magnifying glass, or a low powered microscope. The tools used for fuel system troubleshooting and repair are to be…

  • 29, General Cleaning Instructions QSK19 CM850 Page i-22 Section i — Introduction To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com General Cleaning Instructions Definition of Clean Parts must be free of debris that can contaminate any engine system. This does not necessarily mean they have to appear as new. Sanding gasket surfaces until the fact…

  • 48, QSK19 CM850 Electronic Controlled Fuel System Section F — Familiarization Page F-3 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com NOTE: Some OEMs use a shorting plug. To check for active fault codes, turn the vehicle keyswitch to the OFF position and move the diagnostic switch to the ON position. Turn the vehicle keyswitch to the ON position. If no active fault codes are recorded, all three lights will come on and stay o…

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This Cummins Qsk19 Series Diesel Engine manual contains complete rebuild procedures and specifications. Disassembly, cleaning, inspection, and assembly instructions are included. A listing of accessory and component suppliers is located in Section M – Component Manufacturers. Suppliers can be contacted directly for any information not covered in this manual. Read and follow all safety instructions. Refer to the WARNING in the General Safety Instructions in Section i Introduction.

The repair procedures in this manual are based on the engine or component removed from chassis. Some rebuild procedures require the use of special service tools. Make sure the correct tools are used as described in the procedures.

When a specific brand name, number, or special tool is referenced in this manual, an equivalent product can be used in place of the recommended item. A series of specific service manuals (for example: Troubleshooting and Repair, Specifications, and Alternative Repair) are available and can be ordered by filling out and mailing the Literature Order Form located in Section L – Service Literature. Cummins Engine.

CONTENTS

  • Introduction
  • Engine Identification
  • Complete Engine
  • Cylinder Block
  • Cylinder Head
  • Rocker Levers
  • Cam Followers/Tappets
  • Fuel System
  • Injectors and Fuel Lines
  • Lubricating Oil System
  • Cooling System
  • Drive Units
  • Air Intake System
  • Exhaust System
  • Compressed Air System
  • Electrical Equipment
  • Engine Testing
  • Mounting Adaptations
  • Electronic Engine Controls
  • Service Literature
  • Component Manufacturers
  • Specifications
  • Index

Language: English
Format: PDF
Pages: 634

Cummins Qsk19 Series Diesel Engine Service Repair Manual PDF free online

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    LEJS Series Controller, 63

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  • General Safety Instructions QSK19 CM850 Page i-10 Section i — Introduction To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com When working around operating equipment, appropriately rated hearing …

  • QSK19 CM850 Illustrations Section i — Introduction Page i-7 To buy Cummins Parts and Service Manuals, Training Guides, or Tools go to our website at https://store.cummins.com Illustrations General Information Some of the illustrations throughout this ma …

  • This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com
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  • Page 1
    Shop Manual QSK19 Series Engines Copyright 1997 Bulletin No. 3666232 Cummins Engine Company, Inc. Printed 12/97 All rights reserved…
  • Page 2
    The specifications and rebuild information in this manual is based on the information in effect at the time of printing. Cummins Engine Company, Inc. reserves the right to make any changes at any time without obligation. If differences are found between your engine and the information in this manual, contact a Cummins Authorized Repair Location or call 1-800-DIESELS (1-800-343-7357).
  • Page 3
    Table of Contents Section Introduction ……………………….Engine Identification …………………….. Complete Engine – Group 00 ………………….Cylinder Block – Group 01 ……………………. Cylinder Head – Group 02 ……………………Rocker Levers – Group 03 ……………………Cam Followers/Tappets – Group 04 ………………..Fuel System – Group 05 ……………………Injectors and Fuel Lines –…
  • Page 4
    QSK19 Section i — Introduction Page i-a Section i — Introduction Section Contents Page About the Manual ……………………….. i-1 General Cleaning Instructions…………………….. i-9 Glass or Plastic Bead Cleaning ……………………i-9 Solvent and Acid Cleaning ……………………..i-9 Steam Cleaning ……………………….i-9 General Repair Instructions……………………..
  • Page 5
    Page i-1 About the Manual This manual contains information needed to correctly operate and maintain your engine as recommended by Cummins Engine Company, Inc. Additional service literature (Shop Manual, Troubleshooting and Repair Manual, etc.) can be ordered by filling out and mailing the Literature Order Form located in Service Literature, Section L.
  • Page 6
    Symbols QSK19 Page i-2 Section i — Introduction Symbols The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below: g-01 (full-sym)
  • Page 7
    QSK19 Symbols Section i — Introduction Page i-3…
  • Page 8
    Symbols QSK19 Page i-4 Section i — Introduction…
  • Page 9
    QSK19 Symbols Section i — Introduction Page i-5…
  • Page 10
    Illustrations QSK19 Page i-6 Section i — Introduction Illustrations Some of the illustrations throughout this manual are ge- neric and will not look exactly like the engine or parts used in your application. The illustrations can contain symbols to indicate an action required and an acceptable or not acceptable condition.
  • Page 11
    • Always use tools that are in good condition. Make sure you understand how to use them before performing any service work. Use ONLY genuine Cummins or Cummins ReCon replacement parts. • Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of lesser quality if replacements are necessary.
  • Page 12
    • Follow the specified disassembly and assembly procedures to avoid damage to the components Complete rebuild instructions are available in the shop manual which can be ordered or purchased from a Cummins Authorized Repair Location. Refer to Section L — Service Literature for ordering instructions.
  • Page 13
    90 to 95 degrees Celsius [180 to 200 degrees Fahrenheit]. A cleaning tank that provides a constant mixing and filtering of the cleaning solution will give the best results. Cummins Engine Company, Inc.
  • Page 14
    General Cleaning Instructions QSK19 Page i-10 Section i — Introduction NOTES…

  • Page 15: Table Of Contents

    Section Contents Page Engine Diagrams ……………………….. E-6 Engine Views …………………………. E-6 Engine Identification ……………………….E-1 Cummins Engine Nomenclature ……………………E-1 ECM Dataplate ……………………….E-1 Engine Dataplate ……………………….E-1 Specifications…………………………E-2 Air Intake System ……………………….E-2 Batteries (Specific Gravity) ……………………..E-5 Cooling System ……………………….

  • Page 16: Cummins Engine Nomenclature

    List (CPL) (2), Model (3), and Horsepower and rpm rating (4) provide information for ordering parts and service needs. NOTE: The engine dataplate must not be changed unless approved by Cummins Engine Company, Inc. ECM Dataplate The external ECM dataplate is located on top on the ECM.

  • Page 17: Specifications

    Specifications QSK19 Page E-2 Section E — Engine Identification Specifications General Specifications NOTE: For performance and fuel rate values, refer to the engine data sheet, or the fuel pump code for the particular model involved. Engine Speed ……….. Refer to the fuel pump calibration data for optional speed rating. Displacement ……………………

  • Page 18
    • 1800 rpm: ……………………. 1655 kPa [240 psi] • 2100 rpm: …………………….. 1861 kPa [270 psi] • 2350 rpm: ……………………. 1999 kPa [290 psi] Fuel Filter Specifications (Cummins Engine Company, Inc. Standard No. 14,223) Efficiency: ……………………. 98.7% at 10 microns 96.0% at 8 microns 86.0% at 5 microns…

  • Page 19: Cooling System

    Specifications QSK19 Page E-4 Section E — Engine Identification NOTE: When the rear gear train option is specified, add 7.6 liters [2 U.S. gallons] to the oil pan capacity listed above. Cooling System Coolant Capacity (Engine Only) ………………….32.2 liters [34 U.S.

  • Page 20
    QSK19 Specifications Section E — Engine Identification Page E-5 Batteries (Specific Gravity)
  • Page 21
    Engine Diagrams QSK19 Page E-6 Section E — Engine Identification Engine Diagrams Engine Views The illustrations show the locations of the major external engine components, the filters, and other service and maintenance points. Some external components will be at different locations for different engine models. 1.
  • Page 22
    QSK19 Engine Diagrams Section E — Engine Identification Page E-7 EXHAUST SIDE — QSK19 1. Coolant Outlet A. Turbocharger 2. Coolant Inlet B. Thermostat Housing 3. Alternate Location for Engine C. Fan Idler and Assembly Speed Sensor (ESS)(G-Drive ONLY) D. Coolant Filter 4.
  • Page 23
    Engine Diagrams QSK19 Page E-8 Section E — Engine Identification NOTES…
  • Page 24
    QSK19 Section 0 — Complete Engine — Group 00 Page 0-a Section 0 — Complete Engine — Group 00 Section Contents Page Engine Assembly ……………………….0-58 Assemble …………………………0-58 Engine Disassembly ……………………….0-8 Disassemble …………………………0-9 General Information ……………………….0-8 Assembly …………………………
  • Page 25
    Engine Disassembly and Assembly The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No.
  • Page 26
    Service Tools QSK19 Page 0-2 Section 0 — Complete Engine — Group 00 Tool No. Tool Description Tool Illustration Connecting Rod Guide Pins Special nylon pins used to protect the crankshaft journal by guiding the connecting rod during installation or removal. 3375098 Liner Installation Tool Install cylinder liner in engine.
  • Page 27
    Tool Illustration Pulley Installation Tool Install the alternator and accessory drive pulleys. 3376326 Cummins Sealant Used to prevent coolant or oil leaks. This is one part Room Temperature Vulcanizing (RTV) silicone rubber, adhesive, and 3823494 sealant material having high heat and oil resistance, and low compression rate.
  • Page 28
    Service Tools QSK19 Page 0-4 Section 0 — Complete Engine — Group 00 Tool No. Tool Description Tool Illustration Water Tube Driver Used to install or remove the water transfer tubes from the rocker housings. ST-1319 Torque Wrench A dial-type torque wrench used to accurately adjust injectors in inch-pounds.
  • Page 29
    QSK19 Service Tools Section 0 — Complete Engine — Group 00 Page 0-5 Tool No. Tool Description Tool Illustration Torque Wrench This is a [3/8 inch] drive, [300 in-lb], torque wrench used to set injector preload adjustments on engines with the high pressure 3824783 fuel injection systems such as the QUANTUM™…
  • Page 30
    Service Tools QSK19 Page 0-6 Section 0 — Complete Engine — Group 00 Tool No. Tool Description Tool Illustration O-Ring Pick Use to remove and install o-rings. 3376399 Lubricating Oil Sampling Filter Used to monitor oil contamination. ST-1135 Dowel Pin Extractor Remove dowel pins.
  • Page 31
    QSK19 Service Tools Section 0 — Complete Engine — Group 00 Page 0-7 Tool No. Tool Description Tool Illustration Heat Gun Used to repair connector wires. 3822860 Wiring Repair Kit Contains a variety of connectors, pins, seals, terminals, test leads, and other tools used to repair connectors.
  • Page 32
    Engine Disassembly (000-003) QSK19 Page 0-8 Section 0 — Complete Engine — Group 00 Engine Disassembly (000-003) General Information General Information These procedures apply to all QSK19 engines. The differences between engine model due to the application, the optional equipment on an engine, and the year an engine was built are included in the instructions. Omit the steps that do not apply to the engine being rebuilt.
  • Page 33
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-9 Disassemble Remove the Water Filter Open the draincock on the oil cooler housing and on the water pump. Remove and discard the coolant filter. Prepare Engine to be Mounted on Rebuild Stand WARNING When using steam, wear protective clothing and safety glasses or a face shield.
  • Page 34
    Engine Disassembly (000-003) QSK19 Page 0-10 Section 0 — Complete Engine — Group 00 WARNING Hot oil can cause serious personal injury. Drain the oil when the oil temperature is approximately 60°C [140°F]. WARNING Some State and Federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity.
  • Page 35
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-11 Rail Applications Remove the lubricating oil filters and filter head. Remove the fuel filter and filter head. Remove the coolant filter and filter head. Rail Applications Remove 15 capscrews on the top of the oil pan.
  • Page 36
    Engine Disassembly (000-003) QSK19 Page 0-12 Section 0 — Complete Engine — Group 00 Remove the thread adapter sealing ring (1). Use a clean, lint-free towel to clean the surface of the filter head gasket. Remove the Oil Filters The external appearance of the full-flow (1) the bypass (2) and the combination (3) filters are the same.
  • Page 37
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-13 Remove the Cooling Fan Drive Belt CAUTION The fan belt idler is under tension. Do NOT allow your hands to get between the idler and the belt, or the fan hub.
  • Page 38
    Engine Disassembly (000-003) QSK19 Page 0-14 Section 0 — Complete Engine — Group 00 Check the belt for wear. If the belt indicates any wear, it must be replaced. Remove the Alternator WARNING Always disconnect the negative (-) cable first to avoid sparks that can ignite explosive battery gases.
  • Page 39
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-15 Remove the Fan Drive Idler Arm Assembly CAUTION The belt tensioner and the pivot arm assembly will rotate during removal. Personal injury can result. To avoid personal injury, use a hoist or get personal as- sistance to lift the component.
  • Page 40
    Engine Disassembly (000-003) QSK19 Page 0-16 Section 0 — Complete Engine — Group 00 Remove the aftercooler water supply tube clip (7). Loosen the hose clamps. Remove the support bracket (34). Remove the tube (31). Remove and discard the o-ring. Remove the Coolant Tubes and Hoses — Low Tempera- ture Aftercooling Remove the bypass tube clamp (9).
  • Page 41
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-17 Remove the Turbocharger Coolant Supply and Return Hoses NOTE: This procedure applies to a turbocharger with a water-cooled bearing housing. Disconnect the coolant supply hose and the coolant return hose from the turbocharger.
  • Page 42
    Engine Disassembly (000-003) QSK19 Page 0-18 Section 0 — Complete Engine — Group 00 Rail Applications Remove the 24 capscrews and intake manifold. Remove the Exhaust Manifold Use two [7/16-14×5 in] guide studs (12). Remove two capscrews as shown. Install the guide studs as shown. CAUTION This assembly weighs more than 23 kg [50 lb].
  • Page 43
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-19 OEM Interface Harness — General Information The QSK equipped engines use three separate wiring har- ness to control the engine and some of the vehicle opera- tions.
  • Page 44
    Engine Disassembly (000-003) QSK19 Page 0-20 Section 0 — Complete Engine — Group 00 Disconnect the 2-pin and 6-pin Deutsch connectors. Remove the 21-pin and 31-pin connectors from the harness support brackets. Use a 4 mm [5/32 in] hex head wrench to disconnect the OEM interface harness Deutsch connector from the ECM.
  • Page 45
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-21 Remove the Engine Wiring Harness Disconnect the engine harness from the coolant pressure sensor. Remove the engine harness clamps. Cut the ties on the alternator bracket and front engine cover bracket.
  • Page 46
    Engine Disassembly (000-003) QSK19 Page 0-22 Section 0 — Complete Engine — Group 00 Disconnect the intake manifold temperature sensor and intake manifold pressure sensor. Cut the tie on the engine datalink connector bracket. Remove the bracket. Remove the clamp from the hose. Disconnect the engine harness from the following: 1.
  • Page 47
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-23 Disconnect the engine block ground from the block. Use a 4 mm [5/32 in] hex head wrench to disconnect the engine harness Deutsch connector from the ECM. Cut the seventeen ties holding the engine harness to the support bracket.
  • Page 48
    Engine Disassembly (000-003) QSK19 Page 0-24 Section 0 — Complete Engine — Group 00 Remove the Torque Converter Cooler Cover (if equipped) Remove the oil supply (1) and oil return (2) hoses from the torque converter cooler. Remove the torque converter cooler cover mounting capscrews.
  • Page 49
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-25 Remove the torque converter cooler element mounting nuts. Remove the elements. Remove and discard the o-rings. Remove the Oil Cooler Elements NOTE: There is little clearance between the capscrews and the block on some engines.
  • Page 50
    Engine Disassembly (000-003) QSK19 Page 0-26 Section 0 — Complete Engine — Group 00 CAUTION This assembly weighs more than 23 kg [50 lb]. To avoid personal injury, use a hoist or get personal assistance. Remove the starting motor capscrews, the starter, spacers, and the gaskets.
  • Page 51
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-27 Remove the Dipstick and Dipstick Tube (if equipped on this side of engine) Remove the dipstick and dipstick tube. Remove the turbocharger oil supply and drain lines. Disconnect the oil drain hose and the oil supply hose from the turbocharger.
  • Page 52
    Engine Disassembly (000-003) QSK19 Page 0-28 Section 0 — Complete Engine — Group 00 Remove the Alternator Drive Oil Seal Remove the six button hex head socket capscrews. Use three [1/4-20 x 1 in] capscrews to remove the seal from the alternator drive shaft.
  • Page 53
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-29 Prepare the Engine Rebuild Stand The following instructions apply to the Engine Roll over Stand, Part No. 3375194. If another engine stand is used, follow the manufacturer’s instructions. Disengage the locking pin.
  • Page 54
    Engine Disassembly (000-003) QSK19 Page 0-30 Section 0 — Complete Engine — Group 00 WARNING Engine weighs 2045 kg [4508 lb]. Use a properly rated hoist and engine lifting fixture, Part No. 3822512, to lift the engine. Lift the engine. WARNING Be sure the locking pin on the engine stand is in the “LOCKED”…
  • Page 55
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-31 Remove the Aftercooler Assembly Remove the coolant lines from the aftercooler assembly. CAUTION This assembly weighs more than 23 kg [50 lb]. To avoid personal injury, use a hoist or get personal assistance to lift the component.
  • Page 56
    Engine Disassembly (000-003) QSK19 Page 0-32 Section 0 — Complete Engine — Group 00 Remove the Fuel Manifold Remove the 12 capscrews. Remove the front fuel manifold. Discard the o-rings. Repeat this process for the removal of the rear fuel manifold. Remove the ECM Remove the six capscrews which hold the ECM to the control valve body.
  • Page 57
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-33 Remove the four capscrews. Remove the control valve body assembly. Remove the Rocker Lever Covers NOTE: Crankcase breathers can be mounted in any cyl- inder location. Record the number of breathers and their correct location before mounting.
  • Page 58
    Engine Disassembly (000-003) QSK19 Page 0-34 Section 0 — Complete Engine — Group 00 Remove the Injector and Clamp NOTE: The hold-down clamp can not be removed until the injector is removed. Remove the injector hold-down capscrew. Remove the injector and clamp. Use injector puller, Part No.
  • Page 59
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-35 Remove the Rocker Lever Housing Remove the seven mounting capscrews and the rocker lever housing. Remove and discard rocker lever housing gasket. Remove the Cylinder Head CAUTION This component weighs 23 kg [50 lb] or more.
  • Page 60
    Engine Disassembly (000-003) QSK19 Page 0-36 Section 0 — Complete Engine — Group 00 Remove the cam follower assembly. Pull straight out until the shaft is off the ring dowels. Remove the Dipstick and Dipstick Tube (if equipped on this side of engine) Remove the dipstick and dipstick tube.
  • Page 61
    NOTE: The illustrations shown will be the SS model single cylinder air compressor. Differences in procedures for SS, QE and ST Cummins air will be shown where necessary. Use steam to clean the air compressor. Dry with compressed air.
  • Page 62
    Engine Disassembly (000-003) QSK19 Page 0-38 Section 0 — Complete Engine — Group 00 Remove the coolant lines from the air compressor. CAUTION This assembly weighs more than 23 kg [50 lb]. Handle securely to avoid dropping. Remove the air connections from the air compressor. Remove the air compressor support bracket and capscrews.
  • Page 63
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-39 CAUTION Use a capscrew in the shaft to prevent damage to the shaft threads. Install a [7/16-20×1 in] capscrew in the shaft. Use a standard puller, Part No. ST–647, or equivalent. Remove the accessory drive pulley.
  • Page 64
    Engine Disassembly (000-003) QSK19 Page 0-40 Section 0 — Complete Engine — Group 00 Remove the Accessory Drive Assembly CAUTION The woodruff key must be removed before removing the accessory drive assembly. Damage to the bushing can result. Remove the four capscrews and the nut (31). Remove the accessory drive assembly.
  • Page 65
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-41 Remove the piston cooling nozzle mounting capscrew. Use a slide hammer with a [3/8 x 16 in] thread to remove the nozzle. Remove the Vibration Damper and Pulley Assembly CAUTION This assembly weighs more than 23 kg.
  • Page 66
    Engine Disassembly (000-003) QSK19 Page 0-42 Section 0 — Complete Engine — Group 00 Remove the Front Crankshaft Seal Remove the eight button head hex socket capscrews. Use four [1/4-20 UNCx1 in] capscrews to remove the seal from the crankshaft. Install the capscrews into the clinch nuts in the seal case.
  • Page 67
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-43 Rail Applications Remove the front support mounting bracket by removing fifteen capscrews and washers. Rail Applications Remove the scavenge line by disconnecting the tube from the 90 degree elbow at the base of the front gear cover. Remove the Front Gear Cover NOTE: The master dowel must be removed before the gear cover can be removed.
  • Page 68
    Engine Disassembly (000-003) QSK19 Page 0-44 Section 0 — Complete Engine — Group 00 Remove the Water Pump Idler Gear NOTE: The bolt-in idler shafts have a flange that require the shaft, the idler gear, and the thrust washer to be removed as an assembly.
  • Page 69
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-45 Remove the Camshaft CAUTION Pilots must be used to prevent damage to the camshaft and the bushings. Be sure the hooks do not damage the camshaft bushings. Use camshaft installation pilots, Part No.
  • Page 70
    Engine Disassembly (000-003) QSK19 Page 0-46 Section 0 — Complete Engine — Group 00 Remove the Flywheel CAUTION This component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component.
  • Page 71
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-47 Remove the Camshaft Cover Plate Remove the three capscrews. Remove the camshaft cover. Remove and discard the gasket. Remove the Lubricating Oil Pan and Lubricating Oil Pan Adapter Cover Plate Remove the 28 capscrews from the oil pan.
  • Page 72
    Engine Disassembly (000-003) QSK19 Page 0-48 Section 0 — Complete Engine — Group 00 Remove the Lubricating Oil Pan Adapter Remove the two [7/16-14 inch] capscrews, and the five [3/8-16 inch] capscrews from the flywheel housing. CAUTION The component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component.
  • Page 73
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-49 Use a hoist, a tee handle, and a lifting sling. Install the tee handle. Adjust the hoist until there is tension in the lifting sling. Remove the remaining capscrews. Use a mallet and tap the flywheel housing off the two locating dowels.
  • Page 74
    Engine Disassembly (000-003) QSK19 Page 0-50 Section 0 — Complete Engine — Group 00 WARNING Care must be taken to avoid possible breakage of the capscrew mounting flanges. CAUTION This component weighs 23 kg [50 lb.] or more. To avoid personal injury, use a hoist or get assistance to lift the component.
  • Page 75
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-51 Remove the Rear Gear Drive — Lower Unit CAUTION The component weighs 23 kg [50 lb.] or more. To avoid personal injury, use a hoist or get assistance to lift the component.
  • Page 76
    Engine Disassembly (000-003) QSK19 Page 0-52 Section 0 — Complete Engine — Group 00 After installing two guide pins, Part No. 3375098, in the connecting rod, push the rod up far enough to allow the upper bearing shell to be removed. Use a “T handle” piston pusher to push the rod away from the crankshaft.
  • Page 77
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-53 WARNING Wear eye protection to prevent serious eye damage during this operation. An alternative method to remove the carbon ridge is to use a high quality-steel wire wheel installed in a drill. NOTE: Do not use a steel wire wheel of inferior quality because the wire wheel will lose steel bristles during op- eration, and cause additional contamination.
  • Page 78
    Engine Disassembly (000-003) QSK19 Page 0-54 Section 0 — Complete Engine — Group 00 CAUTION To prevent personal injury and damage to the piston, do not drop the piston while removing the piston pin. When the piston pin is removed from an articulated piston, the skirt will separate from the crown.
  • Page 79
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-55 Remove the Lower Main Bearing CAUTION Remove the bearings one pair at a time. Personal injury and damage to the crankshaft can result if the crank- shaft falls.
  • Page 80
    Engine Disassembly (000-003) QSK19 Page 0-56 Section 0 — Complete Engine — Group 00 Remove the Upper Thrust Bearings Remove the upper thrust bearings from the block at the No. 6 location. Mark them for position. NOTE: If necessary, slide the crankshaft to the front or to the rear to allow the thrust bearings to be removed.
  • Page 81
    QSK19 Engine Disassembly (000-003) Section 0 — Complete Engine — Group 00 Page 0-57 Turn the puller screw until the liner loosens in the block. Remove the tool and the liner. Use a liquid metal marker to mark the cylinder number on each liner.
  • Page 82
    Engine Assembly (000-004) QSK19 Page 0-58 Section 0 — Complete Engine — Group 00 Engine Assembly (000-004) Assemble Clean the bottom of the cylinder liner flange with solvent. NOTE: The seal rings have three locating tabs on the I.D. The tabs have an interference fit to the liner Lower Press Fit (LPF) diameter to hold the seal ring in place during liner installation.
  • Page 83
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-59 Use liner installation tool, Part No. 3375422, or equivalent. Install the bridge assembly and two cylinder head capscrews. Tighten the capscrews. Torque Value: 65 N•m [50 ft-lb] Install the pusher plate in the liner.
  • Page 84
    Engine Assembly (000-004) QSK19 Page 0-60 Section 0 — Complete Engine — Group 00 Main Bearings — General Information NOTE: The upper bearings contain an oil hole. The lower bearings do not have an oil hole. Both bearings are marked on the back side indicating location (UPPER or LOWER) and size (STANDARD [STD] or OVERSIZE [OS]).
  • Page 85
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-61 WARNING This part weighs more than 23 kg [50 lb]. Personal injury can result. Use a lint free cloth. Clean the bearing and the mounting surface. CAUTION Do not lubricate the back of the bearing.
  • Page 86
    Engine Assembly (000-004) QSK19 Page 0-62 Section 0 — Complete Engine — Group 00 Lubricate the cap screw head and threads with SAE EP 140W oil. Allow excess oil to drip off of the capscrews before installing in the block. Install capscrews in the cap.
  • Page 87
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-63 CAUTION Do not rotate the crankshaft until all of the main bearing caps are pulled to the block. Damage will result if the bearings move out of location. NOTE: Use your hands to install the capscrews.
  • Page 88
    Engine Assembly (000-004) QSK19 Page 0-64 Section 0 — Complete Engine — Group 00 Use a dial indicator and measure the crankshaft end clear- ance. Crankshaft End Clearance 0.10 0.004 0.41 0.016 If the clearance is not within specifications, check for for- eign material.
  • Page 89
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-65 NOTE: Do not install the piston rings until the pistons are installed of the rods. NOTE: The piston rings are marked with the part number. The shipping package is marked with the location. The part number on the ring must be positioned toward the top of the piston.
  • Page 90
    Engine Assembly (000-004) QSK19 Page 0-66 Section 0 — Complete Engine — Group 00 CAUTION The connecting rods and caps are not interchangeable. The rods and the caps are machined as an assembly. Failure will result if they are mixed. Install the lower bearing shell in the rod cap.
  • Page 91
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-67 Check to be sure the ring gap position is still correct. CAUTION Be sure the rings fit correctly in the piston rings. Use a piston ring compressor, Part No. 3375342, or equiva- lent.
  • Page 92
    Engine Assembly (000-004) QSK19 Page 0-68 Section 0 — Complete Engine — Group 00 Install the rod and piston until the ring compressor touches the block. Align the rod with the crankshaft journal. Hold the ring compressor firmly against the block. Use a wooden hammer handle to push the piston into the liner.
  • Page 93
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-69 Check the side clearance between the rod and the crank- shaft. The rod must move freely from side-to-side. Measurements over 0.51 mm [0.020 in] must be measured with dial indicator.
  • Page 94
    CAUTION Do not use gasket cement. Damage to the gasket will result. Use Cummins sealant, Part No. 3823494, or equivalent. Apply a small amount to both sides of the gasket at the butt joint. Install the gasket. NOTE: The bottom of the gasket must be even with the bottom of the block and the spacer plate.
  • Page 95
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-71 NOTE: If the oil pan adapter is removed, spacer plate alignment must be checked. If the oil pan adapter is in- stalled, alignment does not require checking. Use a gauge block, Part No.
  • Page 96
    Engine Assembly (000-004) QSK19 Page 0-72 Section 0 — Complete Engine — Group 00 CAUTION Wear protective clothing to prevent personal injury from burns. CAUTION Do not exceed the specified time or the temperature. Damage to the gear and the gear teeth will result. CAUTION Do not attempt to install the gear without using heat.
  • Page 97
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-73 Install the hydraulic pump idler gear. CAUTION Engines that contain a hydraulic pump must have the oil holes in the hydraulic pump idler shaft as shown. Idler gear bushing failure will result if the oil holes are not aligned correctly.
  • Page 98
    Engine Assembly (000-004) QSK19 Page 0-74 Section 0 — Complete Engine — Group 00 CAUTION Engines that do not have a hydraulic pump drive must have a plug installed in place of the idler shaft. Low oil pressure will result if the plug is omitted. CAUTION The capscrew that is used for the lug must not protrude beyond the block.
  • Page 99
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-75 Align the oil holes in the shaft to an angle 45 degrees to the left of vertical. Use the capscrew to pull the shaft into the bore. tighten the capscrew.
  • Page 100
    Engine Assembly (000-004) QSK19 Page 0-76 Section 0 — Complete Engine — Group 00 CAUTION The grooves in the thrust bearing must be positioned toward the gear. NOTE: The timing marks on the camshaft gear must be visible when the gear is installed. Use Lubriplate No.
  • Page 101
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-77 Static Injection Timing-Check If the camshaft or camshaft gear was replaced, check the injection timing. Machine tolerances can cause the timing to be out of specifications. CAUTION Use ONLY the crankshaft to rotate the engine.
  • Page 102
    Engine Assembly (000-004) QSK19 Page 0-78 Section 0 — Complete Engine — Group 00 Turn the indicator so that the stem is touching the plunger. Carefully move the indicator downward until the needle has turned a minimum of five revolutions 12.7 mm [0.500 inch].
  • Page 103
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-79 CAUTION The crankshaft must be turned slowly to accurately count the indicator revolutions. Turn the crankshaft opposite the direction of normal rota- tion until the indicator needle moves two and one-half revo- lutions 6.35 mm [0.250 inch].
  • Page 104
    Engine Assembly (000-004) QSK19 Page 0-80 Section 0 — Complete Engine — Group 00 If the injection timing is not within specification, repeat the measurement procedure to check the tool setup and the ZERO settings. If the timing is still not within specification, the camshaft key must be changed.
  • Page 105
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-81…
  • Page 106
    Engine Assembly (000-004) QSK19 Page 0-82 Section 0 — Complete Engine — Group 00…
  • Page 107
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-83…
  • Page 108
    Engine Assembly (000-004) QSK19 Page 0-84 Section 0 — Complete Engine — Group 00…
  • Page 109
    Install the service gasket piece on top of the oil pan adapter. Use a spray adhesive to hold it in position. Use Cummins sealant, Part No. 3823494, at the joints. This illustration shows the capscrew length requirements for the front cover.
  • Page 110
    Engine Assembly (000-004) QSK19 Page 0-86 Section 0 — Complete Engine — Group 00 Put the clamping plate in position and begin the installation of the capscrew. NOTE: The plate must remain loose until the fan hub or the cover plate is installed. Use a 5/16-8×3 inch capscrew and a mallet.
  • Page 111
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-87 Install the hydraulic pump drive. Using engine oil, lubricate the bushing in the cover. Install the gasket, drive or cover, washers, and capscrews. Tighten the capscrews. Torque Value: 45 N•m [35 ft-lb] NOTE: If an SAE 1 flywheel housing option is used, there…
  • Page 112
    Engine Assembly (000-004) QSK19 Page 0-88 Section 0 — Complete Engine — Group 00 Use a dial indicator. Be sure the two capscrews are holding the lower housing firmly against the cylinder block. Check the gear lash. Lower Housing-To-Cylinder Block Gear Backlash 0.05 0.002 0.51…
  • Page 113
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-89 Install the two capscrews 7/16-14×4 3/4 inch, Part No. 190799, and the five capscrews 3/8-16×4 3/4 inch, Part No. S106-C, with flat washers and lockwashers. Torque Value: 3/8-16 inch 45 N•m [35 ft-lb]…
  • Page 114
    Engine Assembly (000-004) QSK19 Page 0-90 Section 0 — Complete Engine — Group 00 Use only SAE Grade 8 capscrews to install the upper housing. Install the following capscrews according to the table below. Location Part No. Size [inch] Qty Top-Front 3202224 1/2-13 x 9…
  • Page 115
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-91 Use Lubriplate No. 105, or equivalent. Lubricate the outer hydraulic pump support bushing in the upper housing. Lubricate the bushing surfaces on both shafts in the outer hydraulic pump support drive assemblies.
  • Page 116
    Engine Assembly (000-004) QSK19 Page 0-92 Section 0 — Complete Engine — Group 00 Install four capscrews. Hand-tighten the capscrews. Remove the guide studs. Install the remaining three capscrews. Use the sequence and torque as shown. Tighten the capscrews. Torque Value: 70 N•m [50 ft-lb] Install the other outer hydraulic pump using the same procedure.
  • Page 117
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-93 Measure the flywheel housing alignment. NOTE: The bore and the face of the housing must be in alignment with the crankshaft. NOTE: The indicator arm must be rigid for an accurate reading.
  • Page 118
    Engine Assembly (000-004) QSK19 Page 0-94 Section 0 — Complete Engine — Group 00 Record the indicator reading at 3 different points; 3 o’clock, 6 o’clock, and 9 o’clock. Turn backward to the original position. Be sure the needle still points to ZERO. Determine the total indicator runout (TIR).
  • Page 119
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-95 Install the flywheel housing mounting capscrews. Tighten the capscrews. Torque Value: 205 N•m [150 ft-lb] Install a new o-ring on the seal housing. Use vegetable oil to lubricate the o-ring. To aid in seal installation, use a small nonmetallic bristle brush to apply a thin film of 15W-40 oil to the inside di- ameter of the seal case.
  • Page 120
    Engine Assembly (000-004) QSK19 Page 0-96 Section 0 — Complete Engine — Group 00 Use the pin supplied in the seal kit to align the seal mount- ing holes with the mounting capscrew holes in the flywheel housing. Attach the seal installation tool that is supplied with the seal to the crankshaft, using three flywheel mounting capscrews.
  • Page 121
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-97 Remove the seal installation tool. Install the seal mounting capscrews. Tighten the capscrews. Torque Value: 11 N•m [95 in-lb] NOTE: Use a contact adhesive such as 3M Spray 77 or 3M 4693 to hold the bolt seals in position.
  • Page 122
    Engine Assembly (000-004) QSK19 Page 0-98 Section 0 — Complete Engine — Group 00 Use Cummins sealant, Part No.3823494, or equivalent. Apply the sealant as shown. CAUTION The component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component.
  • Page 123
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-99 Install the two [7/16-inch] washers and capscrews shown. Tighten the capscrews. Torque Value: 65 N•m [50 ft-lb] NOTE: Capscrews No. 24 through 28 thread into the front cover on engines.
  • Page 124
    Engine Assembly (000-004) QSK19 Page 0-100 Section 0 — Complete Engine — Group 00 CAUTION This component weighs 23 kg [50 lbs.] or more. To avoid personal injury, use a hoist or get assistance to lift the component. Install the support, washers, and capscrews. Tighten the capscrews.
  • Page 125
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-101 Rail Applications CAUTION Gasket cement will prevent the gasket from sealing properly. NOTE: Use a contact adhesive such as 3M Spray 77 or 3M 4693 to hold the gasket in position. Install the gasket and lubricating oil pan.
  • Page 126
    Engine Assembly (000-004) QSK19 Page 0-102 Section 0 — Complete Engine — Group 00 To aid in seal installation, use a small nonmetallic bristle brush to apply a thin film of clean SAE 15W-40 oil to the inside diameter of the seal. NOTE: Do not allow oil to come in contact with other areas of the seal.
  • Page 127
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-103 Put the pulley installation housing on the pulley installer. Align the three clinch nuts on the back of the seal carrier flange with the three counterbores in the gear cover seal mounting surface.
  • Page 128
    Engine Assembly (000-004) QSK19 Page 0-104 Section 0 — Complete Engine — Group 00 Install the six, button head hex socket capscrews. Tighten the capscrews alternately and evenly. Torque Value: 11 N•m [96 in-lb] CAUTION Do not use a hammer to drive the pulley into position. The thrust washers will be damaged.
  • Page 129
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-105 Install the seal on the accessory drive shaft. Use the seal installation tool that is supplied with the ser- vice seal to push the seal on the accessory drive shaft. Put the installation tool against the seal.
  • Page 130
    Engine Assembly (000-004) QSK19 Page 0-106 Section 0 — Complete Engine — Group 00 Align the three clinch nuts on the back of the seal carrier flange with the three counterbores in the gear cover seal mounting surface. Use the tool to push the seal on the shaft until the seal carrier flange contacts the gear cover.
  • Page 131
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-107 Install the keyway seal. Install the woodruf key into accessory drive shaft. NOTE: Keyway seal must be installed prior to installation of keyway and accessory drive pulley. Install the accessory drive pulley.
  • Page 132
    Engine Assembly (000-004) QSK19 Page 0-108 Section 0 — Complete Engine — Group 00 Use vegetable oil to lubricate the new o-ring. Do not soak the new o-ring in engine oil. CAUTION Use care when handling the piston cooling nozzle. Any damage to the piston cooling nozzle can result in major engine damage.
  • Page 133
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-109 Rotate the barring device and align the next valve set mark with the mark cast into the gear cover. Repeat the process to install the remaining piston cooling nozzles.
  • Page 134
    Engine Assembly (000-004) QSK19 Page 0-110 Section 0 — Complete Engine — Group 00 Tighten the compressor to the accessory drive capscrews (2). Torque Value: 60 N•m [45 ft-lb] Tighten the bracket to the block capscrews (5). Torque Value: 45 N•m [35 ft-lb] CAUTION The bracket MUST be flat against the compressor.
  • Page 135
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-111 CAUTION The support MUST be flat against the block. Rotate the compressor until the support is aligned properly against the block. If the support in NOT flat, the compressor and/or accessory drive will fail.
  • Page 136
    Engine Assembly (000-004) QSK19 Page 0-112 Section 0 — Complete Engine — Group 00 Clean the top of the cylinder block and the cylinder liners. Use a scraper or a fibrous abrasive pad such as Scotch- Brite 7477, or equivalent, and solvent. Clean the top deck surface of the block.
  • Page 137
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-113 Install the cylinder head. It must slide easily over the groove pins. Lubricate the capscrew head flange with SAE EP 140W oil. Lubricate the capscrew threads with clean engine oil. Allow excess oil to drip off of the capscrews before installing in the block.
  • Page 138
    Engine Assembly (000-004) QSK19 Page 0-114 Section 0 — Complete Engine — Group 00 Use clean, 15W-40 oil. Lubricate the o-rings. Install the hold-down clamp on the side of the injector. Install the injector and hold-down clamp in the cylinder head.
  • Page 139
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-115 Use vegetable oil. Lubricate the o-rings (2). Install the o-rings. Install the water transfer tube (1). NOTE: The gasket and housing must be aligned correctly with the dowel pins. Install the gasket and the housing.
  • Page 140
    Engine Assembly (000-004) QSK19 Page 0-116 Section 0 — Complete Engine — Group 00 Install the rocker levers. NOTE: Be sure the ring dowel that aligns the rocker shaft is installed in the housing. NOTE: Be sure the adjusting screws are loose. Position the rocker lever assembly on the housing.
  • Page 141
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-117 Determine the Cylinder in Position for Valve Set The valves will be adjusted on the cylinder that has all the valves closed. Use the table to determine the cylinders for valve position.
  • Page 142
    Engine Assembly (000-004) QSK19 Page 0-118 Section 0 — Complete Engine — Group 00 Valves – Setting Valve Adjustment (Initial Set) Reference Point 0.81 Exhaust 0.032 0.36 Intake 0.014 NOTE: To provide a consistent set, lubricate the adjusting screws prior to setting the valves. NOTE: Be sure the crosshead is firmly in place on the valve stem tips.
  • Page 143
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-119 NOTE: The feeler gauge must slide backward and for- ward with only a slight drag. NOTE: The adjusting screw must not turn when the lock nut is tightened. Torque Value: With Torque Wrench Adapter, Part No.
  • Page 144
    Engine Assembly (000-004) QSK19 Page 0-120 Section 0 — Complete Engine — Group 00 1. Engine firing order 1-5-3-6-2-4 2. Cylinders are numbered from the front gear cover end of the engine. 3. Two crankshaft revolutions are required to adjust all of the valves and the injectors. 4.
  • Page 145
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-121 NOTE: Do not use gasket cement. It will prevent the gasket from sealing properly. Install the rocker lever cover, gasket, and capscrews. Tighten the capscrews. Torque Value: 45 N•m [35 ft-lb] Install the coolant thermostat housing support.
  • Page 146
    Engine Assembly (000-004) QSK19 Page 0-122 Section 0 — Complete Engine — Group 00 Use vegetable oil to lubricate the o-ring. Install a new o-ring on the aftercooler water supply tube (31). Install the tube in the bore of the thermostat housing. Install the retainer clip (7) and capscrew.
  • Page 147
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-123 Low Temperature Aftercooling Install the o-rings (19) on the water transfer tube. Use vegetable oil. Lubricate the o-rings. Install the tube in the bore of the rocker lever housing. Align the bore in the thermostat housing support with the transfer tube.
  • Page 148
    Engine Assembly (000-004) QSK19 Page 0-124 Section 0 — Complete Engine — Group 00 Use vegetable oil to lubricate the o-ring. Install a new o-ring on the aftercooler water supply tube (31). Install the tube in the bore of the thermostat housing. Install the retainer clip (7) and capscrew.
  • Page 149
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-125 Install the cam follower assembly. The shaft must fit on both ring dowels. Install the capscrews. Torque Value: Step 1 55 N•m [40 ft-lb] 2 110 N•m [80 ft-lb] 3 165 N•m [120 ft-lb]…
  • Page 150
    Engine Assembly (000-004) QSK19 Page 0-126 Section 0 — Complete Engine — Group 00 Rail Applications Connect the turbocharger drain hose to the scavenge cross. Torque Value: 80 N•m [60 ft-lb] NOTE: The dipstick tube and fuel filter mounting locations vary depending on the application of the engine.
  • Page 151
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-127 Remove the two straight threaded o-ring plugs from the timing holes in the front cover. Check the index mark alignment. CAUTION Do not use the ‘‘A’’ on the camshaft idler gear for the accessory drive alignment unless the ‘‘X’’…
  • Page 152
    Engine Assembly (000-004) QSK19 Page 0-128 Section 0 — Complete Engine — Group 00 Install the accessory drive seal. NOTE: The keyway seal must be installed before installing the woodruff key. Install the keyway seal. Install the woodruff key. CAUTION Do not use a hammer to drive the pulley into position.
  • Page 153
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-129 Lubricate the shaft O.D. and the pulley I.D. with engine oil. Align the keyway in the pulley with the key in the shaft. Use the tool to push the pulley on the shaft until it touches the step on the shaft.
  • Page 154
    Engine Assembly (000-004) QSK19 Page 0-130 Section 0 — Complete Engine — Group 00 Connect the fuel line to the fuel filter head. Install a new thread adapter sealing ring supplied with the new filter. A fuel-water separator or fuel filter and water separator combination must be installed.
  • Page 155
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-131 Tighten the nut that holds the electrical connection post on the fuel shutoff valve coil. Torque Value: 3 N•m [25 in-lb] Install the electrical connection on the fuel shutoff valve. Install the nut on the threaded post of the coil.
  • Page 156
    Engine Assembly (000-004) QSK19 Page 0-132 Section 0 — Complete Engine — Group 00 Connect the fuel supply hose (1), the timing rail pressure line (2), and the metering rail pressure lines (3) to the control valve body. Tighten the fuel supply hose (1). Tighten the timing pressure (2) and rail pressure lines (3).
  • Page 157
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-133 Install the engine wiring harness and brackets. Fuel Tank-To-Fuel Filter Install and tighten the fuel inlet line. Torque Value: 115 N•m [85 ft-lb] Fuel Rail Supply Line Fuel Timing Supply Line Loosely assemble the fuel tubes and clamps.
  • Page 158
    Engine Assembly (000-004) QSK19 Page 0-134 Section 0 — Complete Engine — Group 00 Tighten the fuel tube clamps. Torque Value: 27 N•m [20 ft-lb] On engines equipped with an air compressor, install the air compressor air inlet connection with a new hose and gas- ket.
  • Page 159
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-135 Fuel Inlet Line Install new o-rings on the fuel pump inlet fitting and fuel filter head outlet fitting. Check for proper o-ring installation. Install the hose at the fuel pump inlet and fuel filter head outlet fitting.
  • Page 160
    Engine Assembly (000-004) QSK19 Page 0-136 Section 0 — Complete Engine — Group 00 CAUTION This component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component. Install the aftercooler and the bottom row of capscrews. Tighten the capscrews only enough to hold the part.
  • Page 161
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-137 Rail Applications Install the face seal o-ring. Install the turbocharger drain line to scavenge cross. Torque Value: 80 N•m [60 ft-lb] Rail Applications Install hose and tighten hose clamp. Torque Value: 8 N•m [75 in-lb] Connect the inlet hose.
  • Page 162
    Engine Assembly (000-004) QSK19 Page 0-138 Section 0 — Complete Engine — Group 00 Install two guide studs. Put the gasket and housing into position. Install, but do not tighten, capscrews. CAUTION Do not tighten the capscrews until the oil cooler cover or torque converter cooler cover is installed.
  • Page 163
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-139 Install the oil cooler cover. Install the elements. Tighten the self-locking nuts. Torque Value: 130 N•m [95 ft-lb] Use new o-rings. Lubricate the o-rings with vegetable oil. Install the o-rings on the cooler elements.
  • Page 164
    Engine Assembly (000-004) QSK19 Page 0-140 Section 0 — Complete Engine — Group 00 NOTE: Be sure the capscrews are the correct length. Use vegetable oil to lubricate the o-rings on the cooler element and the bores in the cover. Install the gasket and cover.
  • Page 165
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-141 Use vegetable oil. Lubricate the o-ring on the water bypass tube. Install the bypass tube. Install the retainer (9) and capscrew. Tighten the capscrew and hose clamp. Torque Value: Capscrew 45 N•m…
  • Page 166
    Engine Assembly (000-004) QSK19 Page 0-142 Section 0 — Complete Engine — Group 00 Tighten the capscrews to the values specified and in the sequence shown. Torque Value: 45 N•m [35 ft-lb] Use vegetable oil. Lubricate the o-rings (13). Install the transfer tube in the water pump outlet connec- tion.
  • Page 167
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-143 CAUTION Do not use gasket cement or the gasket will fail. Install the guide studs used during removal. Use contact adhesive and attach the gasket on the cylinder head exhaust ports.
  • Page 168
    Engine Assembly (000-004) QSK19 Page 0-144 Section 0 — Complete Engine — Group 00 Holset turbocharger(s) are used on the QSK19 engine. Refer to the data tag on the turbocharger to determine the model. NOTE: The name is also cast on the housing of a turbocharger.
  • Page 169
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-145 Bearing Housing Adjustment Bend the lockplate off the capscrew heads. Remove the capscrews. Rotate the bearing housing. Align the drain tube and the capscrew holes. Install the lockplates and capscrews. Tighten the capscrews.
  • Page 170
    Engine Assembly (000-004) QSK19 Page 0-146 Section 0 — Complete Engine — Group 00 Connect the oil supply hose. Tighten the hose fitting. Torque Value: 31 N•m [23 ft-lb] Connect the coolant supply hose and the coolant return hose to the turbocharger. Tighten the hose fittings.
  • Page 171
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-147 Install the hose and two hose clamps on the air crossover tube. Install the air crossover. Slide the hose down and over the turbocharger outlet. Install the gasket and capscrews. Use the sequence illustrated.
  • Page 172
    Engine Assembly (000-004) QSK19 Page 0-148 Section 0 — Complete Engine — Group 00 Install the belt tensioner on the idler arm. Tighten the capscrews. Torque Value: 201 N•m [75 ft-lb] Install the idler arm assembly and capscrews (2). Tighten the capscrews. Torque Value: 45 N•m [35 ft-lb] Install the belt tensioning nut (1).
  • Page 173
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-149 Install the inlet connection (1), gasket, and capscrews. Tighten the capscrews. Torque Value: 40 N•m [30 ft-lb] NOTE: Do not tighten the support bracket until the water pump is assembled to the engine.
  • Page 174
    Engine Assembly (000-004) QSK19 Page 0-150 Section 0 — Complete Engine — Group 00 Use vegetable oil and lubricate the o-rings (13). Install the transfer tube in the water pump outlet connec- tion. Install the water pump outlet connection, gasket, and capscrews.
  • Page 175
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-151 Install the coolant filter. Turn the filter until the seal touches the filter head. Turn an additional 1/2 to 3/4 of a turn after contact. Turn the valve to the ON position. Lubricate the shaft with engine oil.
  • Page 176
    Engine Assembly (000-004) QSK19 Page 0-152 Section 0 — Complete Engine — Group 00 CAUTION Do not attempt to pry the belt on the pulley to avoid damage to pulley and belt. Install the belt. Turn the adjusting screw counterclockwise to shorten the link if necessary.
  • Page 177
    QSK19 Engine Assembly (000-004) Section 0 — Complete Engine — Group 00 Page 0-153 NOTE: Not all engines use spacers. NOTE: The wet type flywheel housing requires gaskets for the starting motor. Install any spacer or gaskets. Install the starting motor and capscrews. Use the following to tighten the capscrews.
  • Page 178
    Engine Assembly (000-004) QSK19 Page 0-154 Section 0 — Complete Engine — Group 00 NOTES…
  • Page 179
    Section 1 — Cylinder Block — Group 01 Page 1-a Section 1 — Cylinder Block — Group 01 Section Contents Page Bearings, Connecting Rod ……………………..1-5 Clean …………………………..1-5 Inspect for Reuse ……………………….1-5 Bearings, Main …………………………1-5 Clean …………………………..1-5 Inspect for Reuse ……………………….
  • Page 180
    Page 1-b Section 1 — Cylinder Block — Group 01 Page Cylinder Liner…………………………1-51 Clean …………………………… 1-51 Inspect for Reuse ……………………….1-52 Cylinder Liner Protrusion ……………………..1-79 Adjust …………………………… 1-79 Gear Cover Accessory Drive Bushing ………………….1-80 Install …………………………… 1-80 Remove …………………………
  • Page 181
    NOTE: The camshaft does not have to be removed to remove the camshaft gear. Use the Camshaft gear puller, Part No. 3376400. Camshaft’s that are damaged or worn on the injector or the valve lobes must be replaced. Cummins Engine Co., Inc. does not recommend the grinding of camshaft lobes.
  • Page 182
    Service Tools Cylinder Block The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No.
  • Page 183
    Service Tools Section 1 — Cylinder Block — Group 01 Page 1-3 Tool No. Tool Description Tool Illustration Liner Installation Tool Install cylinder liner in engine. 3375422 Crack Detection Kit Check for cracks in any engine component. Contains cleaner, developer, and penetrant. 3375432 Injection Timing Tool Check injection timing.
  • Page 184
    Section 1 — Cylinder Block — Group 01 Tool No. Tool Description Tool Illustration Cummins Sealant Used to prevent coolant or oil leaks. This is one part Room Temperature Vulcanizing (RTV) silicone rubber, adhesive, and 3823494 sealant material having high heat and oil resistance, and low compression rate.

  • Page 185: Bearings, Connecting Rod

    Bearings, Connecting Rod (001-005) Section 1 — Cylinder Block — Group 01 Page 1-5 Bearings, Connecting Rod (001-005) Clean The bearings must be marked for location as they are removed for future identification. Each bearing must be installed in its original location if the bearing is installed again.

  • Page 186: Inspect For Reuse

    Bearings, Thrust (001-007) Page 1-6 Section 1 — Cylinder Block — Group 01 Inspect for Reuse Use a ball-end micrometer. Measure the bearing thickness at the wear location. The bearing must be replaced if it is not within specifications. Main Bearing Thickness Standard or Oversize (OS) Size Standard…

  • Page 187: Assemble

    Camshaft (001-008) Section 1 — Cylinder Block — Group 01 Page 1-7 Assemble Camshaft (001-008) Clean Use solvent and compressed air. Clean the camshaft. After the camshaft has been cleaned, do not touch the machined surfaces with bare hands. This will cause rust to form.

  • Page 188
    Camshaft (001-008) Page 1-8 Section 1 — Cylinder Block — Group 01 Inspect the camshaft thrust bearing. . Visually inspect the amount of copper exposure on the camshaft bushing. If it extends more than 180 degrees around the bushing, the bushing must be replaced. Measure the I.D.
  • Page 189
    Camshaft (001-008) Section 1 — Cylinder Block — Group 01 Page 1-9 CAUTION Use the coil shot method. Use a coil that is a minimum of 305 mm [12 in]. Apply coil shot. Use the continuous method. Amperage (Ampere Turns) 3600 D.C.
  • Page 190
    Camshaft Gear (Camshaft Removed) (001-013) Page 1-10 Section 1 — Cylinder Block — Group 01 Limits of Acceptance- Open Indications An open indication is visible to the eye after the suspension has been removed. An indication below the surface is not visible to the eye after the suspension has been removed.

  • Page 191: Inspect For Reuse

    The push rod travel numerical value will increase. NOTE: This applies to ALL Cummins engines. NOTE: The direction of normal rotation on a QSK19 engine crankshaft is clockwise as viewed from the front of the engine.

  • Page 192: Magnetic Crack Inspect

    Camshaft Gear (Camshaft Removed) (001-013) Page 1-12 Section 1 — Cylinder Block — Group 01 Visually inspect the camshaft gear for cracks, chipped or broken teeth. Visually inspect the bore of the gear for fretting or burrs. Measure the I.D. Camshaft Gear I.D.

  • Page 193
    Camshaft Gear (Camshaft Removed) (001-013) Section 1 — Cylinder Block — Group 01 Page 1-13 CAUTION If the gear contains a keyway, position the gear so that the keyway points toward the coil. Use the residual method. Apply coil shot amperage. Adjust the amperage to the specified value.
  • Page 194
    Camshaft Gear (Camshaft Removed) (001-013) Page 1-14 Section 1 — Cylinder Block — Group 01 Limits of Acceptance — on Forged Surfaces Do not use the gear if: • There is an open indication that is in a circumfer- ential direction. •…

  • Page 195: Camshaft Bushings

    Camshaft Bushings (001-010) Section 1 — Cylinder Block — Group 01 Page 1-15 WARNING Wear protective clothing to prevent personal injury from burns. CAUTION Do not exceed the specified time or the temperature. Damage to the gear and the gear teeth will result. CAUTION Do not attempt to install the gear without using heat.

  • Page 196
    Camshaft Bushings (001-010) Page 1-16 Section 1 — Cylinder Block — Group 01 Remove the camshaft bushings. Inspect for Reuse Inspect the camshaft bores in the block for reuse. Use an emery cloth to remove any burrs and sharp edges from the bore.
  • Page 197
    Camshaft Bushings (001-010) Section 1 — Cylinder Block — Group 01 Page 1-17 CAUTION Clean the oil groove in the back of the camshaft bush- ing to prevent contamination of the lubrication system. Use the camshaft bushing driver assembly, Part No. 3376637, and the specified engine kit (mandrel).

  • Page 198: Clean

    Connecting Rod (001-014) Page 1-18 Section 1 — Cylinder Block — Group 01 Connecting Rod (001-014) Clean WARNING When using solvents, acids or alkaline materials for cleaning, follow the manufacture’s recommendations for use. Wear goggles and protective clothing to avoid personal injury.

  • Page 199
    Connecting Rod (001-014) Section 1 — Cylinder Block — Group 01 Page 1-19 Visually inspect the bearing seating surface for nicks or burrs. If it is not possible to remove any nicks or burrs with a fine crocus cloth, the rod must be replaced. Measure the connecting rod wrist pin bearing I.D.
  • Page 200
    Connecting Rod (001-014) Page 1-20 Section 1 — Cylinder Block — Group 01 CAUTION Use a vise with brass jaws to hold the rod. Notches, scratches, or dents in the I-beam area will cause engine failure. CAUTION The number on the connecting rod must be the same as the number on the rod cap.
  • Page 201
    Connecting Rod (001-014) Section 1 — Cylinder Block — Group 01 Page 1-21 CAUTION The rod cap must be installed and torqued to specifi- cation or the measurements will be wrong. A connecting rod of known length, bend, and twist, called a master rod, is required to calibrate the fixture.
  • Page 202
    Connecting Rod (001-014) Page 1-22 Section 1 — Cylinder Block — Group 01 Be sure the indicators are at the “0” setting. If the indicator needles do not return to “0”, adjust the indicator so that the “0” moves 1/2 of the indicated differ- ence from the needle to the “0”…
  • Page 203
    Connecting Rod (001-014) Section 1 — Cylinder Block — Group 01 Page 1-23 Record the indicator reading. The difference of the cali- brated “0” of the indicators must be added or subtracted from the known length of the master rod to determine the length of the rod being measured.
  • Page 204
    Connecting Rod (001-014) Page 1-24 Section 1 — Cylinder Block — Group 01 Magnetic Crack Inspect Use a magnetic particle testing machine. The connecting rod and cap must be assembled during this check. Use the residual method. Apply head shot amperage. Ad- just the amperage to 1500 ampere D.C.

  • Page 205: Crankshaft

    Crankshaft (001-016) Section 1 — Cylinder Block — Group 01 Page 1-25 Crankshaft (001-016) Clean NOTE: New crankshafts are coated with a heavy preser- vative. Use solvent to remove the coating thoroughly. Brush or flush the packing debris from the oil drilling before in- stalling the crankshaft in the engine.

  • Page 206
    Crankshaft (001-016) Page 1-26 Section 1 — Cylinder Block — Group 01 Use a bristle brush and solvent to clean all of the oil drilling. To prevent rust use, a light preservative oil to lubricate the crankshaft. Inspect for Reuse Measure the O.D.
  • Page 207
    Crankshaft (001-016) Section 1 — Cylinder Block — Group 01 Page 1-27 Measure the O.D. Rod Bearing Journal O.D. (4) 101.524 3.997 101.600 4.000 Main Bearing Journal O.D. (5) 139.637 5.4975 139.700 5.5000 Measure the thrust distance between the thrust faces on the No.
  • Page 208
    Crankshaft (001-016) Page 1-28 Section 1 — Cylinder Block — Group 01 Use the coil shot method. Use a coil that is a minimum of 514 mm [20 1/4-inch] in diameter. Use the continuous method. Apply coil shot. Amperage — (Ampere Turns) 4500 D.C.

  • Page 209: Bend And Twist Inspect

    Crankshaft (001-016) Section 1 — Cylinder Block — Group 01 Page 1-29 CAUTION The crankshaft must be demagnetized completely and cleaned thoroughly. Small metal particles will cause engine damage. Demagnetize the crankshaft. CAUTION Wear protective clothing to prevent personal injury from burns.

  • Page 210
    Crankshaft (001-016) Page 1-30 Section 1 — Cylinder Block — Group 01 3. Adjacent Journal Run Out: The relationship of the TIR of a main bearing journal as it is rotated on a common axis to the TIR of an adjacent journal.
  • Page 211
    Crankshaft (001-016) Section 1 — Cylinder Block — Group 01 Page 1-31 Rotate the crankshaft and measure the TIR at each bearing journal. Record the value and the clock position for each journal. Determine the Crankshaft Bow Crankshaft bow as specified, is the TIR of the center journal when the crankshaft is rotated thru 360 degrees, while supported on the end of the journals.
  • Page 212
    Crankshaft (001-016) Page 1-32 Section 1 — Cylinder Block — Group 01 Draw a straight line between the plotted points, (from jour- nal No. 1 to No. 2, and from No. 2 to No. 3), until all journals are plotted on the chart. To determine the Adjacent Journal Run Out, measure the length of the line from each journal to its corresponding journal point.
  • Page 213
    Crankshaft (001-016) Section 1 — Cylinder Block — Group 01 Page 1-33…

  • Page 214: Remove

    Crankshaft Gear, Front (Crankshaft Installed) (001-018) Page 1-34 Section 1 — Cylinder Block — Group 01 Crankshaft Gear, Front (Crankshaft Installed) (001-018) Remove Remove the gear cover and all related components. Refer to the QSK19 Troubleshooting and Repair Manual, Bulletin No.

  • Page 215: Install

    Crankshaft Gear, Front (Crankshaft Installed) (001-018) Section 1 — Cylinder Block — Group 01 Page 1-35 Inspect for Reuse Clean and visually inspect the crankshaft for reuse. Mea- sure the O.D. Crankshaft O.D. (Gear Location) 111.25 4.380 111.28 4.381 Install Install the key.

  • Page 216: Crankshaft Pulley

    Crankshaft Gear, Rear (Crankshaft Installed) (001-020) Page 1-36 Section 1 — Cylinder Block — Group 01 CAUTION Wear protective clothing to prevent personal injury from burns. CAUTION Allow the gear to air cool slowly. Do not use water or oil to reduce the cooling time.

  • Page 217: Inspect For Reuse

    Crankshaft Pulley (001-022) Section 1 — Cylinder Block — Group 01 Page 1-37 Inspect for Reuse Check all mounting pilots and surfaces for damage from fretting. If it is not possible to remove the damage with a 240 grit abrasive cloth, the part must be replaced. CAUTION The mounting pilots and surfaces control the center and spacing of the pulleys.

  • Page 218: Cylinder Block

    Cylinder Block (001-026) Page 1-38 Section 1 — Cylinder Block — Group 01 Cylinder Block (001-026) Worksheet Cylinder Block Inspection Checklist 1. Cylinder Liner Counterbore a.Upper Bore I.D. b. Lower Bore I.D. c. Depth d. Ledge Flatness e. Ledge Cracking 2.

  • Page 219: Clean

    Cylinder Block (001-026) Section 1 — Cylinder Block — Group 01 Page 1-39 Clean Use a drill, a sheet metal screw, and the following parts from a light duty puller kit, Part No. 3375784: • Slide hammer • Hook Remove the following cup plugs: 1.

  • Page 220
    Cylinder Block (001-026) Page 1-40 Section 1 — Cylinder Block — Group 01 Remove the cup plug from the hydraulic pump idler oil passage. Remove the straight thread pipe plug from the lubricating pump oil passage. Use a dowel pin extractor, Part No. ST-1134, or equivalent. Remove the 12 cylinder head groove pins.
  • Page 221
    Remove the block from the engine stand. Follow the instructions of the manufacturer of the cleaning tank and the manufacturer of the cleaning solution. NOTE: Cummins Engine Co., Inc. does not recommend any specific cleaning solution. Past experience shows that the best results are obtained using a cleaning solution that can be heated from 80°C to…
  • Page 222
    Cylinder Block (001-026) Page 1-42 Section 1 — Cylinder Block — Group 01 CAUTION Do not install any cup plugs or pipe plugs in the block until the inspection and any necessary repair proce- dures are completed. This will prevent dirt from being trapped in the oil passages.
  • Page 223
    Cylinder Block (001-026) Section 1 — Cylinder Block — Group 01 Page 1-43 If the block height is less than 408.20 mm [16.071 inch] a 0.51 mm [0.020 inch] oversize head gasket must be used. The height of the block must not vary more than 0.05 mm [0.002 inch] from end to end of the block.
  • Page 224
    Cylinder Block (001-026) Page 1-44 Section 1 — Cylinder Block — Group 01 Use your hands to install the checking ring in the main bearing bore. If the ring will not slide through the bore, check the bore for burrs. If the ring will still not slide through the bore, the bore is undersized and must be repaired.
  • Page 225
    Cylinder Block (001-026) Section 1 — Cylinder Block — Group 01 Page 1-45 Check the main bearing caps that are loose. The main bearing cap must be replaced if : • The clearance causes the main bore alignment not to be within specifications. •…
  • Page 226
    Cylinder Block (001-026) Page 1-46 Section 1 — Cylinder Block — Group 01 Capscrew Hole Cracks Cracks that extend from the counterbore wall to the capscrew hole are acceptable for reuse only if it does not extend into the threaded portion of the hole. Cracks that extend into threaded portion of the hole require repair with a blind end thread insert.

  • Page 227: General Information

    Cylinder Block and Liner Seats (001-027) Section 1 — Cylinder Block — Group 01 Page 1-47 Cylinder blocks with vertical cracks that extend from a coolant passage down over the counterbore ledge can not be repaired. Cylinder Block and Liner Seats (001-027) General Information Definition of numerical terms (call-outs):…

  • Page 228
    Cylinder Block and Liner Seats (001-027) Page 1-48 Section 1 — Cylinder Block — Group 01 Inspect the cylinder block to determine if an oversize or a standard size head gasket is required. NOTE: An oversize head gasket may be required on blocks that have had material removed from the top surface of the block.
  • Page 229
    Cylinder Block and Liner Seats (001-027) Section 1 — Cylinder Block — Group 01 Page 1-49 Measure NOTE: Be sure the micrometer contacts the flat surface of the ledge. It must not touch the radius. NOTE: If the counterbore depth does not meet specifica- tions, a thicker or thinner seal ring may have been used in a previous machining bore process.
  • Page 230
    Cylinder Block and Liner Seats (001-027) Page 1-50 Section 1 — Cylinder Block — Group 01 Measure the I.D. of the upper counterbore (1). The point of measurement must be within 2.54 mm [0.100 inch] from the top of the block. Counterbore Diameter — UPPER Press Fit Diameter 188.16 7.409…

  • Page 231: Leak Test

    Cylinder Liner (001-028) Section 1 — Cylinder Block — Group 01 Page 1-51 Leak Test Cylinder Liner (001-028) Clean CAUTION Do not use a hone, deglazing, or prebrushing to clean the cylinder liners. Abrasives can damage the finish and the crosshatch pattern and can contaminate the liner. WARNING Wear eye protection.

  • Page 232
    Cylinder Liner (001-028) Page 1-52 Section 1 — Cylinder Block — Group 01 Inspect for Reuse Visually inspect the liners for cracks on the inside and the outside diameters. Inspect for cracks under the flange. NOTE: Cracks can also be detected by using either mag- netic inspection or the dye method.
  • Page 233
    Cylinder Liner (001-028) Section 1 — Cylinder Block — Group 01 Page 1-53 Visually inspect the inside diameter for liner bore polishing. A moderate polish produces a bright mirror finish in the worn area with traces of the original hone marks or an indication of an etch pattern.
  • Page 234
    Cylinder Liner (001-028) Page 1-54 Section 1 — Cylinder Block — Group 01 NOTE: The liner design incorporates a press fit between the upper liner bore and the area of the liner directly below the liner flange. This is referred to as the Lower Press Fit (LPF) design.
  • Page 235
    Gear Cover Spacer Plate (001-029) Section 1 — Cylinder Block — Group 01 Page 1-55 Gear Cover Spacer Plate (001-029) Clean Use solvent, clean the Gear Cover Spacer Plate. Dry with compressed air. Inspect for Reuse Inspect the plate for reuse. Check for fretting damage on both sides of the gasket surface.
  • Page 236
    Gear Cover, Front (001-031) Page 1-56 Section 1 — Cylinder Block — Group 01 Inspect for Reuse Measure the I.D. of the bushings. The bushings must be replaced if not within specifications. Accessory Drive & Water Pump Drive Bushing I.D. 39.75 1.565 39.90…

  • Page 237: Measure

    Idler Gear, Camshaft (001-036) Section 1 — Cylinder Block — Group 01 Page 1-57 Install the retaining ring. Rotate the shaft. Check for correct assembly. Measure Barring Mechanism Bushing Bore Measure the I.D. of the bushing bore. Barring Mechanism Bushing Bore 18.215 0.717 18.265…

  • Page 238
    Idler Gear, Camshaft (001-036) Page 1-58 Section 1 — Cylinder Block — Group 01 Magnetic Crack Inspect CAUTION Use a copper braid contact that has neoprene covers to avoid burning the teeth of the gear. CAUTION If the gear contains a keyway, position the gear so that the keyway points toward one of the contacts when checking.
  • Page 239
    Idler Gear, Hydraulic Pump (001-039) Section 1 — Cylinder Block — Group 01 Page 1-59 Limits of Acceptance — on Machined Surfaces An open indication is visible to the eye after the wetting operation has been completed. An indication below the surface is not visible to the eye after the wetting operation has been completed.
  • Page 240
    Idler Gear, Water Pump (001-040) Page 1-60 Section 1 — Cylinder Block — Group 01 Inspect for Reuse Check the gear and parts for any damage. Idler Gear, Water Pump (001-040) Clean Use solvent clean the part. Dry with compressed air Inspect for Reuse Check all parts for damage.
  • Page 241
    Piston (001-043) Section 1 — Cylinder Block — Group 01 Page 1-61 CAUTION Do not contaminate the wash tank solution with bead blast materials. Use a kerosene emulsion-based solvent. Do not use a solvent that is higher than 9.5 pH. Do not use a solvent that contains chlorinated hydrocarbons with cresol, phenols, or cresylic components.
  • Page 242
    Piston (001-043) Page 1-62 Section 1 — Cylinder Block — Group 01 Visually inspect the ring grooves. The pistons must be replaced if there is a visible ridge in the back of the groove. The piston must be replaced if a lip has formed on the O.D. of the groove.
  • Page 243
    Vibration Damper (001-052) Section 1 — Cylinder Block — Group 01 Page 1-63 Measure the piston pin outside diameter and length. Piston Pin O.D. 60.929 2.3988 60.935 2.3990 Piston Pin Length 132.59 5.220 132.85 5.230 Vibration Damper (001-052) Clean Vibration dampers have a limited service life. The damper must be replaced after 15,000 hours in service.
  • Page 244
    Vibration Damper (001-052) Page 1-64 Section 1 — Cylinder Block — Group 01 NOTE: The following illustrates the procedure to check the damper for fluid leakage. Use the crack detection kit, Part No. 3375434, or equiva- lent, and spray the rolled lip of the damper. NOTE: The crack detection kit, Part No.

  • Page 245: Cylinder Block Counterbore

    NOTE: The cylinder block counterbore tool, Part No. 3376684, contains the tools listed above. The same kit contains the tools to machine the counterbore depth on all Cummins engines except the L10. Install the drive unit (1) on the adapter plate (2). Torque Value: 40 N•m…

  • Page 246
    Cylinder Block Counterbore (001-058) Page 1-66 Section 1 — Cylinder Block — Group 01 CAUTION Part No. 3377468 must be used to machine the count- erbore ledge. Install the tool bit in the cutter plate. Position the bit so it will cut when the plate is moving clockwise.
  • Page 247
    Cylinder Block Counterbore (001-058) Section 1 — Cylinder Block — Group 01 Page 1-67 There must be no clearance between the adapter plate mounting surface and the block head surface. Align the holes in the adapter plate (2) with two cylinder head capscrew holes in the block.
  • Page 248
    Cylinder Block Counterbore (001-058) Page 1-68 Section 1 — Cylinder Block — Group 01 CAUTION Do not turn the handle clockwise. The tool will damage the bore. Use the handle to turn the tool counterclockwise. Listen for the sound of the tool bit scraping the bore wall as it is turned a minimum of 180 degrees.
  • Page 249
    Cylinder Block Counterbore (001-058) Section 1 — Cylinder Block — Group 01 Page 1-69 CAUTION Loosen and retract the tool bit before attempting to raise the tool. Raise the cutter plate. Remove the tool from the block. Use a fine, India type stone. Remove any burrs and sharp edges from the counterbore ledge.
  • Page 250
    Cylinder Block Counterbore (001-058) Page 1-70 Section 1 — Cylinder Block — Group 01 Check the counterbore for cracks. NOTE: Liners and sealing ring(s) must be identified by cylinder number for proper assembly. Measure the liner flange thickness at four equally spaced points around the flange.
  • Page 251
    These instructions cover the counterbore depth and the upper counterbore I.D. machining at the same time. NOTE: Cummins Engine Company, Inc., recommends that the accuracy of the tool be checked before machining the customer’s block. If possible, machine a scrap block and check the accuracy of the cut.
  • Page 252
    Cylinder Block Counterbore (001-058) Page 1-72 Section 1 — Cylinder Block — Group 01 Install the base plate to the main housing. Install the four capscrews. Torque Value: 40 N•m [30 ft-lb] Position the cutter plate assembly with the tapered edge away from the housing.
  • Page 253
    Cylinder Block Counterbore (001-058) Section 1 — Cylinder Block — Group 01 Page 1-73 INSTALL THE TOOL To “LOCK” the feed mechanism, turn the knob on top clockwise. To “UNLOCK” the feed mechanism, turn the knob coun- terclockwise. Put the tool on the block. “UNLOCK”…
  • Page 254
    Cylinder Block Counterbore (001-058) Page 1-74 Section 1 — Cylinder Block — Group 01 Tighten the set screw. Move the micrometer to check the setting. Repeat the setting process until the cutter assembly is accurately set. ADJUST MACHINING DEPTH Raise and “LOCK” the drive assembly. Put the cutter assembly in the cutter plate.
  • Page 255
    Cylinder Block Counterbore (001-058) Section 1 — Cylinder Block — Group 01 Page 1-75 FINAL ADJUSTMENTS FOR DEPTH The style of the block being machined determines the next adjustment. CAUTION Do not cut the counterbore depth with this tool. Follow these instructions for the QSK19. Turn the depth stoop collar 1/2 of a turn (180 degrees) counterclockwise.
  • Page 256
    Cylinder Block Counterbore (001-058) Page 1-76 Section 1 — Cylinder Block — Group 01 WARNING Hold the drill firmly. The drill will be hard to hold when the tool first contacts the block. Lower the cutting plate until the cutting assembly is 1.50 mm [1/16-inch] above the block.
  • Page 257
    Cylinder Block Counterbore (001-058) Section 1 — Cylinder Block — Group 01 Page 1-77 Use a hone stone. Remove burrs from the sharp corner of the I.D. Measure the upper counterbore I.D. (1) in the location shown. Machine the diameter again if the I.D. is smaller than specification.
  • Page 258
    Cylinder Block Counterbore (001-058) Page 1-78 Section 1 — Cylinder Block — Group 01 CAUTION The upper counterbore and the top surface of the block must be clean. Put the tool in the cylinder block liner bore to be checked. Slide the contact plate until both contact pins touch the upper counterbore I.D.
  • Page 259
    Cylinder Liner Protrusion (001-064) Section 1 — Cylinder Block — Group 01 Page 1-79 Move the tool 180 degrees backward to the original “ZERO” position. Repeat the measurement procedure when the indicator does not read “ZERO”. CAUTION Concentricity must be within specification. Engine dam- age will result when the liner is not seated correctly in the bore.
  • Page 260
    Gear Cover Accessory Drive Bushing (001-066) Page 1-80 Section 1 — Cylinder Block — Group 01 Gear Cover Accessory Drive Bushing (001-066) Remove Use the appropriate bushing mandrel and an arbor press. Remove the accessory drive, water pump, and the hydrau- lic pump drive bushings.
  • Page 261
    QSK19 Section 2 — Cylinder Head — Group 02 Page 2-a Section 2 — Cylinder Head — Group 02 Section Contents Page Crosshead ………………………….. 2-4 Clean …………………………..2-4 Inspect for Reuse ……………………….2-4 Cylinder Head …………………………2-5 Assemble …………………………2-14 Clean …………………………..
  • Page 262
    QSK19 Cylinder Head — General Information Section 2 — Cylinder Head — Group 02 Page 2-1 Cylinder Head — General Information General Information The QSK19 uses a torque-turn method for torquing all cylinder head capscrews. This method provides better con- trol of the load on the capscrews.
  • Page 263
    Service Tools Cylinder Head The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No.
  • Page 264
    QSK19 Service Tools Section 2 — Cylinder Head — Group 02 Page 2-3 Tool No. Tool Description Tool Illustration Valve Seat Grinding Machine Used to grind the valve seats. ST-685 Valve Vacuum Tester Used to test the valve to valve seat connection. ST-1257 Valve Seat Extractor Used to remove the valve seats.
  • Page 265
    Crosshead (002-001) QSK19 Page 2-4 Section 2 — Cylinder Head — Group 02 Crosshead (002-001) Clean WARNING When using solvents, acids or alkaline materials for cleaning, follow the manufactures recommendations for use. Wear goggles and protective clothing to avoid personal injury. Use solvent.
  • Page 266
    QSK19 Cylinder Head (002-004) Section 2 — Cylinder Head — Group 02 Page 2-5 Cylinder Head (002-004) Exploded View 1. Screw, Twelve Point Cap 11. Insert, Valve, Intake 2. Gasket, Cylinder Head 12. Plug, Expansion 3. Seal, Valve Stem 13. Plug, Expansion 4.
  • Page 267
    Cylinder Head (002-004) QSK19 Page 2-6 Section 2 — Cylinder Head — Group 02 Clean WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury. Clean the heads with solvent.
  • Page 268
    QSK19 Cylinder Head (002-004) Section 2 — Cylinder Head — Group 02 Page 2-7 Using flange head capscrews with the torque plus angle method of installation, places the capscrew beyond the yield point and permanently stretches the capscrew. These capscrews can be reused throughout the life of the engine unless the capscrew exceeds the specified free length.
  • Page 269
    Cylinder Head (002-004) QSK19 Page 2-8 Section 2 — Cylinder Head — Group 02 The capscrew can also be checked using a set of calipers. The maximum allowable free length is measured from the bottom of the flange to the end of the capscrew (Dimension Cylinder Head Capscrew Free Length 207.3 8.160…
  • Page 270
    QSK19 Cylinder Head (002-004) Section 2 — Cylinder Head — Group 02 Page 2-9 Install the pressure regulator between the air supply and the quick disconnect fitting. NOTE: The arrow on the top of the pressure regulator must point in the direction of the air flow (toward the quick dis- connect fitting).
  • Page 271
    The valve and the valve seats must be clean and dry. NOTE: The valve vacuum tester, Part No. ST-1257 can be used to test all Cummins’ engine models. Choose the correct cup for the engine model that is to be…
  • Page 272
    QSK19 Cylinder Head (002-004) Section 2 — Cylinder Head — Group 02 Page 2-11 Chose the correct seal. 1. Intake valve 2. Exhaust valve NOTE: A new seal is available that has the appearance of (1), but is manufactured from a softer material. The new seal is to be used on cylinder heads that are machined with a relief valve between all four bores.
  • Page 273
    Cylinder Head (002-004) QSK19 Page 2-12 Section 2 — Cylinder Head — Group 02 When the gauge indicates between 20 in-Hg and 25 in-Hg, turn the vacuum control valve (4) to the “CLOSED” or “OFF” position. Turn the toggle switch (3) to the “OFF” position. Use a stop watch.
  • Page 274
    QSK19 Cylinder Head (002-004) Section 2 — Cylinder Head — Group 02 Page 2-13 Disassemble CAUTION The valve springs are under compression. Be cautious when using the valve spring compressor. Personal in- jury can result if the tool slips from your hands. Use a valve spring compressor, Part No.
  • Page 275
    Cylinder Head (002-004) QSK19 Page 2-14 Section 2 — Cylinder Head — Group 02 Assemble Use cup plug Loctite sealant, Part No. 3375068. NOTE: Use the correct expansion plug driver to make sure the expansion plugs are installed to the correct depth in the cylinder head.
  • Page 276
    QSK19 Cylinder Head Injector Bore (002-011) Section 2 — Cylinder Head — Group 02 Page 2-15 CAUTION The valve springs are under compression. Be cautious when using the valve spring compressor. Personal in- jury can result if the tool slips from your hands. Use a valve spring compressor, Part No.
  • Page 277
    Cylinder Head Injector Bore (002-011) QSK19 Page 2-16 Section 2 — Cylinder Head — Group 02 Use a dummy injector with no injector o-rings installed. Use Prussian Blue™, apply a thin coating on the sealing ring. CAUTION Support the cylinder head to prevent damage to the injector tip that protrudes from the combustion face.
  • Page 278
    QSK19 Cylinder Head Injector Bore (002-011) Section 2 — Cylinder Head — Group 02 Page 2-17 Adjust Use a gauge block, Part No. ST-547, or equivalent to mea- sure the injector protrusion. Measure as shown. Injector Protrusion 2.42 0.095 2.92 0.115 If the protrusion is not within specifications, use an oversize sealing ring.
  • Page 279
    Valve Guide, Cylinder Head (002-017) QSK19 Page 2-18 Section 2 — Cylinder Head — Group 02 Inspect the contact pattern in the injector bore. A blue band 1.52 mm (0.060 in) wide and 360 degrees full circumfer- ence minimum must be visible. NOTE: If the pattern does not meet the specification, clean the injector bore with a tapered brush.
  • Page 280
    QSK19 Valve Guide, Cylinder Head (002-017) Section 2 — Cylinder Head — Group 02 Page 2-19 Inspect Measure the I.D. of the valve guide bore. Valve Guide Bore I.D. 21.438 0.8440 21.463 0.8450 If the bore is not within specifications, ream the bore for oversize valve guides.
  • Page 281
    Valve Seat Bore (002-018) QSK19 Page 2-20 Section 2 — Cylinder Head — Group 02 Valve Seat Bore (002-018) Initial Check With the valve seats removed, measure the I.D. and the depth of the insert bore in the head Valve Seat Bore Measurements Intake Diameter 60.37 2.377…
  • Page 282
    QSK19 Valve Seat Insert, Cylinder Head (002-019) Section 2 — Cylinder Head — Group 02 Page 2-21 Install Clean the valve seat insert bore. Check the length of any cracks extending into the valve seat insert bore. NOTE: The cylinder head must be replaced if a crack extends into the bottom of the bore.
  • Page 283
    Valve, Cylinder Head (002-020) QSK19 Page 2-22 Section 2 — Cylinder Head — Group 02 If the width of the valve seat is not within specifications, remove surface material on the I.D. and the O.D. to de- crease the width of the seat. NOTE: If the valve seat specifications are not obtained by grinding, the insert must be replaced.
  • Page 284
    QSK19 Valve, Cylinder Head (002-020) Section 2 — Cylinder Head — Group 02 Page 2-23 Inspect for Reuse Inspect the collet grooves for wear. Measure the O.D. of the valve stem. Valve Stem O.D. 10.490 0.4130 10.510 0.4138 Use a valve head checking tool, Part No. 3824861, to mea- sure the head thickness of the valve.
  • Page 285
    Valve, Cylinder Head (002-020) QSK19 Page 2-24 Section 2 — Cylinder Head — Group 02 Coil Shot Amperage (Ampere Turns) 400 D.C. or rectified A.C. 800 D.C. or rectified A.C. NOTE: An ampere turn is an electrical current of one am- pere flowing through the coil, multiplied by the number of turns in the coil.
  • Page 286
    QSK19 Valve, Cylinder Head (002-020) Section 2 — Cylinder Head — Group 02 Page 2-25 Use a valve facing machine, Part No. 3376256 or equiva- lent, to grind the face of the valve. NOTE: Follow the instructions supplied with the valve fac- ing machine for the correct setup before grinding the valves.
  • Page 287
    Valve, Cylinder Head (002-020) QSK19 Page 2-26 Section 2 — Cylinder Head — Group 02 Use a fine lapping compound, Part No. 3375805, or equiva- lent. Apply a thin and even coating on the valve. Use a power or a hand suction lapping tool to provide pressure in the center of the valve.
  • Page 288
    QSK19 Valve, Cylinder Head (002-020) Section 2 — Cylinder Head — Group 02 Page 2-27 CAUTION The valve springs are under compression. Use caution when using the valve spring compressor. Personal in- jury can result. Use a valve spring compressor, Part No. ST-448, or Part No.
  • Page 289
    Valve, Cylinder Head (002-020) QSK19 Page 2-28 Section 2 — Cylinder Head — Group 02 NOTES…
  • Page 290
    Section 3 — Rocker Levers — Group 03 Page 3-a Section 3 — Rocker Levers — Group 03 Section Contents Page Crankcase Breather (External)……………………. 3-4 Clean …………………………..3-5 Install …………………………..3-6 Remove ………………………….. 3-4 Rocker Lever …………………………3-7 Assemble …………………………3-9 Disassemble …………………………
  • Page 291
    Rocker Levers — General Information Section 3 — Rocker Levers — Group 03 Page 3-1 Rocker Levers — General Information General Information The QSK19 utilizes the Outer Base Circle (OBC) overhead set procedure. NOTE: The OBC procedure requires the use of an accurate inch-pound torque wrench.
  • Page 292
    Service Tools Rocker Levers The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No.
  • Page 293
    Service Tools Section 3 — Rocker Levers — Group 03 Page 3-3 Tool No. Tool Description Tool Illustration Rocker Lever Bushing Mandrel Used to install and/or remove the rocker lever bushings 3162458…

  • Page 294: Crankcase Breather (External)

    Crankcase Breather (External) (003-001) Page 3-4 Section 3 — Rocker Levers — Group 03 Crankcase Breather (External) (003-001) Remove Loosen the hose clamp at the breather vent tube. Remove the tube support bracket capscrew and the bracket. Remove the vent tube and the hose from the engine. If the vent tube is blocked, it should be cleaned to prevent excess crankcase pressure buildup.

  • Page 295: Clean

    Crankcase Breather (External) (003-001) Section 3 — Rocker Levers — Group 03 Page 3-5 Rail Applications Loosen the hose clamp and remove the crankcase breather hose from breather canister. Loosen the tube clamp between the breather canister and the hand hole cover. Remove the breather canister from the hand hole cover.

  • Page 296
    Crankcase Breather (External) (003-001) Page 3-6 Section 3 — Rocker Levers — Group 03 Rail Applications Loosen the hose clamp and remove the crankcase breather hose from breather canister. Check hose internally for obstructions or sludge buildup. If the hose is blocked, clean it to prevent excess crankcase pressure buildup.

  • Page 297: Disassemble

    Rocker Lever (003-008) Section 3 — Rocker Levers — Group 03 Page 3-7 Install the parts in the following order: (4) Screen Mesh (5) Element (4) Screen Mesh (3) Breather Cap (2) Washer (1) Wing Nut If the breather is not used, install the service plug and o-ring.

  • Page 298: Magnetic Crack Inspect

    Rocker Lever (003-008) Page 3-8 Section 3 — Rocker Levers — Group 03 Remove the socket from the ball on the rocker lever shaft. Place the ball in a vise as shown. Wiggle the rocker lever until the ball swivels. Use a mallet to tap the rocker lever until the ball comes out.

  • Page 299
    Rocker Lever (003-008) Section 3 — Rocker Levers — Group 03 Page 3-9 Assemble Install the adjusting screw and the lock nut in each lever. Do not completely tighten the lock nut until the assembly is installed on the engine. CAUTION Do not overstress the press fit.

  • Page 300: Rocker Lever Assembly

    Rocker Lever Assembly (003-009) Page 3-10 Section 3 — Rocker Levers — Group 03 Rocker Lever Assembly (003-009) Exploded View…

  • Page 301
    Rocker Lever Assembly (003-009) Section 3 — Rocker Levers — Group 03 Page 3-11 1. Screw, Hexagon Head Cap 11. Seal, O-ring 2. Washer, Plain 12. Washer, Plain 3. Dowel, Ring 13. Screw, Rocker Lever Adjusting 4. Gasket, Rocker Lever Housing 14.

  • Page 302: Clean

    Rocker Lever Assembly (003-009) Page 3-12 Section 3 — Rocker Levers — Group 03 Clean WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury. Use solvent.

  • Page 303: Disassemble

    Rocker Lever Assembly (003-009) Section 3 — Rocker Levers — Group 03 Page 3-13 Inspect the socket for wear on both the injector and valve sockets. Inspect the crosshead pad for wear. NOTE: If there is damage that can be felt with the finger- nail, the parts should be replaced.

  • Page 304: Install

    Rocker Lever Bushings (003-010) Page 3-14 Section 3 — Rocker Levers — Group 03 Assemble Use clean engine oil to lubricate the shaft. CAUTION The oil drillings in the shaft must be in alignment with the oil drillings in the rocker levers. The plug (4) in the main oil drilling must be nearest to the exhaust lever (1).

  • Page 305: Rocker Lever Cover

    Rocker Lever Cover (003-011) Section 3 — Rocker Levers — Group 03 Page 3-15 Rocker Lever Cover (003-011) Clean WARNING When using solvents, acids or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury.

  • Page 306: Assemble

    Rocker Lever Housing (003-013) Page 3-16 Section 3 — Rocker Levers — Group 03 Inspect for Reuse Inspect the parts for damage. If the ring dowel (4) is dam- aged, it must be replaced. Use a blind hole puller con- tained in light duty puller kit, Part No.

  • Page 307
    Section 4 — Cam Followers/Tappets — Group 04 Page 4-a Section 4 — Cam Followers/Tappets — Group 04 Section Contents Page Cam Follower Assembly ……………………..4-2 Assemble …………………………4-5 Clean …………………………..4-3 Disassemble …………………………4-3 Exploded View ………………………… 4-2 Inspect for Reuse ……………………….4-4 Cam Follower Cover……………………….
  • Page 308
    Cam Followers/Tappets — General Information Section 4 — Cam Followers/Tappets — Group 04 Page 4-1 Cam Followers/Tappets — General Information CAUTION The cam follower mounting capscrews are special 12- point flange heads. Failure will result if standard capscrews are used. Pressurized engine oil is supplied to each cam follower assembly through an oil cavity around the mounting capscrews of each assembly.

  • Page 309: Cam Follower Assembly

    Cam Follower Assembly (004-001) Page 4-2 Section 4 — Cam Followers/Tappets — Group 04 Cam Follower Assembly (004-001) Exploded View 1. Ring, Retaining 9. Roller, Cam Follower 2. Lever, Cam Follower 10. Lockwire, Tpt Roller Pin 3. Lockwire, Tpt Roller Pin 11.

  • Page 310: Clean

    Cam Follower Assembly (004-001) Section 4 — Cam Followers/Tappets — Group 04 Page 4-3 Disassemble Remove the 12 point capscrews. Remove the retaining ring. Pull the shaft out. Mark and tag the parts for future installation identification. Clean CAUTION When using solvents, acids or alkaline materials for cleaning, follow the manufacture’s recommendations for use.

  • Page 311
    Cam Follower Assembly (004-001) Page 4-4 Section 4 — Cam Followers/Tappets — Group 04 Inspect for Reuse Inspect the cam follower assembly for reuse. The shaft must rotate easily. If resistance is apparent, disassemble and check for burrs on the shaft. Inspect the cam follower shaft for damage and roughness.
  • Page 312
    Cam Follower Assembly (004-001) Section 4 — Cam Followers/Tappets — Group 04 Page 4-5 The roller must rotate easily. Check the clearance of the roller. Cam Follower Roller Clearance Reference Point 0.230 0.009 0.610 0.024 0.076 0.003 0.114 0.0045 NOTE: If the clearances do not meet specifications, the cam follower lever assembly must be replaced.

  • Page 313: Cam Follower Cover

    Cam Follower Cover (004-002) Page 4-6 Section 4 — Cam Followers/Tappets — Group 04 Cam Follower Cover (004-002) General Information The QSK19 has a one-piece, aluminum cam follower cover with an oil fill. NOTE: This is the only style of cam follower cover available. Clean CAUTION When using solvents, acids, or alkaline materials for…

  • Page 314: Clean

    Push Rods or Tubes (004-014) Section 4 — Cam Followers/Tappets — Group 04 Page 4-7 Push Rods or Tubes (004-014) General Information The QSK19 uses push rods that are machined from solid bar stock instead of tubing. The ball end and the socket are machined on the rod.

  • Page 315
    Push Rods or Tubes (004-014) Page 4-8 Section 4 — Cam Followers/Tappets — Group 04 Visually inspect the socket end of the push rod for uneven wear or scratches. If a worn socket is found, the mating adjusting screw in the rocker lever must also be replaced.
  • Page 316
    Section 5 — Fuel System — Group 05 Page 5-a Section 5 — Fuel System — Group 05 Section Contents Page Fuel Pump………………………….. 5-6 Calibrate …………………………5-7 Clean …………………………..5-6 Inspect for Reuse ……………………….5-6 Fuel Shutoff Valve (FSOV) ……………………..5-9 Clean ……………………………
  • Page 317
    NOTE: Warranty repairs are not to be made to the fuel pump unless the work is performed in a shop meeting all requirements established by Cummins Engine Company, Inc. to accurately calibrate, test and repair the fuel systems on Cummins engines.
  • Page 318
    Fuel System — General Information Page 5-2 Section 5 — Fuel System — Group 05 The QSK fuel pump throttle shaft is locked in the full closed position. There is no mechanical throttle on the QSK fuel pump. The QSK fuel pump does not contain an AFC valve. The pump only has an AFC cover plate.
  • Page 319
    Fuel System — General Information Section 5 — Fuel System — Group 05 Page 5-3 Rail Applications NOTE: The lubricating oil scavenge pump (A) must be removed prior to removing the fuel pump (B) to allow ac- cess to the fuel pump mounting capscrews. NOTE: The fuel pump (B) must be installed prior to in- stalling the lubricating oil scavenge pump (A).
  • Page 320
    Service Tools Fuel System The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No.
  • Page 321
    Service Tools Section 5 — Fuel System — Group 05 Page 5-5 Tool No. Tool Description Tool Illustration Remote Starter Switch Used to crank the engine to measure the cranking fuel pressure. 3376506 Optical Tachometer Measure engine rpm. 3377462 Adapter S-Tool Kit Used to hook QSK fuel pump to a fuel pump test stand.
  • Page 322
    Fuel Pump (005-016) Page 5-6 Section 5 — Fuel System — Group 05 Fuel Pump (005-016) Clean WARNING When using solvents, acids or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury.
  • Page 323
    CPL number. NOTE: Calibration of the fuel pump must be performed at a Cummins Authorized Repair location. NOTE: The throttle shaft is purposely locked in the closed position. Rotation of the shaft is not necessary for pressure checks.
  • Page 324
    Fuel Pump (005-016) Page 5-8 Section 5 — Fuel System — Group 05 Mount the fuel pump on the test stand. Refer to your par- ticular test stand manufacturer’s operating and service manual for pump installation instructions. Set the test stand pump drive to 2100 rpm and purge any air from the fuel pump and test stand.
  • Page 325
    Fuel Shutoff Valve (FSOV) (005-043) Section 5 — Fuel System — Group 05 Page 5-9 Check point three 1. Reduce the test stand drive speed to 600 rpm. 2. Adjust the flow to about 286 Pph. 3. Record the rpm, flow, and inlet restriction. 4.
  • Page 326
    Fuel Shutoff Valve (FSOV) (005-043) Page 5-10 Section 5 — Fuel System — Group 05 Remove the four capscrews. Remove the coil housing and the fuel shield. Discard the o-ring. Remove the spring washer, valve disc, actuator disc, and actuator spacer from the valve housing. Discard the o-ring.
  • Page 327
    Fuel Shutoff Valve (FSOV) (005-043) Section 5 — Fuel System — Group 05 Page 5-11 Check the coil assembly with a multimeter. Replace the coil if it does not have 28 to 32 Ω of resistance. NOTE: If the coil assembly shows 0 ohms, there is an electrical short in the coil.
  • Page 328
    Fuel Shutoff Valve (FSOV) (005-043) Page 5-12 Section 5 — Fuel System — Group 05 Align the actuator disc (5), spacer (7), and valve disc (4) on the electronic control valve body (8). Install a new o-ring (6). Put the spring washer (3) on the valve disc (4), with the cavity side positioned upward.
  • Page 329
    Section 6 — Injectors and Fuel Lines — Group 06 Page 6-a Section 6 — Injectors and Fuel Lines — Group 06 Section Contents Page Fuel Filter Head …………………………. 6-2 Install …………………………..6-2 Remove ………………………….. 6-2 Fuel Manifold (Supply)……………………….. 6-3 Clean …………………………..
  • Page 330
    Injectors and Fuel Lines — General Information Section 6 — Injectors and Fuel Lines — Group 06 Page 6-1 Injectors and Fuel Lines — General Information General Information The QSK19 uses a QSK fuel system that requires a split fuel manifold and three fuel circuits. The three circuits are rail (1), timing (2), and drain (3).

  • Page 331: Fuel Filter Head

    Fuel Filter Head (006-017) Page 6-2 Section 6 — Injectors and Fuel Lines — Group 06 Rail Applications The ten-micron fuel filters/water separators (A) are remote mounted on the lubricating oil pan on the front side of the engine. Fuel Filter Head (006-017) Remove Disconnect the fuel line from the fuel filter head.

  • Page 332: Fuel Manifold (Supply)

    Fuel Manifold (Supply) (006-022) Section 6 — Injectors and Fuel Lines — Group 06 Page 6-3 Connect the fuel line to the fuel filter head. Fuel Manifold (Supply) (006-022) Clean Remove the four fuel connection block capscrews. Remove the fuel connection block. Discard the o-rings.

  • Page 333: Inspect For Reuse

    Fuel Supply Lines (006-024) Page 6-4 Section 6 — Injectors and Fuel Lines — Group 06 Inspect for Reuse Check the manifold for cracks in the fuel passages. The manifold must be replaced if damaged. Use clean engine oil to lubricate the o-rings. Install the 3/8 in (2) and 1/2 in plugs (1).

  • Page 334: Inspect For Reuse

    Fuel Supply Lines (006-024) Section 6 — Injectors and Fuel Lines — Group 06 Page 6-5 Inspect for Reuse Fuel Tank-To-Fuel Filter Visually inspect the inside of the hose. • The inner lining of the hose can separate from the center hose section.

  • Page 335: Fuel Inlet Line

    Injector (006-026) Page 6-6 Section 6 — Injectors and Fuel Lines — Group 06 Use compressed air. Flush the lines and remove any loose dirt particles. Fuel Inlet Line Visually inspect the inside of the hose. • The inner lining of the hose can separate from the center hose section.

  • Page 336
    Injector (006-026) Section 6 — Injectors and Fuel Lines — Group 06 Page 6-7 NOTE: The four new o-rings must be installed and oriented correctly on the injector. Identify the o-rings to install them in the correct grooves. Remove the o-rings (2, 3, 4, and 5). Carefully check the area where the sealing ring touches the injector.
  • Page 337
    Injector (006-026) Page 6-8 Section 6 — Injectors and Fuel Lines — Group 06 Check the rail (6) and timing (7) filter for proper installation. Screens must be securely snapped into correct position. Use a small screwdriver to remove the filter screen by gently prying up on the connector clip.
  • Page 338
    Section 7 — Lubricating Oil System — Group 07 Page 7-a Section 7 — Lubricating Oil System — Group 07 Section Contents Page Lubricating Oil Cooler……………………….7-3 Clean …………………………..7-4 Exploded View ………………………… 7-3 General Information ……………………….7-4 Inspect for Reuse ……………………….7-4 Lubricating Oil Filter Head ……………………..
  • Page 339
    Lubricating Oil System — General Information Section 7 — Lubricating Oil System — Group 07 Page 7-1 Lubricating Oil System — General Information General Information WARNING Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity.
  • Page 340
    Lubricating Oil System The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No.
  • Page 341
    Lubricating Oil Cooler (007-003) Section 7 — Lubricating Oil System — Group 07 Page 7-3 Lubricating Oil Cooler (007-003) Exploded View 1. Screw, Hexagon Head Cap 2. Washer, Lock 3. Adirondack 4. Washer, Plain 5. Seal, O-ring 6. Screw, Twelve Point Cap 7.
  • Page 342
    Lubricating Oil Cooler (007-003) Page 7-4 Section 7 — Lubricating Oil System — Group 07 General Information All QSK19 engine oil cooler housings are cast iron. Clean WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use.
  • Page 343
    Lubricating Oil Filter Head (007-015) Section 7 — Lubricating Oil System — Group 07 Page 7-5 Lubricating Oil Filter Head (007-015) General Information The oil filter head contains two spring loaded plungers. One plunger controls the oil pressure for the piston cooling nozzles.
  • Page 344
    Lubricating Oil Filter Head (007-015) Page 7-6 Section 7 — Lubricating Oil System — Group 07 Exploded View…
  • Page 345
    Lubricating Oil Filter Head (007-015) Section 7 — Lubricating Oil System — Group 07 Page 7-7 1. Screw, Captive Washer Cap 2. Gasket, Lube Oil Fill Cover 3. Seal, O-ring 4. Elbow, Male Union 5. Seal, O-ring 6. Screw, Hexagon Head Cap 7.
  • Page 346
    Lubricating Oil Filter Head (007-015) Page 7-8 Section 7 — Lubricating Oil System — Group 07 Disassemble WARNING The threaded plug is under pressure, wear goggles to prevent personal injury. Remove the bypass regulator plunger and related parts. 2. Regulator plug 3.
  • Page 347
    Lubricating Oil Filter Head (007-015) Section 7 — Lubricating Oil System — Group 07 Page 7-9 LF670 Filter Head Adapter Use a 1-1/2 inch socket to remove the adapters. Clean WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use.
  • Page 348
    Lubricating Oil Filter Head (007-015) Page 7-10 Section 7 — Lubricating Oil System — Group 07 Check the piston cooling nozzle spring. Piston Cooling Nozzle Spring Free Length 88.98 3.500 Working Height (6) 50.80 2.000 Use a valve spring tester, Part No. 3375182, or equivalent to measure the spring force (7) and the working height (6).
  • Page 349
    Lubricating Oil Filter Head (Remote-Mounted) (007-017) Section 7 — Lubricating Oil System — Group 07 Page 7-11 LF3000 Filter Head Adapter Lubricate the o-ring (1) and install in the filter head before the adapter. Lubricate the o-rings (2 and 3) and install in the adapter. NOTE: When installing the filter head adapter, use a lo- cating pin to properly align the filter head adapter to the filter head.
  • Page 350
    Lubricating Oil Filter Head (Remote-Mounted) (007-017) Page 7-12 Section 7 — Lubricating Oil System — Group 07 Clean WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury.
  • Page 351
    Lubricating Oil Filter Head Adapter (007-018) Section 7 — Lubricating Oil System — Group 07 Page 7-13 Lubricating Oil Filter Head Adapter (007-018) General Information When installing a new filter element, always check to be sure there is no interference between the filter head adapter and the filter element.
  • Page 352
    Lubricating Oil Filter Head Adapter (007-018) Page 7-14 Section 7 — Lubricating Oil System — Group 07 LF670 Check the threads on the adaptors for damage. Replace if any damage is found.
  • Page 353
    Lubricating Oil Pan (007-025) Section 7 — Lubricating Oil System — Group 07 Page 7-15 Lubricating Oil Pan (007-025) General Information Oil pan sumps are available in various capacities. Compare the part number to the chart below to find the correct high and low capacities.
  • Page 354
    Lubricating Oil Pan Adapter (007-027) Page 7-16 Section 7 — Lubricating Oil System — Group 07 Lubricating Oil Pan Adapter (007-027) Clean WARNING Always read and follow the solvent manufacturers safety precautions to avoid severe personal injury or death. Remove any hand hole covers not previously removed. Use a solvent that will not harm aluminum clean the oil pan adapter and hand hole covers.
  • Page 355
    Lubricating Oil Pump (007-031) Section 7 — Lubricating Oil System — Group 07 Page 7-17 Lubricating Oil Pump (007-031) General Information The QSK19 lubricating oil pump uses a retaining ring to secure the pressure regulator assembly. Use pressure regulator removal tool, Part No. 3375055, to service the pressure regulator assembly when the lube oil pump is installed in the engine.
  • Page 356
    Lubricating Oil Pump (007-031) Page 7-18 Section 7 — Lubricating Oil System — Group 07 Exploded View 1. Seal, O-ring 2. Seal, Rectangular Ring 3. Screw, Captive Washer Cap 4. Screw. Hexagon Head Cap 5. Washer, Lock 6. Screw, Captive Washer Cap 7.
  • Page 357
    Lubricating Oil Pump (007-031) Section 7 — Lubricating Oil System — Group 07 Page 7-19 Disassemble Remove the four capscrews. Remove the cover from the housing. Use a mallet to tap on the dowel to separate the cover from the housing. Lift the idler gear and the shaft from the housing.
  • Page 358
    Lubricating Oil Pump (007-031) Page 7-20 Section 7 — Lubricating Oil System — Group 07 Inspect for Reuse WARNING Some State and Federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil.
  • Page 359
    Lubricating Oil Pump (007-031) Section 7 — Lubricating Oil System — Group 07 Page 7-21 Check the gears for damage. Measure the O.D. Shaft O.D. 22.212 0.8745 22.225 0.8750 Only disassemble when the gear or the shaft must be replaced. Support the gear, use an arbor press to push the shaft through the gear.
  • Page 360
    Lubricating Oil Pump (007-031) Page 7-22 Section 7 — Lubricating Oil System — Group 07 Assemble Use clean engine oil to lubricate the regulator plunger (5) and the bore. Install the regulator plunger, spring, and retainer (4). Use and arbor press, and mandrel (1), to compress the spring, and put the retainer in position.
  • Page 361
    Oil Transfer Connection (007-061) Section 7 — Lubricating Oil System — Group 07 Page 7-23 Oil Transfer Connection (007-061) Disassemble Remove the straight thread o-ring plugs (1), (2), and (3). Discard the o-rings Remove the vent tube (1). CAUTION The threaded plug (2) is under spring pressure. Remove the piston cooling nozzle plunger (3) and spring (4).
  • Page 362
    Oil Transfer Connection (007-061) Page 7-24 Section 7 — Lubricating Oil System — Group 07 Check the piston cooling nozzle spring. Piston Cooling Nozzle Spring Free Length 88.98 3.500 Working Height (6) 50.80 2.000 Use a valve spring tester, Part No. 3375182, or equivelent to measure the spring force and the working height Spring Force (7) N•m…
  • Page 363
    Section 8 — Cooling System — Group 08 Page 8-a Section 8 — Cooling System — Group 08 Section Contents Page Coolant Thermostat ……………………….8-4 Install …………………………..8-6 Conventional Aftercooling……………………8-6 Low Temperature Aftercooling ………………….. 8-7 Remove ………………………….. 8-4 Test …………………………..8-8 Engine Thermostats ……………………..
  • Page 364
    Cooling System — General Information Section 8 — Cooling System — Group 08 Page 8-1 Cooling System — General Information General Information The primary function of the cooling system is to remove heat energy, created by the combustion process, from the engine.
  • Page 365
    Page 8-2 Section 8 — Cooling System — Group 08 The following publications, available through Cummins Dis- tributors or Cummins Dealers, provide cooling system in- stallation recommendations and specifications approved by Cummins Engine Company, Inc. • Automotive Installation Recommendations (Cooling System), Bulletin No.
  • Page 366
    Service Tools Cooling System The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No.

  • Page 367: Coolant Thermostat

    Coolant Thermostat (008-013) Page 8-4 Section 8 — Cooling System — Group 08 Coolant Thermostat (008-013) Remove Conventional Aftercooling WARNING Some coolants are poisonous. Keep away from children and animals. Save for reuse or dispose of in accordance with local authorities. NOTE: If the engine is equipped with an air compressor, remove the air compressor coolant return tube.

  • Page 368: Low Temperature Aftercooling

    Coolant Thermostat (008-013) Section 8 — Cooling System — Group 08 Page 8-5 Low Temperature Aftercooling WARNING Allow the engine to cool before draining to avoid burns from hot liquid. WARNING Some coolants are poisonous. Keep away from children and animals. Save for reuse or dispose of in accordance with local authorities.

  • Page 369
    Coolant Thermostat (008-013) Page 8-6 Section 8 — Cooling System — Group 08 Install Engine Thermostats Conventional Aftercooling CAUTION The seal must be installed with the part number point- ing up. Use a mallet and thermostat seal driver, Part No. 3375411, or equivalent.
  • Page 370
    Coolant Thermostat (008-013) Section 8 — Cooling System — Group 08 Page 8-7 Low Temperature Aftercooling CAUTION The seal must be installed with the part number point- ing up. Use a mallet and thermostat seal driver, Part No. 3375411, or equivalent. Install the thermostat seal no more than 0.51 mm [0.020 in] below the top of the cast edge.

  • Page 371: Test

    Coolant Thermostat (008-013) Page 8-8 Section 8 — Cooling System — Group 08 Install the aftercooler water return tube (1), tube clip, and capscrew. Install the connecting hose (2). Tighten the hose clamps and capscrew. Torque Value: Capscrew 20 N•m [15 ft-lb] Torque Value: Hose Clamp…

  • Page 372: Low Temperature Aftercooling Thermostat

    Coolant Thermostat (008-013) Section 8 — Cooling System — Group 08 Page 8-9 Low Temperature Aftercooling Thermostat Suspend the thermostat and a 100°C [212°F] thermometer in a container of water. NOTE: Do not allow the thermostat or thermometer to touch the container. Heat the water and check the thermostat as follows.

  • Page 373: Coolant Thermostat Housing Support

    Coolant Thermostat Housing Support (008-015) Page 8-10 Section 8 — Cooling System — Group 08 Coolant Thermostat Housing Support (008-015) General Information LTA Cooling System The Low Temperature Aftercooling (LTA) arrangement incorporates a dual loop cooling system that shares a single water pump. Thermostat Support The thermostat assembly contains a support and thermostat housing.

  • Page 374
    Fan Drive Idler Arm Assembly (008-029) Section 8 — Cooling System — Group 08 Page 8-11 Fan Drive Idler Arm Assembly (008-029) Disassemble Remove the three mounting capscrews holding the pivot shaft support to the alternator support. Remove the snap ring from the idler lever. Remove the idler lever.

  • Page 375: Clean

    Fan Drive Idler Pulley Assembly (008-030) Page 8-12 Section 8 — Cooling System — Group 08 Assemble Use an arbor press to install the new bushings. Install new oil seals. Install the idler lever into the pivot shaft support. Install the snap ring into the snap ring groove on the idler lever.

  • Page 376
    Fan Drive Idler Pulley Assembly (008-030) Section 8 — Cooling System — Group 08 Page 8-13 Inspect for Reuse Check the clearance. Bearing End Clearance 0.08 0.003 0.25 0.010 Rotate the pulley. Check for rough or damaged bearings. The bearings must be replaced if any of the above con- ditions are found.
  • Page 377
    Fan Hub, Belt Driven (008-036) Page 8-14 Section 8 — Cooling System — Group 08 Fan Hub, Belt Driven (008-036) General Information NOTE: For service and parts information for the fan hub with a clutch, refer to Bulletin No. 3810250, Rockford Fan Clutch Service and Parts Manual.
  • Page 378
    Fan Hub, Belt Driven (008-036) Section 8 — Cooling System — Group 08 Page 8-15 Clean WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury. Use solvent to clean the fan hub.

  • Page 379: Assemble

    Fan Hub, Belt Driven (008-036) Page 8-16 Section 8 — Cooling System — Group 08 Assemble CAUTION Do not lubricate the seal surface of the shaft. The seal and seal surface must be clean and dry. Lightly grease the bearing (11) with Mobiplex 48 grease or equivalent.

  • Page 380
    Fan Hub, Belt Driven (008-036) Section 8 — Cooling System — Group 08 Page 8-17 CAUTION Remove all grease from the threads on the shaft before installing the lock nut. Grease on the threads reduce the torque retention of the lock nut. Install the hardened washer (5).
  • Page 381
    The majority of equipment that has a Cummins engine has a radiator and a fan. The radiator and fan transfer heat from the cooling water to the atmosphere. The fan selection process must conclude that the fan, the fan mounting arrangement, and the fan drive system are designed and matched for compatibility.
  • Page 382
    Water Pump (008-062) Section 8 — Cooling System — Group 08 Page 8-19 Water Pump (008-062) Inspect for Reuse Rotate the shaft and inspect for rough or damaged bearings. Inspect the drive shaft for wear. If the drive shaft splines are worn, check the female splines in the pump and in the water pump drive.
  • Page 383
    Water Pump (008-062) Page 8-20 Section 8 — Cooling System — Group 08 Remove the parts. 5. Shutoff valve capscrew 6. Water shutoff valve 7. Washer 8. O-ring 9. Water transfer tube (Loosen the flare nut at each end.) 10. Grommets Discard the o-ring and grommets.

  • Page 384: Clean

    Water Pump (008-062) Section 8 — Cooling System — Group 08 Page 8-21 Support the water pump body as shown. Use an arbor press to push on the impeller end of the shaft. Remove the bearing and shaft assembly. Discard the water pump seal seat. Remove and discard the water seal and oil seal.

  • Page 385
    Water Pump (008-062) Page 8-22 Section 8 — Cooling System — Group 08 Measure the I.D. of the water pump housing bore. Housing Bore I.D. (13) Water Seal 36.45 1.435 36.47 1.436 (14) Oil Seal 44.43 1.749 44.48 1.751 (15) Rear Bearing 51.996 2.0471 52.215…
  • Page 386
    Water Pump (008-062) Section 8 — Cooling System — Group 08 Page 8-23 Support the water pump housing. Use an arbor press and water pump bearing mandrel, Part No. 3375318, or equivalent, or push on the end of the shaft. Install the shaft and bearing assembly.
  • Page 387
    Water Pump (008-062) Page 8-24 Section 8 — Cooling System — Group 08 CAUTION More than one drop will glue the faces of the seal to- gether. It can result in damage to the seal. Apply one drop of Loctite 290, or equivalent to the seal seat as shown.
  • Page 388
    Water Pump (008-062) Section 8 — Cooling System — Group 08 Page 8-25 Use vegetable oil to lubricate the o-ring. Install the parts as shown. Install the capscrews. Torque Value: 45 N•m [35 ft-lb] Install the inlet connection (1), gasket, and capscrews. Torque Value: 40 N•m [30 ft-lb] NOTE: Do not tighten the support bracket until the water…

  • Page 389: Torque Converter Cooler

    Torque Converter Cooler (008-065) Page 8-26 Section 8 — Cooling System — Group 08 Torque Converter Cooler (008-065) General Information The engine mounted torque converter cooler is available as an option. This option can be added to a standard engine by purchasing the torque converter cooler housing, the cooler cover, and the elements.

  • Page 390: Assemble

    Torque Converter Cooler (008-065) Section 8 — Cooling System — Group 08 Page 8-27 Inspect for Reuse NOTE: Heating the water in the tank to 50° C [120° F] will improve the test results. Pressure test the elements. Apply air pressure, and check for leaks. NOTE: Discard the elements if any debris is found, the engine has had a debris causing failure, or the torque converter has failed.

  • Page 391: Clean

    Water Pump Bearings (008-071) Page 8-28 Section 8 — Cooling System — Group 08 Disassemble Remove the torque converter cover mounting bolts and cover. NOTE: The cover must be pried from the housing, because of the tight fit between the cover and the o-rings on the elements.

  • Page 392
    Water Pump Bearings (008-071) Section 8 — Cooling System — Group 08 Page 8-29 Install CAUTION The mandrel must make contact on the inner race of the bearing to prevent damage to the bearing. Support the shaft. Use an arbor press and a water pump bearing mandrel, Part No.
  • Page 393
    Water Pump Bearings (008-071) Page 8-30 Section 8 — Cooling System — Group 08 NOTES…
  • Page 394
    Section 9 — Drive Units — Group 09 Page 9-a Section 9 — Drive Units — Group 09 Section Contents Page Accessory Drive Pulley ………………………. 9-3 Inspect for Reuse ……………………….9-3 Install …………………………..9-3 Remove ………………………….. 9-3 Drive Units — General Information……………………9-1 General Information ……………………….
  • Page 395
    Page 9-b Section 9 — Drive Units — Group 09 Page Water Pump Drive Pulley ……………………..9-52 Clean …………………………… 9-52 Inspect for Reuse ……………………….9-53…
  • Page 396
    Drive Units — General Information Section 9 — Drive Units — Group 09 Page 9-1 Drive Units — General Information General Information The accessory drive housing is manufactured of aluminum. The aluminum housing does not contain a bushing, and does not require thrust washers. CAUTION Installation of an air compressor on a fuel pump drive housing will result in failure due to the lack of lubrication.
  • Page 397
    Service Tools Drive Units The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No.

  • Page 398: Remove

    Accessory Drive Pulley (009-004) Section 9 — Drive Units — Group 09 Page 9-3 Accessory Drive Pulley (009-004) Remove CAUTION Use a capscrew in the shaft to prevent damage to the shaft threads. Install a [7/16-20×1 in] capscrew in the shaft. Use a standard puller, Part No.

  • Page 399
    Accessory Drive Pulley (009-004) Page 9-4 Section 9 — Drive Units — Group 09 Install the woodruff key. CAUTION Do not use a hammer to drive the pulley into position. Damage to the thrust bearing will result. Use pulley installation tool kit, Part No. 3376326. Insert the appropriate adapter (7) in the pusher.

  • Page 400: General Information

    Fuel Pump Drive (009-011) Section 9 — Drive Units — Group 09 Page 9-5 Fuel Pump Drive (009-011) General Information The accessory drive housing is manufactured of aluminum. The aluminum housing does not contain a bushing, and does not require thrust washers. CAUTION Installation of an air compressor on a fuel pump drive housing will result in failure due to the lack of lubrication.

  • Page 401
    Fuel Pump Drive (009-011) Page 9-6 Section 9 — Drive Units — Group 09 Exploded View 1. Coupling, Lovejoy Type (Upper) 1. Coupling, Spline Type (Lower) 2. Gear, Air Compressor and Fuel Pump Drive 3. Key, Plain Woodruff 5. Shaft, Accessory Drive 6.
  • Page 402
    Fuel Pump Drive (009-011) Section 9 — Drive Units — Group 09 Page 9-7 Clean WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury. Use solvent to clean the outer housing of the fuel pump drive.
  • Page 403
    Fuel Pump Drive (009-011) Page 9-8 Section 9 — Drive Units — Group 09 Check the grooved surface for damage. Measure the thickness. Thrust Bearing Thickness 2.36 0.093 2.41 0.095 NOTE: On an aluminum housing ONLY, check the two machined thrust surfaces for damage. Use a depth micrometer.
  • Page 404
    Fuel Pump Drive (009-011) Section 9 — Drive Units — Group 09 Page 9-9 Measure the I.D. of the coupling. Lovejoy Coupling I.D. 25.425 1.0010 25.438 1.0015 Spline Coupling I.D. 25.400 1.0000 25.425 1.0010 Disassemble Remove the special capscrew and the washer. CAUTION Install the capscrew back into the drive unit without the washer until it touches the shaft to prevent damage to…

  • Page 405: Assemble

    Fuel Pump Drive (009-011) Page 9-10 Section 9 — Drive Units — Group 09 Assemble Position the grooved surface of the thrust bearing as shown. Install the thrust bearing. NOTE: An aluminum housing does not contain thrust bearings. Use Lubriplate No.

  • Page 406
    Fuel Pump Drive Gear and Shaft (009-013) Section 9 — Drive Units — Group 09 Page 9-11 Rotate the shaft to check for correct assembly. Use a dial indicator. Measure the end clearance. End Clearance 0.05 0.002 0.30 0.012 If the end clearance is not within specifications, be sure the coupling is positioned tightly against the clamping washer.

  • Page 407: Fuel Pump Drive Gear And Shaft

    Fuel Pump Drive Gear and Shaft (009-013) Page 9-12 Section 9 — Drive Units — Group 09 Assemble Support the gear. Use engine oil to lubricate the shaft. Align the key with the key slot in the gear. Use an arbor press to press the shaft through the gear until the shoulder of the shaft touches the gear.

  • Page 408
    Fuel Pump Drive Gear and Shaft (009-013) Section 9 — Drive Units — Group 09 Page 9-13 CAUTION Allow the air to cool the gear. Do not use water or oil to reduce the cooling time. Damage to the gear can result. Use a feeler gauge to measure the distance between the shoulder of the shaft and the gear.
  • Page 409
    Hydraulic Pump Drive (009-016) Page 9-14 Section 9 — Drive Units — Group 09 Hydraulic Pump Drive (009-016) General Information A hydraulic pump can be mounted on the front or at the rear of the gear cover. The SAE A two-bolt type flange is required to mount a hydraulic pump at the rear of the gear cover. The SAE B four-bolt type flange is required for a hydraulic pump to be mounted on the front of the gear cover.

  • Page 410: Disassemble

    Hydraulic Pump Drive (009-016) Section 9 — Drive Units — Group 09 Page 9-15 Clean Remove the capscrews and the lockwashers. Remove the cover from the pump. WARNING When using solvents, acids or alkaline materials for cleaning, follow the manufacture’s recommendation for use.

  • Page 411: Assemble

    Hydraulic Pump Drive (009-016) Page 9-16 Section 9 — Drive Units — Group 09 Remove the retaining ring. Remove the clamping washer. Remove the thrust bearing. Remove the housing. Remove the thrust bearing. Assemble Use Lubriplate No. 105 or equivalent to lubricate the grooved surface of the thrust bearing.

  • Page 412: Disassemble

    Hydraulic Pump Drive Gear and Shaft (009-019) Section 9 — Drive Units — Group 09 Page 9-17 Use Lubriplate No. 105 or equivalent to lubricate the grooved surface of the thrust bearing. With the grooved surface positioned up, slide the thrust bearing over the shaft.

  • Page 413: Assemble

    Rear Gear Drive (Lower Assembly) (009-023) Page 9-18 Section 9 — Drive Units — Group 09 Assemble Use Loctite 609 or the equivalent, apply a smooth layer on the I.D. of the gear. Support the gear and position the part number down. Use an arbor press to press the shaft through the gear until the shaft shoulder touches the gear.

  • Page 414
    Rear Gear Drive (Lower Assembly) (009-023) Section 9 — Drive Units — Group 09 Page 9-19 CAUTION The component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component. Use a 5/8 in guide stud.
  • Page 415
    Rear Gear Drive (Lower Assembly) (009-023) Page 9-20 Section 9 — Drive Units — Group 09 Remove the adapter cover plate or the oil pan (whichever is in the rear position). Angle the cover plate to allow the oil to drain. Remove and discard the gasket.
  • Page 416
    Rear Gear Drive (Lower Assembly) (009-023) Section 9 — Drive Units — Group 09 Page 9-21 CAUTION Be sure the rear gear train lower housing is secure BEFORE removing the flywheel housing. The lower housing rests on the guide studs and dowel pins, but is NOT fastened to the block.
  • Page 417
    Rear Gear Drive (Lower Assembly) (009-023) Page 9-22 Section 9 — Drive Units — Group 09 Use a mallet to tap the lower housing of the rear gear train off the two locating dowel pins in the rear face of the cylinder block.
  • Page 418
    Rear Gear Drive (Lower Assembly) (009-023) Section 9 — Drive Units — Group 09 Page 9-23 Exploded View Rear Gear Drive…
  • Page 419
    Rear Gear Drive (Lower Assembly) (009-023) Page 9-24 Section 9 — Drive Units — Group 09 Rear Gear Drive Exploded View Table 42. Gasket, Hydraulic Pump Flange Cover 1. Dowel Pin 43. Cover, Hydraulic Pump Flange 2. Seal, Rectangular Ring 44.

  • Page 420: Disassemble

    Rear Gear Drive (Lower Assembly) (009-023) Section 9 — Drive Units — Group 09 Page 9-25 Disassemble Remove the three capscrews from the idler shaft. If the idler shaft has three holes, use a soft punch and a mallet. Rotate the idler shaft 30 degrees until the capscrew holes in the housing are not visible through the capscrew holes in the idler shaft.

  • Page 421
    Rear Gear Drive (Lower Assembly) (009-023) Page 9-26 Section 9 — Drive Units — Group 09 Inspect for Reuse Remove all pipe plugs and clean all oil drillings. Be sure the oil drillings intersect. Clean and check the lower housing for damage. CAUTION Check for debris in the main oil rifle.
  • Page 422
    Rear Gear Drive (Lower Assembly) (009-023) Section 9 — Drive Units — Group 09 Page 9-27 Use pipe sealant, Part No. 3375066, or equivalent sealant with liquid Teflon . Install five 1/8 in internal hex pipe plugs into the lower housing. Torque Value: 16 N•m [12 ft-lb] Position the lower housing horizontally with the block mat-…
  • Page 423
    Rear Gear Drive (Lower Assembly) (009-023) Page 9-28 Section 9 — Drive Units — Group 09 Make sure the machined surface on the back side of the lower housing is supported to prevent cracking of the hous- ing. Use an arbor press to press the idler shaft into the lower housing until the mounting flange contacts the housing.

  • Page 424: Install

    Rear Gear Drive (Lower Assembly) (009-023) Section 9 — Drive Units — Group 09 Page 9-29 Install NOTE: If an SAE 1 flywheel housing option is used, there must be two [5/8–11 x 6 1/2 in] studs, Part No. 3065777, installed in the upper holes of the cylinder block.

  • Page 425
    Rear Gear Drive (Lower Assembly) (009-023) Page 9-30 Section 9 — Drive Units — Group 09 Use a dial indicator. Be sure the two capscrews are holding the lower housing firmly against the cylinder block. Check the gear lash. Lower Housing-To-Cylinder Block Gear Backlash 0.05 0.002 0.51…
  • Page 426
    Rear Gear Drive (Lower Assembly) (009-023) Section 9 — Drive Units — Group 09 Page 9-31 Install the two capscrews 7/16-14×4 3/4 inch, Part No. 190799, and the five capscrews 3/8-16×4 3/4 inch, Part No. S106-C, with flat washers and lockwashers. Torque Value: 3/8-16 inch 45 N•m…
  • Page 427
    Rear Gear Drive (Lower Assembly) (009-023) Page 9-32 Section 9 — Drive Units — Group 09 Use only SAE Grade 8 capscrews to install the upper housing. Install the following capscrews according to the table below. Location Part No. Size [inch] Qty Top-Front 3202224 1/2-13 x 9…
  • Page 428
    Rear Gear Drive (Lower Assembly) (009-023) Section 9 — Drive Units — Group 09 Page 9-33 Use Lubriplate No. 105, or equivalent. Lubricate the outer hydraulic pump support bushing in the upper housing. Lubricate the bushing surfaces on both shafts in the outer hydraulic pump support drive assemblies.
  • Page 429
    Rear Gear Drive (Lower Assembly) (009-023) Page 9-34 Section 9 — Drive Units — Group 09 Install four capscrews. Hand-tighten the capscrews. Remove the guide studs. Install the remaining three capscrews. Use the sequence and torque as shown. Tighten the capscrews. Torque Value: 70 N•m [50 ft-lb] Install the other outer hydraulic pump using the same…
  • Page 430
    Rear Gear Drive (Upper Assembly) (009-024) Section 9 — Drive Units — Group 09 Page 9-35 Rear Gear Drive (Upper Assembly) (009-024) Exploded View Rear Gear Drive…
  • Page 431
    Rear Gear Drive (Upper Assembly) (009-024) Page 9-36 Section 9 — Drive Units — Group 09 Rear Gear Drive Exploded View Table 42. Gasket, Hydraulic Pump Flange Cover 1. Dowel Pin 43. Cover, Hydraulic Pump Flange 2. Seal, Rectangular Ring 44.

  • Page 432: Disassemble

    Rear Gear Drive (Upper Assembly) (009-024) Section 9 — Drive Units — Group 09 Page 9-37 Disassemble NOTE: The hydraulic pump supports and the hydraulic pump adapters can be different. Mark the parts for loca- tion. Remove the hydraulic pump support and the hydraulic pump adapters or cover plates.

  • Page 433
    Rear Gear Drive (Upper Assembly) (009-024) Page 9-38 Section 9 — Drive Units — Group 09 CAUTION This component weighs 23 kg [50 lb] or more. To avoid personal injury, use a hoist or get assistance to lift the component. Use a hoist and lifting sling.
  • Page 434
    Rear Gear Drive (Upper Assembly) (009-024) Section 9 — Drive Units — Group 09 Page 9-39 Remove the tapered retaining ring from the hydraulic pump drive shaft on the pump side. Remove the bearing spacer and the thrust bearing. Check the bearing spacer for wear against the shaft shoulder.
  • Page 435
    Rear Gear Drive (Upper Assembly) (009-024) Page 9-40 Section 9 — Drive Units — Group 09 Inspect for Reuse Use a bore cleaning brush and safety solvent. Clean and inspect the upper housing for damage. Clean and inspect all oil drillings for debris. NOTE: Do not remove the 1-inch internal hex pipe plug in the upper housing near the center drive bore.
  • Page 436
    Rear Gear Drive (Upper Assembly) (009-024) Section 9 — Drive Units — Group 09 Page 9-41 Check the center drive shaft. Check the external splines for wear. Inspect the bushing diameters on the shaft for wear. If a fingernail will catch on scratches or grooves, replace the shaft.

  • Page 437: Assemble

    Rear Gear Drive (Upper Assembly) (009-024) Page 9-42 Section 9 — Drive Units — Group 09 Inspect the hydraulic pump support bushing in the shaft support plate. If a fingernail will catch on the scratches or grooves, replace the bushing. Measure the bushing inside diameter.

  • Page 438
    Rear Gear Drive (Upper Assembly) (009-024) Section 9 — Drive Units — Group 09 Page 9-43 Install the bearing spacers and tapered retaining ring with the beveled side facing the pump side of the drive shaft. Use Lubriplate 105 or equivalent. Lubricate the engine side bushing surface on the center hydraulic pump drive shaft and the bushing in the hydraulic pump drive shaft and the bushing in the hydraulic pump drive shaft.
  • Page 439
    Rear Gear Drive (Upper Assembly) (009-024) Page 9-44 Section 9 — Drive Units — Group 09 Use Lubriplate 105 or equivalent. Lubricate the outer hy- draulic pump support bushings in the upper housing. Lu- bricate the bushing surfaces on both shafts in the outer hydraulic pump support drive assemblies.
  • Page 440
    Rear Gear Drive (Upper Assembly) (009-024) Section 9 — Drive Units — Group 09 Page 9-45 Use a dial indicator. Make sure the outer hydraulic drive shaft will not move. Measure the center drive gear to the outer drive gear backlash. Center Drive Gear to Outer Drive Gear Backlash 0.10 0.004…
  • Page 441
    Rear Gear Drive (Upper Assembly) (009-024) Page 9-46 Section 9 — Drive Units — Group 09 Install four capscrews. Hand tighten the capscrews. Re- move the guide studs. Install the remaining three capscrews. Use the sequence and tighten as shown. Torque Value: 70 N•m [50 ft-lb] Use the same procedures to install the other hydraulic drive…
  • Page 442
    Rear Gear Drive (Upper Assembly) (009-024) Section 9 — Drive Units — Group 09 Page 9-47 The water pump drive is mounted on the front gear housing. It is connected to the water pump with a spline coupling. A pulley on the end of the water pump drive shaft provides power to the vehicle alternator with a belt. There is a bushing in the front gear cover at the front of the water pump drive shaft.
  • Page 443
    Rear Gear Drive (Upper Assembly) (009-024) Page 9-48 Section 9 — Drive Units — Group 09 Exploded View 1. Plug, Protective 2. Pulley, Alternator Drive 3. Gear, Water Pump and Alternator Drive 4. Shaft, Water Pump and Alternator Drive 5. Gasket, Water Pump Support 6.

  • Page 444: Disassemble

    Rear Gear Drive (Upper Assembly) (009-024) Section 9 — Drive Units — Group 09 Page 9-49 Inspect for Reuse Measure the water pump drive end clearance. Water Pump Drive End Clearance 0.23 0.009 0.33 0.013 If the end clearance is not within specifications, replace or rebuild the assembly.

  • Page 445: Assemble

    Rear Gear Drive (Upper Assembly) (009-024) Page 9-50 Section 9 — Drive Units — Group 09 Remove the gear and front thrust bearing. Remove the pipe plug from the water pump support housing. Remove the shaft and rear thrust bearing. Check the water pump support for an orifice expansion plug (A).

  • Page 446: Disassemble

    Water Pump Drive Gear and Shaft (009-031) Section 9 — Drive Units — Group 09 Page 9-51 CAUTION The front thrust bearing MUST be installed with the oil grooves TOWARD the gear. Failure will result if the bear- ing is NOT installed correctly. Lubricate the oil groove surface of the front thrust bearing with Lubriplate No.

  • Page 447: Assemble

    Water Pump Drive Bushing (009-030) Page 9-52 Section 9 — Drive Units — Group 09 Assemble Use Loctite 609 or equivalent. Apply a smooth coating on the I.D. of the gear. Support the gear. Use an arbor press to press the shaft in the gear until it touches the shoulder of the shaft.

  • Page 448: Disassemble

    Outer Hydraulic Pump Support Drive (009-036) Section 9 — Drive Units — Group 09 Page 9-53 Inspect for Reuse Check the grooves of the pulley for wear. Check the wear sleeve on the accessory drive pulley. If the wear sleeve needs replaced, use a chisel and remove the wear sleeve.

  • Page 449
    Outer Hydraulic Pump Support Drive (009-036) Page 9-54 Section 9 — Drive Units — Group 09 Remove the thrust bearing, gear, and non-tapered retain- ing ring from the splined drive shaft. Inspect for Reuse Visually inspect the idler gear for chipped, broken, or cracked teeth.
  • Page 450
    Outer Hydraulic Pump Support Drive (009-036) Section 9 — Drive Units — Group 09 Page 9-55 Clean and inspect the thrust bearings. Measure the thrust bearing thickness. Thrust Bearing Thickness 2.27 0.085 2.31 0.091 Check the retaining rings for damage. Inspect the hydraulic pump support bushing.
  • Page 451
    Outer Hydraulic Pump Support Drive (009-036) Page 9-56 Section 9 — Drive Units — Group 09 Assemble Install the non-tapered snap ring onto the drive shaft. Use Lubriplate 105 or equivalent. Lubricate the external splines on the drive shaft and the internal splines on the gear.
  • Page 452
    Hydraulic Pump Support Bushing (009-037) Section 9 — Drive Units — Group 09 Page 9-57 With the beveled side up, install the bearing spacer over the drive shaft. With the beveled side up, install the tapered retaining ring into the groove on the drive shaft. Measure the gear end clearance.
  • Page 453
    Hydraulic Pump Support Bushing (009-037) Page 9-58 Section 9 — Drive Units — Group 09 Inspect for Reuse Measure the bushing bore. Hydraulic Pump Support Bore I.D. 53.86 2.121 53.92 2.123 NOTE: If the bushing bore is not within specifications, replace the support.
  • Page 454
    Section 10 — Air Intake System — Group 10 Page 10-a Section 10 — Air Intake System — Group 10 Section Contents Page Aftercooler Assembly ………………………. 10-3 Assemble …………………………10-5 Clean …………………………… 10-4 Disassemble …………………………. 10-4 Exploded View……………………….. 10-3 Inspect for Reuse ……………………….10-4 Aftercooler Coolant Tube ……………………..
  • Page 455
    Air Intake System — General Information Section 10 — Air Intake System — Group 10 Page 10-1 Air Intake System — General Informa- tion Preparatory The combustion air system consists of air intake system, turbocharger (A), air crossover (C), and aftercooler assem- bly (D).
  • Page 456
    Air Intake System The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No.

  • Page 457: Aftercooler Assembly

    Aftercooler Assembly (010-002) Section 10 — Air Intake System — Group 10 Page 10-3 Aftercooler Assembly (010-002) Exploded View 1. Gasket, Intake Manifold 15. Screw, Captive Washer Cap 2. Seal, Grommet 16. Gasket, Exhaust Manifold 3. Retainer, Seal 17. Screw, Hex Flange Head Cap 4.

  • Page 458: Inspect For Reuse

    Aftercooler Assembly (010-002) Page 10-4 Section 10 — Air Intake System — Group 10 Clean WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury. Use solvent to clean the exterior of the aftercooler assem- bly.

  • Page 459
    Aftercooler Assembly (010-002) Section 10 — Air Intake System — Group 10 Page 10-5 Remove the aftercooler cover capscrews and cover. Remove the element and gaskets. Inspect the cover and intake manifold gasket surfaces for damage. Inspect the threaded holes for damage. Discard the gaskets.

  • Page 460: Aftercooler Coolant Tube

    Aftercooler Coolant Tube (010-006) Page 10-6 Section 10 — Air Intake System — Group 10 Use engine oil to lubricate the seals. Install the seal on the retainer. Use clean engine oil to lubricate the O.D. of the water bosses on the aftercooer element. Slide the gasket on the water bosses.

  • Page 461: Air Crossover

    Air Crossover (010-019) Section 10 — Air Intake System — Group 10 Page 10-7 Air Crossover (010-019) Clean WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury.

  • Page 462: Clean

    Charge Air Cooler (CAC) (010-027) Page 10-8 Section 10 — Air Intake System — Group 10 Charge Air Cooler (CAC) (010-027) Clean If the engine experiences a turbocharger failure or any other occasion where oil or debris is put into the CAC, (charge air cooler) the CAC must be cleaned.

  • Page 463
    Charge Air Cooler (CAC) (010-027) Section 10 — Air Intake System — Group 10 Page 10-9 Leak Test WARNING To prevent possible injury if either plug blows off during the test, secure safety chains on the test plugs to any convenient capscrew on the radiator assembly.
  • Page 464
    Turbocharger, Water-Cooled (010-037) Page 10-10 Section 10 — Air Intake System — Group 10 Turbocharger, Water-Cooled (010-037) Clean WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury.

  • Page 465: Turbocharger Heat Shield

    Turbocharger Heat Shield (010-076) Section 10 — Air Intake System — Group 10 Page 10-11 Turbocharger Heat Shield (010-076) Remove Marine Applications CAUTION Do not remove insulation from inside of turbocharger heat shield. Insulation is permanently affixed to the heat shield. Remove the turbocharger heat shield mounting capscrews.

  • Page 466
    Turbocharger Heat Shield (010-076) Page 10-12 Section 10 — Air Intake System — Group 10 NOTES…
  • Page 467
    Section 11 — Exhaust System — Group 11 Page 11-a Section 11 — Exhaust System — Group 11 Section Contents Page Exhaust Manifold, Dry ………………………. 11-1 Assemble …………………………11-3 Clean …………………………..11-1 Marine Applications ……………………..11-2 Disassemble …………………………. 11-2 Inspect for Reuse ……………………….11-2 Marine Applications ……………………..

  • Page 468: Section 11 — Exhaust System — Group 11

    Exhaust System — General Information Section 11 — Exhaust System — Group 11 Page 11-1 Exhaust System — General Information General Information This section covers ONLY those repairs to the exhaust manifold. Please refer muffler and exhaust pipe repairs to the original equipment manufacturer.

  • Page 469: Marine Applications

    Exhaust Manifold, Dry (011-007) Page 11-2 Section 11 — Exhaust System — Group 11 Use a 240 grit emery cloth to clean all of the exhaust manifold gasket surfaces. Marine Applications WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use.

  • Page 470: Marine Applications

    Exhaust Manifold Heat Shield (011-015) Section 11 — Exhaust System — Group 11 Page 11-3 Inspect the capscrew holes in the center section for dam- age. NOTE: The manifold has been subjected to high tempera- tures if the capscrew threads are visible on the side of the capscrew holes.

  • Page 471: Inspect For Reuse

    Exhaust Manifold Heat Shield (011-015) Page 11-4 Section 11 — Exhaust System — Group 11 Inspect for Reuse Inspect the heat shield for any cracks or damage.

  • Page 472
    Section 12 — Compressed Air System — Group 12 Page 12-a Section 12 — Compressed Air System — Group 12 Section Contents Page Compressed Air System — General Information ……………….. 12-1 General Information ………………………. 12-1…

  • Page 473: General Information

    The compressed air system normally consists of a gear- driven air compressor, an air governor, air tanks and all necessary plumbing. The Holset and Cummins single and two cylinder air com- pressors are engine-driven, piston-type compressors which supply compressed air to operate air activated devices.

  • Page 474
    Compressed Air System — General Information Page 12-2 Section 12 — Compressed Air System — Group 12 Typical Schematic for Twin Cylinder Air Compressor 1. Engine air filter 10. 2500 cubic inch receiver tank 2. Engine 11. Heated spitter valve 3.
  • Page 475
    Section 13 — Electrical Equipment — Group 13 Page 13-a Section 13 — Electrical Equipment — Group 13 Section Contents Page Alternator Adjusting Link ……………………..13-4 Clean …………………………… 13-4 Inspect for Reuse ……………………….13-4 Alternator Bracket……………………….13-2 Clean …………………………… 13-2 Inspect for Reuse ……………………….
  • Page 476
    Electrical Equipment — General Information Section 13 — Electrical Equipment — Group 13 Page 13-1 Electrical Equipment — General Information General Information The basic heavy-duty electrical system consists of: • Batteries (1) — (Usually two or four connected in parallel) •…
  • Page 477
    Alternator Bracket (013-003) Page 13-2 Section 13 — Electrical Equipment — Group 13 Alternator Bracket (013-003) Clean WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury.
  • Page 478
    Starting Motor (013-020) Section 13 — Electrical Equipment — Group 13 Page 13-3 Turn the adjusting screw clockwise to tighten the belt tension. NOTE: The lower jam nut has left-hand threads. Tighten the jam nuts on the adjusting screw. Tighten the adjusting link and alternator mounting capscrews.
  • Page 479
    Alternator Adjusting Link (013-022) Page 13-4 Section 13 — Electrical Equipment — Group 13 Inspect for Reuse Inspect the gear, shaft, and the bushing for wear or dam- age. Lubricate the bushing with engine oil. NOTE: A pipe plug must be removed to lubricate the bush- ing on some starter motors.
  • Page 480
    QSK19 Section 14 — Engine Testing — Group 14 Page 14-a Section 14 — Engine Testing — Group 14 Section Contents Page Dynamometer Worksheet……………………..14-10 Worksheet …………………………14-10 Engine Run-in (Chassis Dynamometer) …………………. 14-23 General Information ……………………..14-23 Engine Throttle Control……………………14-24 Run-In Instructions ………………………
  • Page 481
    QSK19 Engine Testing — General Information Section 14 — Engine Testing — Group 14 Page 14-1 Engine Testing — General Information General Information This section outlines engine testing and engine run-in rec- ommendations for QSK19 engines. All engines must be run-in after a rebuild or a repair involving the replacement of one or more piston ring sets, cylinder liners or pistons.
  • Page 482
    Below is a description of the fuel measuring device, available from Cummins Engine Com- pany, along with installation and operation recommenda- tions. The fuel measuring device, Part No. 3376375, can be used with either a chassis or engine dynamometer.
  • Page 483
    QSK19 Engine Testing — General Information Section 14 — Engine Testing — Group 14 Page 14-3 Operation This is a schematic of the fuel measuring device, Part No. 3376375. The device consists of the following components: • Fuel Filter • Flowmeter •…
  • Page 484
    Engine Testing — General Information QSK19 Page 14-4 Section 14 — Engine Testing — Group 14 The fuel measuring device recirculates return fuel to the engine fuel inlet by routing the return fuel to the top side of the float tank. The fuel is deaerated as it passes through the baffling in the float tank. A ball float valve at the bottom of the float tank maintains an adequate volume in the tank for deaeration.
  • Page 485
    QSK19 Engine Testing — General Information Section 14 — Engine Testing — Group 14 Page 14-5 The fuel measuring device is installed in series between the fuel supply tank and the engine fuel inlet. The quantity of fuel being drawn through the flowmeter is known as MAKE-UP fuel or the amount of fuel being burned by the engine. The flowmeter is graduated to read fuel flow in pounds per hour.
  • Page 486
    Specifications QSK19 Page 14-6 Section 14 — Engine Testing — Group 14 Specifications Engine Testing Maintain the following limits during the engine test/run-in procedures: Due to variations in ratings of different engine models, refer to the specific ‘‘Engine Data Sheet’’ for the particular engine model being tested.
  • Page 487
    QSK19 Specifications Section 14 — Engine Testing — Group 14 Page 14-7 Lubricating Oil System Oil Pressure (With 15W-40 Oil at 107° C [225° F]) At Idle (Minimum Allowable) ………………..138 kPa [20 psi] At No Load Governed Speed …………….345 to 483 kPa [50 to 70 psi] Oil Temperature Maximum ……………………..
  • Page 488
    Service Tools Engine Testing The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No.
  • Page 489
    Section 14 — Engine Testing — Group 14 Page 14-9 Tool No. Tool Description Tool Illustration Fuel Measuring Device Measure the rate of fuel consumption of a Cummins diesel en- gine. 3376375 Digital Optical Tachometer Used to measure engine speed (RPM). 3377462 Blowby Check Tool Used with manometer, Part No.
  • Page 490
    Dynamometer Worksheet (014-001) QSK19 Page 14-10 Section 14 — Engine Testing — Group 14 Dynamometer Worksheet (014-001) Worksheet Date: Repair Order No: Operator: ESN: CPL: Fuel Pump Code: Complaint: SC Code: PARAMETER CODE SPECIFICATIONS ACTUAL READING Fuel Pressure (psi @ rpm) 150 to 180 psi at Idle Fuel Pressure (psi @ rpm) 225 to 250 psi at 1800 rpm…
  • Page 491
    QSK19 Engine Testing (Chassis Dynamometer) (014-002) Section 14 — Engine Testing — Group 14 Page 14-11 Engine Testing (Chassis Dynamometer) (014-002) Setup The performance of an engine installed in on-highway ve- hicles can be tested on a chassis dynamometer. NOTE: Due to driveline inefficiencies and engine-driven accessories, the rated horsepower will be reduced by ap- proximately: •…
  • Page 492
    Engine Testing (Chassis Dynamometer) (014-002) QSK19 Page 14-12 Section 14 — Engine Testing — Group 14 Adjust the vehicle and dynamometer room exhaust system to be sure that all exhaust gases are removed from the room. Refer to the chassis dynamometer and vehicle manufac- turer’s recommendations and specifications for testing procedures.
  • Page 493
    API gravity) than No. 2 diesel fuel. The lighter the fuel, the lower the energy content (BTU) per gallon (liter, etc.). Engine operating specifications can be found in publica- tions available from your local Cummins Authorized Repair Location.
  • Page 494
    Engine Testing (Chassis Dynamometer) (014-002) QSK19 Page 14-14 Section 14 — Engine Testing — Group 14 Test To properly monitor engine performance, record the fol- lowing parameters. To limit dynamometer operating time, instrument the engine to perform as many checks as pos- sible.
  • Page 495
    QSK19 Engine Testing (Chassis Dynamometer) (014-002) Section 14 — Engine Testing — Group 14 Page 14-15 Fuel Rate Use fuel measuring device, Part No. 3376375, to measure the rate of fuel consumption. Refer to General Information located in the front of this section. Fuel Inlet Restriction Measure the fuel inlet restriction.
  • Page 496
    Engine Testing (Chassis Dynamometer) (014-002) QSK19 Page 14-16 Section 14 — Engine Testing — Group 14 Intake Air Temperature Control — Chassis Dynamometer Test When operating an engine on a chassis dynamometer, follow these steps for best results and safe operation. If the engine is equipped with automatic fan, lock the cool- ing fan in the ON mode.
  • Page 497
    QSK19 Engine Testing (Chassis Dynamometer) (014-002) Section 14 — Engine Testing — Group 14 Page 14-17 Exhaust Restriction Measure the exhaust air restriction. Install the pressure gauge, Part No. ST-1273, or a manometer in the exhaust air piping. The gauge adapter must be installed near the turbocharger in a straight section of pipe at the turbine outlet.
  • Page 498
    Engine Testing (Chassis Dynamometer) (014-002) QSK19 Page 14-18 Section 14 — Engine Testing — Group 14 Operate the engine at rated rpm and full load (wide open throttle) until a steady reading is obtained. Compare the blowby readings to previous readings on the engine.
  • Page 499
    QSK19 Engine Testing (Chassis Dynamometer) (014-002) Section 14 — Engine Testing — Group 14 Page 14-19 Specifications Engine Blowby New/Rebuilt Used 7.67 mm [0.302 in] Orifice: mm H [in H mm H [in H All ratings [20] 1270 [50] 2000 and above [14] [35] 1500 to 1900…
  • Page 500
    Engine Testing (Chassis Dynamometer) (014-002) QSK19 Page 14-20 Section 14 — Engine Testing — Group 14 Isolate the turbocharger to determine if the high crankcase pressure is due to seal leakage in the turbocharger. WARNING Some state and federal agencies in the United States of America have determined that used engine oil can be carcinogenic and can cause reproductive toxicity.
  • Page 501
    QSK19 Engine Testing (Chassis Dynamometer) (014-002) Section 14 — Engine Testing — Group 14 Page 14-21 Operate the engine at rated speed. Record the blowby value. CAUTION Do not operate the engine with valve A open and valve B closed for more than 1 minute. Operation for more than 1 minute can result in severe engine damage.
  • Page 502
    No Pressure Cap 241 kPa [35 psi] Air Compressor NOTE: All air compressors manufactured by Cummins En- gine Company, Inc. must be operating during the engine run-in. During the performance check, all air compressors must be in the unload or non-operating mode.
  • Page 503
    QSK19 Engine Run-in (Chassis Dynamometer) (014-003) Section 14 — Engine Testing — Group 14 Page 14-23 Use an air tank (2). Install an air regulator (3) capable of maintaining 345 to 517 kPa [50 to 75 psi] air pressure at both minimum and maximum engine rpm.
  • Page 504
    Engine Run-in (Chassis Dynamometer) (014-003) QSK19 Page 14-24 Section 14 — Engine Testing — Group 14 Check the engine lubricating oil level to be sure it is filled to the proper level. WARNING Check the coolant level only when the engine is stopped.
  • Page 505
    QSK19 Engine Run-in (Chassis Dynamometer) (014-003) Section 14 — Engine Testing — Group 14 Page 14-25 Engine operating specifications can be found in publica- tions available from your local Cummins Authorized Repair Location.
  • Page 506
    Engine Run-in (Chassis Dynamometer) (014-003) QSK19 Page 14-26 Section 14 — Engine Testing — Group 14 Run-In Instructions Refer to Chassis Dynamometer — Operation, Procedure No. 014-002, for general operating procedures and safety precautions. Use this chart to determine the test load. Example: The test load for a 475 HP engine rated at 2000 rpm with a 15 percent torque rise is 225 ft-lb.
  • Page 507
    QSK19 Engine Run-in (Chassis Dynamometer) (014-003) Section 14 — Engine Testing — Group 14 Page 14-27 Adjust the engine rpm to 1200 rpm. Adjust the dynamom- eter load to the test load as previously determined. Operate the engine at this setting until the coolant temperature indicates 70°C [160°F].
  • Page 508
    Engine Run-in (Without Dynamometer) (014-004) QSK19 Page 14-28 Section 14 — Engine Testing — Group 14 Decrease the dynamometer load until the engine rpm in- creases to the rated RPM. Operate the engine at this load for 5 minutes. Check all the gauges and record the readings. Decrease the dynamometer load completely.
  • Page 509
    QSK19 Engine Run-in (Without Dynamometer) (014-004) Section 14 — Engine Testing — Group 14 Page 14-29 Use a pump capable of supplying 205 kPa [30 psi] con- tinuous pressure. Connect the pump to the front of the engine oil cooler as shown. Use a supply of clean oil.
  • Page 510
    QSK19 Page 14-30 Section 14 — Engine Testing — Group 14 Engine operating specifications can be found in publica- tions available from your local Cummins Authorized Repair Location. Run-In Instructions Engines that are run on an engine dynamometer require that the engine harness be installed, and connected to the engine.
  • Page 511
    QSK19 Engine Testing (Engine Dynamometer) (014-005) Section 14 — Engine Testing — Group 14 Page 14-31 Do not idle the engine for more than 5 minutes at any one time. Do not operate the engine at rated rpm. Operate at 75 percent of rated RPM or lower.
  • Page 512
    Intake Air Temperature Control The use of a remote heat exchanger is mandatory when- ever a Cummins LTA engine is attached to an engine dy- namometer for the purpose of engine run-in, performance testing and engine diagnostics. Do not attempt to run a Cummins LTA engine without any means of controlling the intake manifold air temperature.
  • Page 513
    QSK19 Engine Testing (Engine Dynamometer) (014-005) Section 14 — Engine Testing — Group 14 Page 14-33 Use a pump capable of supplying 205 kPa [30 psi] con- tinuous pressure. Connect the pump to the front of the engine oil cooler as shown. Use a supply of clean oil.
  • Page 514
    Engine Dynamometer Kit Part No. 3162245. Engine operating specifications are available from your local Cummins Authorized Repair Location. Test To properly monitor engine performance, record the fol- lowing parameters. To limit dynamometer operating time, instrument the engine to make as many checks as possible.
  • Page 515
    QSK19 Engine Testing (Engine Dynamometer) (014-005) Section 14 — Engine Testing — Group 14 Page 14-35 Engine Speed (RPM) With a Verified Tachometer Use digital optical tachometer, Part No. 3377462, to check and verify engine speed. Fuel Supply Pressure Refer to Procedure 005-016. Fuel Rate Use fuel measuring device, Part No.
  • Page 516
    Engine Testing (Engine Dynamometer) (014-005) QSK19 Page 14-36 Section 14 — Engine Testing — Group 14 Fuel Drain Line Restriction Use Pressure Gauge, Part No. ST-1273, to measure fuel drain line restriction. NOTE: Do not measure fuel drain line restriction with the fuel measuring device installed.
  • Page 517
    QSK19 Engine Testing (Engine Dynamometer) (014-005) Section 14 — Engine Testing — Group 14 Page 14-37 Engine Blowby NOTE: Excessive blowby indicates an air compressor, a turbocharger, or an engine malfunction, allowing combus- tion gases or air to enter the crankcase and build a pressure higher than normal.
  • Page 518
    Engine Testing (Engine Dynamometer) (014-005) QSK19 Page 14-38 Section 14 — Engine Testing — Group 14 QSK19 Blowby Limits (using 0.302 inch diameter orifice at rated load and speed) Engine HP (RPM Rating) New/Rebuilt Used Engine Limit 699 HP and Below 305 mm H 762 mm H (1500 — 1900)
  • Page 519
    QSK19 Engine Testing (Engine Dynamometer) (014-005) Section 14 — Engine Testing — Group 14 Page 14-39 Isolate the turbocharger to determine if the high crankcase pressure is due to seal leakage in the turbocharger. Disconnect the turbocharger drain line from the oil pan adaptor.
  • Page 520
    Engine Testing (Engine Dynamometer) (014-005) QSK19 Page 14-40 Section 14 — Engine Testing — Group 14 Compare the value to the original reading. If the blowby is now acceptable, replace the turbocharger. Isolate the air compressor to determine if it is malfunction- ing and causing the high blowby pressure.
  • Page 521
    Measure the coolant pressure at the water manifold (1). Coolant Pressure NOMINAL Air Compressor NOTE: All air compressors manufactured by Cummins En- gine Company, Inc. must be operating during the engine run-in. During the performance check, all air compressors must be in the unload or non-operating mode.
  • Page 522
    Engine Run-in (Engine Dynamometer) (014-006) QSK19 Page 14-42 Section 14 — Engine Testing — Group 14 Starting Motor Inspect the voltage rating on the starting motor before installing the electrical wiring. Install the electrical wiring to the starting motor and bat- teries, if used.
  • Page 523
    QSK19 Engine Run-in (Engine Dynamometer) (014-006) Section 14 — Engine Testing — Group 14 Page 14-43 Engine Dynamometer Run-In This is the preferred method of run-in for engines that have been rebuilt out-of-chassis. It is not practical, nor recom- mended that an engine be removed from the application to conduct the run-in after a rebuild or cylinder repair has been performed in-chassis.
  • Page 524
    Engine Run-in (Engine Dynamometer) (014-006) QSK19 Page 14-44 Section 14 — Engine Testing — Group 14 Run-In Instructions Refer to Engine Testing-Engine Dynamometer, Procedure No. 014-005, for general operating procedures and safety precautions. Use this chart to determine the test load. The run-in test must be performed with the engine operating at torque peak rpm.
  • Page 525
    QSK19 Engine Run-in (Engine Dynamometer) (014-006) Section 14 — Engine Testing — Group 14 Page 14-45 CAUTION Do not crank the starting motor for more than 30 sec- onds. Excessive heat will damage the starter. START the engine. If the engine does not begin operating after 30 seconds, allow two minutes for the starting motor to cool.
  • Page 526
    Engine Run-in (Engine Dynamometer) (014-006) QSK19 Page 14-46 Section 14 — Engine Testing — Group 14 Adjust the engine rpm to the torque peak rpm. Adjust the dynamometer load to equal two times the test load. Op- erate the engine for two minutes. Check all the gauges and record the readings.
  • Page 527
    QSK19 Engine Testing (In Chassis) (014-008) Section 14 — Engine Testing — Group 14 Page 14-47 Decrease the dynamometer load completely. CAUTION Do not turn the engine OFF immediately. The engine must be allowed to cool. Move the throttle lever to the LOW IDLE position. Operate the engine at this setting for 3 to 5 minutes.
  • Page 528
    Engine Testing (In Chassis) (014-008) QSK19 Page 14-48 Section 14 — Engine Testing — Group 14 The following equipment is needed for this check: • Stop watch • Digital tachometer, Part No. 3375631. or a hand held optical tachometer, Part No. ST-3377462. •…
  • Page 529
    QSK19 Engine Testing (In Chassis) (014-008) Section 14 — Engine Testing — Group 14 Page 14-49 Operate the engine until the coolant temperature is up to 70°C [160°F] and the converter temperature is 80°C [180°F] or above. Alternately, shift from neutral to the highest speed gear possible and operate at part throttle.
  • Page 530
    Engine Testing (In Chassis) (014-008) QSK19 Page 14-50 Section 14 — Engine Testing — Group 14 Check the stall speed (rpm) against the specifications that are for the equipment, converter, or automatic transmis- sion. NOTE: The stall speed for the engine and converter/ transmission can vary plus/minus 8 percent (±8%) from the manufacturer’s specifications.
  • Page 531
    QSK19 Engine Testing (In Chassis) (014-008) Section 14 — Engine Testing — Group 14 Page 14-51 Quickly move the throttle to the full open position and start the stop watch at the same time. When the engine speed is 90 percent (90%) of the stall speed rpm, stop the stop watch.
  • Page 532
    Engine Testing (In Chassis) (014-008) QSK19 Page 14-52 Section 14 — Engine Testing — Group 14 Stall Speed Check List If The Stall Speed Is Too Low, Check The Following: _____ _____ The tachometer is in error. _____ _____ The engine is up to or above 70°C [160°F]. _____ _____ The converter oil is up to temperature 80°C [180°F].
  • Page 533
    The converter charging pressure is correct. The reasons for abnormal stall speeds listed above are some which have been encountered by Cummins represen- tatives and probably do not include all possible causes. The correction of the problem is either covered in the vehicle…
  • Page 534
    Engine Testing (In Chassis) (014-008) QSK19 Page 14-54 Section 14 — Engine Testing — Group 14 NOTES…
  • Page 535
    Section 16 — Mounting Adaptations — Group 16 Page 16-a Section 16 — Mounting Adaptations — Group 16 Section Contents Page Engine Support Bracket, Front……………………16-4 Clean …………………………… 16-4 Inspect for Reuse ……………………….16-4 Flywheel …………………………… 16-4 Clean …………………………… 16-4 Inspect for Reuse ……………………….
  • Page 536
    Mounting Adaptations — General Information Section 16 — Mounting Adaptations — Group 16 Page 16-1 Mounting Adaptations — General Information General Information The Mounting Adaptations group consists of the flywheel housing, flywheel, and the front engine support. Flywheel Housing For various applications, the flywheel housings are available in different styles, sizes, and materials. Check the appropriate parts book and the engine parts listing for the correct part number for the engine application being serviced.
  • Page 537
    Mounting Adaptations — General Information Page 16-2 Section 16 — Mounting Adaptations — Group 16 Rail Applications The flywheel housing has been modified to allow the en- gine to be mounted horizontally (intake side down). The intake side starter option in mandatory to keep a low profile design for the railcar applications.
  • Page 538
    Service Tools Mounting Adaptations The following special tools are recommended to perform procedures in this section. The use of these tools is shown in the appropriate procedure. These tools can be purchased from your local Cummins Authorized Repair Location. Tool No.

  • Page 539: Engine Support Bracket, Front

    Engine Support Bracket, Front (016-002) Page 16-4 Section 16 — Mounting Adaptations — Group 16 Engine Support Bracket, Front (016-002) Clean WARNING When using steam or hot, high pressure water for clean- ing, wear goggles and protective clothing to avoid per- sonal injury.

  • Page 540: Inspect For Reuse

    Flywheel (016-005) Section 16 — Mounting Adaptations — Group 16 Page 16-5 Inspect for Reuse Visually inspect for nicks or burrs. Use a crocus cloth to remove small nicks and burrs. WARNING Do not use a cracked flywheel. A cracked flywheel can break or cause serious personal injury.

  • Page 541: Flywheel Housing

    Flywheel Housing (016-006) Page 16-6 Section 16 — Mounting Adaptations — Group 16 Flywheel Housing (016-006) Clean WARNING When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to avoid personal injury.

  • Page 542: Redowel

    Flywheel Housing (016-006) Section 16 — Mounting Adaptations — Group 16 Page 16-7 Redowel The tools needed to perform this procedure are: Drill Ream Fixture, Part No. ST-1232, that contains: 1. Plate, Part No. ST-1232-1 2. Locator Pin, Part No. 3375052 3.

  • Page 543
    0.001 in] smaller than the dowel. The dowel must be long enough to protrude from the block one-half of the flywheel housing wall thickness. NOTE: There are three oversize dowel pins available from Cummins Engine Company, Inc. Oversize Dowel Pin O.D. Overall Dimension Oversize 13.08 mm [0.515 in]…
  • Page 544
    Flywheel Housing (016-006) Section 16 — Mounting Adaptations — Group 16 Page 16-9 Install the appropriate drill bushings (4). The table shows the bushings available from Cummins Engine Company, Inc. Drill/Ream Bushing Sets — 25.4 mm [1 Inch] O.D. Oversize…

  • Page 545: Flywheel Ring Gear

    Flywheel Ring Gear (016-008) Page 16-10 Section 16 — Mounting Adaptations — Group 16 Remove the plate from the crankshaft. CAUTION Be sure the dowel hole does not contain any metal chips. Engine damage will result. Use a square nose drift. Drive each dowel in until it touches the bottom of the hole in the block.

  • Page 546: Assemble

    Flywheel Ring Gear (016-008) Section 16 — Mounting Adaptations — Group 16 Page 16-11 Assemble CAUTION Wear protective clothing to prevent personal injury from burns. CAUTION Do not exceed the specified time or temperature. Dam- age to the gear and to the gear teeth will result. CAUTION Do not attempt to install the gear without using heat.

  • Page 547
    Flywheel Ring Gear (016-008) Page 16-12 Section 16 — Mounting Adaptations — Group 16 NOTES…
  • Page 548
    Section 19 — Electronic Engine Controls — Group 19 Page 19-a Section 19 — Electronic Engine Controls — Group 19 Section Contents Page Electronic Engine Controls — General Information ………………19-1 General Information ………………………. 19-1 Connector Pins — Checking ………………….. 19-3 Continuity Check ……………………..

  • Page 549: General Information

    Electronic Engine Controls — General Information Section 19 — Electronic Engine Controls — Group 19 Page 19-1 Electronic Engine Controls — General Information General Information How To Use A Digital Volt/Ohm Meter On most meters, the negative (black) meter lead must be plugged in the “COM”…

  • Page 550
    Electronic Engine Controls — General Information Page 19-2 Section 19 — Electronic Engine Controls — Group 19 How To Measure Voltage Select the AC voltage (Vz) or DC voltage (V−) function on the meter. Turn on the power in the circuit being measured. Put the leads of the meter in parallel with the component to measure the voltage potential difference between the two points of the component.
  • Page 551
    Electronic Engine Controls — General Information Section 19 — Electronic Engine Controls — Group 19 Page 19-3 Connector Pins — Checking When disconnecting connectors during troubleshooting, the pins must always be inspected to make sure they are not the cause of a bad connection. The three things to look for are bent, corroded, and pushed back pins.
  • Page 552
    Electronic Engine Controls — General Information Page 19-4 Section 19 — Electronic Engine Controls — Group 19 Short Circuit To Ground — Check Short circuit to ground is a condition where a connection from a wire to ground exists when it is not suppose to. The procedure for checking for a short circuit to ground is as follows: Turn the key switch to the “OFF”…
  • Page 553
    Electronic Engine Controls — General Information Section 19 — Electronic Engine Controls — Group 19 Page 19-5 Short Circuit From Pin To Pin — Check Short circuit from pin to pin is a condition where an elec- trical path exists between two pins where it is not suppose to exist.
  • Page 554
    Electronic Engine Controls — General Information Page 19-6 Section 19 — Electronic Engine Controls — Group 19 Use the appropriate test leads from the wiring harness repair kit, Part No. 3822926, to avoid damage to the con- nector pins. Touch one of the VOM test leads to the correct lead to be tested.
  • Page 555
    Electronic Engine Controls — General Information Section 19 — Electronic Engine Controls — Group 19 Page 19-7 Continuity Check Continuity is an electrical connection between two pins that is less than a certain resistance value. For harness wires, the specification is less than 10 ohms. Turn the key switch to the “OFF”…
  • Page 556
    Engine Wiring Harness (019-043) Page 19-8 Section 19 — Electronic Engine Controls — Group 19 Resistance Check — Coil Disconnect the harness from the coil. Turn the dial of the VOM to measure resistance. Turn the key switch to the “OFF” position. CAUTION Use the appropriate test leads from the wiring harness repair kit, Part No.
  • Page 557
    OEM Wiring Harness (019-071) Section 19 — Electronic Engine Controls — Group 19 Page 19-9 OEM Wiring Harness (019-071) General Information The OEM harness is supplied and installed by the vehicle manufacturer. Follow the vehicle manufacturer’s instructions, if replace- ment is necessary. Refer to the vehicle manufacturer’s troubleshooting and repair manual.
  • Page 558
    OEM Interface Harness (019-072) Page 19-10 Section 19 — Electronic Engine Controls — Group 19 NOTES…
  • Page 559
    QSK19 Section L — Service Literature Page L-a Section L — Service Literature Section Contents Page Additional Service Literature……………………… L-1 Literature Order Form……………………….L-3 Service Literature Ordering Location………………….L-2…
  • Page 560
    The following publications can be purchased by filling in and mailing the Literature Order Form: Bulletin No. Title of Publication 3666098–01 Troubleshooting and Repair Manual QSK19 Series Engines 3885786 Users Guide Electronic Software and Database Network Version 3.1 3666120 Operation and Maintenance Manual QSK Fuel System/QSK19 Engine Series…
  • Page 561
    Australia and New Zealand) Literature Center 8 Tanjong Penjuru Jurong Industrial Estate Singapore Australia and New Zealand Cummins Diesel Australia Maroondah Highway, P .O.B. 139 Ringwood 3134 Victoria, Australia Obtain current price information from your local Cummins Distributor. g-01 (loc)
  • Page 562
    Quantity Each Amount Order Total Contact your Cummins distributor for prices and availability. For problems with literature orders (for U.S.A. and Canada), contact 1-800-DIESELS (1-800-343-7357). All other locations contact your local Distributor. Prices subject to change without notice. Please cut on dotted line —…
  • Page 563
    Literature Order Form QSK19 Page L-4 Section L — Service Literature Mail the Literature Order Form along with your ship-to address to your nearest Cummins distributor. FROM: Name: Street Address: City: State/Province: Zip/Postal Code: Country: SHIP TO: (Name and address where literature is to be shipped)
  • Page 564
    QSK19 Section M — Component Manufacturers Page M-a Section M — Component Manufacturers Section Contents Page Component Manufacturers’ Addresses ………………….M-1 Air Compressors……………………….M-1 Air Cylinders …………………………M-1 Air Heaters …………………………M-1 Air Starting Motors ……………………….M-1 Alternators…………………………M-1 Auxiliary Brakes ……………………….M-1 Belts…………………………..
  • Page 565
    Section M — Component Manufacturers Page M-1 Component Manufacturers’ Addresses NOTE: The following list contains addresses and telephone numbers of suppliers of accessories used on Cummins engines. Suppliers can be contacted directly for any specifications not covered in this manual. Air Compressors…
  • Page 566
    Component Manufacturers’ Addresses QSK19 Page M-2 Section M — Component Manufacturers Fault Lamps Twin Disc Incorporated The Nason Company 1328 Racine Street 2810 Blue Ridge Blvd. Cutler-Hammer Products Racine, WI 53403 West Union, SC 29696 Eaton Corporation Telephone: (414) 634-1981 Telephone: (803) 638-9521 4201 N.
  • Page 567
    QSK19 Component Manufacturers’ Addresses Section M — Component Manufacturers Page M-3 Heat Sleeves Grasslin U.K. Ltd. Kim Hotstart Co. Vale Rise P .O. Box 11245 Bentley Harris Manufacturing Co. Tonbridge Spokane, WA 99211-0245 100 Bentley Harris Way Kent Telephone: (509) 534-6171 Gordonville, TN 38563 TN9 1TB Prelubrication Systems…
  • Page 568
    Component Manufacturers’ Addresses QSK19 Page M-4 Section M — Component Manufacturers NOTES…
  • Page 569
    Section V — Specifications Page V-a Section V — Specifications Section Contents Page Air Intake System — Specifications …………………… V-42 Aftercooler Assembly ……………………..V-42 Turbocharger, Water-Cooled ……………………V-42 Air Intake System — Torque Values …………………… V-43 Aftercooler Assembly ……………………..V-43 Turbocharger Heat Shield……………………..
  • Page 570
    Page V-b Section V — Specifications Page Valve Seat Bore……………………….V-21 Valve Seat Insert, Cylinder Head ……………………. V-21 Drive Belt Tension ……………………….V-47 Drive Units — Specifications……………………… V-35 Fuel Pump Drive ……………………….V-35 Fuel Pump Drive Gear and Shaft …………………… V-36 Hydraulic Pump Drive ……………………..
  • Page 571
    Complete Engine — Specifications Section V — Specifications Page V-1 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Complete Engine — Specifications Engine Assembly (001-058) Cylinder Liner I.D. (New) 158.737 mm 6.2495 in 158.775 mm 6.2510 in Cylinder Liner Protrusion 0.13 mm 0.003 in 0.18 mm 0.007 in…
  • Page 572
    Complete Engine — Specifications Page V-2 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Camshaft Idler Gear End Clearance 0.29 mm 0.012 in 0.51 mm 0.020 in Lower Housing-To-Cylinder Block Gear Backlash 0.05 mm 0.002 in 0.51 mm 0.015 in Idler Gear Backlash 0.05 mm…
  • Page 573
    Complete Engine — Torque Values Section V — Specifications Page V-3 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Complete Engine — Torque Values Engine Disassembly (009-029) Engine Stand Mounting Capscrews 45 N•m 35 ft-lb Engine Assembly (001-016) Main Bearing Cap Bolts 265 N•m 195 ft-lb 605 N•m…
  • Page 574
    Complete Engine — Torque Values Page V-4 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Camshaft Idler Gear Install Camshaft Idler Gear Mountig Capscrew 45 N•m 35 ft-lb 95 N•m 70 ft-lb 150 N•m 110 ft-lb Flywheel Housing Mounting Capscrews 100 N•m 75 ft-lb 205 N•m…
  • Page 575
    Complete Engine — Torque Values Section V — Specifications Page V-5 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Air Compressor Mounting Capscrews Capscrew 5 60 N•m 45 ft-lb Capscrew 4 45 N•m 35 ft-lb Capscrew 2 45 N•m 35 ft-lb Cylinder Head Capscrews Step 1 68 N•m…
  • Page 576
    Complete Engine — Torque Values Page V-6 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Thermostat Housing Support Capscrews 45 N•m 35 ft-lb Capscrew 20 N•m 15 ft-lb Hose Clamp 6 N•m 50 in-lb Aftercooler Coolant Return Tube Capscrews 6 N•m 50 in-lb…
  • Page 577
    Complete Engine — Torque Values Section V — Specifications Page V-7 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Cam Follower Mounting Capscrews 55 N•m 40 ft-lb 110 N•m 80 ft-lb 165 N•m 120 ft-lb Cam Follower Cover Capscrews 27 N•m 20 ft-lb Filter Head Capscrews 45 N•m…
  • Page 578
    Complete Engine — Torque Values Page V-8 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Fuel Control Valve Body Assembly Capscrew 45 N•m 35 ft-lb Electrical Connection Post 3 N•m 25 in-lb Electrical Connection Nut 2 N•m 15 in-lb Control Valve Body Hoses Fuel Supply Hose (1)
  • Page 579
    Complete Engine — Torque Values Section V — Specifications Page V-9 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Aftercooler Capscrews Step 1 25 N•m 20 ft-lb 45 N•m 35 ft-lb Turbocharger Oil Return Line 45 N•m 35 ft-lb Rail Applications, Air Crossover Clamp 8 N•m 75 in-lb Oil Cooler Element Capscrews…
  • Page 580
    Complete Engine — Torque Values Page V-10 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Oil Cooler Cover Capscrews 45 N•m 35 ft-lb Water Pump Outlet Connection Capscrews 45 N•m 35 ft-lb Water Pump Outlet Connection Hose Clamps 6 N•m 50 in-lb…
  • Page 581
    Complete Engine — Torque Values Section V — Specifications Page V-11 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Turbocharger Inlet Piping Clamp 8 N•m 75 in-lb Turbocharger Exhaust Piping Clamp 8 N•m 75 in-lb Belt Tensioner Capscrews 201 N•m 75 ft-lb Idler Arm Assembly Capscrews 45 N•m 35 ft-lb…
  • Page 582
    Complete Engine — Torque Values Page V-12 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Water Pump Support Bracket Capscrew 206 N•m 150 ft-lb Alternator Pulley Nut 100 N•m 75 ft-lb Belt Tensioning Jam Nuts 55 N•m 40 ft-lb Alternator Mounting Capscrews 55 N•m…
  • Page 583
    Cylinder Block — Specifications Section V — Specifications Page V-13 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Cylinder Block — Specifications Bearings, Main (001-006) Thrust Bearing Thickness Standard or Oversize (OS) Standard 3.82 mm 0.1505 in 3.90 mm 0.1535 in 0.010 (OS) 4.08 mm 0.1605 in…
  • Page 584
    Cylinder Block — Specifications Page V-14 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Camshaft Bushing I.D. 82.550 mm 3.2500 in 82.640 mm 2.2535 in Connecting Rod (001-014) Capscrew Length (1) 117.09 mm 4.610 in 117.86 mm 4.640 in Capscrew O.D.
  • Page 585
    Cylinder Block — Specifications Section V — Specifications Page V-15 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Measure the Connecting Rod Twist Maximum Connecting Rod Twist Bushing Installed 0.25 mm 0.010 in Bushing Removed 0.51 mm 0.020 in Crankshaft (001-016) Crankshaft O.D.
  • Page 586
    Cylinder Block — Specifications Page V-16 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Counterbore Diameter — UPPER Press Fit Diameter 188.16 mm 7.409 in 188.21 mm 7.410 in Counterbore Diameter — LOWER Press Fit Diameter 180.09 mm 7.090 in 180.14 mm 7.092 in…
  • Page 587
    Cylinder Block — Specifications Section V — Specifications Page V-17 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Gear Cover Spacer Plate (001-029) Accessory Drive Stud (1)- Installed Height 31.88 mm 1.255 in 33.15 mm 1.305 in Water Pump Drive Stud (2) — Installed Height Gear Spacer Plate and Gear Housing 62.99 mm…
  • Page 588
    Cylinder Block — Specifications Page V-18 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Piston Pin O.D. 60.929 mm 2.3988 in 60.935 mm 2.3990 in Piston Pin Length 132.59 mm 5.220 in 132.85 mm 5.230 in Cylinder Block Counterbore (001-058) Cylinder Liner Protrusion 0.13 mm 0.003 in…
  • Page 589
    Cylinder Block — Torque Values Section V — Specifications Page V-19 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Cylinder Block — Torque Values Crankshaft Pulley (001-052) Vibration Damper 140 N•m 105 ft-lb Cylinder Block (001-026) Step 1 270 N•m 200 ft-lb Step 2 610 N•m 450 ft-lb…
  • Page 590
    Cylinder Head — Specifications Page V-20 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Cylinder Head — Specifications Cylinder Head (002-004) Allowable Crack Length 6 mm 0.25 in Allowable Valve Depth from the Combustion Face 0.00 mm 0.000 in 0.51 mm 0.020 in…
  • Page 591
    Cylinder Head — Specifications Section V — Specifications Page V-21 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Valve Guide Bore I.D. 21.438 mm 0.8440 in 21.463 mm 0.8450 in Valve Guide Height (to Spring Pocket) 37.97 mm 1.495 in 38.48 mm 1.515 in Valve Guide Height (to Top of Head) 13.97 mm…
  • Page 592
    Cylinder Head — Specifications Page V-22 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Coil Shot Amperage Coil Shot Amperage (Ampere Turns) 400 D.C. or rectified A.C. 800 D.C. or rectified A.C. Head Shot Amperage Head Shot Amperage (Ampere) 500 D.C.
  • Page 593
    Rocker Levers — Specifications Section V — Specifications Page V-23 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Rocker Levers — Specifications Rocker Lever (003-008) Amperage (Ampere Turns) Amperage (Ampere Turns) 1200 D.C. or rectified A.C. 2000 D.C. or rectified A.C. Rocker Lever Assembly (003-009) Rocker Arm Shaft O.D.
  • Page 594
    Cam Followers/Tappets — Specifications Page V-24 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Cam Followers/Tappets — Specifications Cam Follower Assembly (004-001) Cam Follower Shaft O.D. 28.538 mm 1.1235 in 28.575 mm 1.125 in Cam Follower Roller Clearance Cam Follower Roller Clearance Reference Point 0.230…
  • Page 595
    Fuel System — Torque Values Section V — Specifications Page V-25 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Fuel System — Torque Values Fuel Shutoff Valve (FSOV) (005-043) 3 N•m 25 in-lb 8 N•m 72 in-lb 2 N•m 15 in-lb…
  • Page 596
    Injectors and Fuel Lines — Torque Values Page V-26 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Injectors and Fuel Lines — Torque Values Fuel Manifold (Supply) (006-022) Manifold Plugs Plug (1): 20 N•m 180 in-lb Plug (2): 7 N•m 60 in-lb Fuel Connection Block…
  • Page 597
    Lubricating Oil System — Specifications Section V — Specifications Page V-27 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Lubricating Oil System — Specifications Lubricating Oil Filter Head (007-015) Bypass Plunger Spring Free Length 88.98 mm 3.500 in Working Height (6) 50.80 mm 2.000 in Spring Force (7)
  • Page 598
    Lubricating Oil System — Specifications Page V-28 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Pressure Regulator Spring Free Length 95 mm Nominal 3.75 in Spring Force @ 63.88 mm [2.5 in] Working Height 322 N 72 lb 344 N 77 lb Shaft O.D.
  • Page 599
    Lubricating Oil System — Torque Values Section V — Specifications Page V-29 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Lubricating Oil System — Torque Values Lubricating Oil Cooler (007-003) Lube Oil Cooler Element Pressure Test 415 kPa 60 psi Lubricating Oil Filter Head (007-015) Bypass Plunger and Spring 54 N•m 40 ft-lb…
  • Page 600
    Lubricating Oil System — Torque Values Page V-30 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Oil Transfer Connection (007-061) 9/16 Plug 14 N•m 10 ft-lb 1 3/16 Plug 54 N•m 40 ft-lb 1 7/8 Plug 95 N•m 70 ft-lb…
  • Page 601
    Cooling System — Specifications Section V — Specifications Page V-31 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Cooling System — Specifications Fan Drive Idler Pulley Assembly (008-030) Bearing End Clearance 0.08 mm 0.003 in 0.25 mm 0.010 in Fan Hub, Belt Driven (008-036) Bearing End Clearance 0.025 mm 0.001 in…
  • Page 602
    Cooling System — Specifications Page V-32 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Water Pump Bearings (008-071) Bearing to Shaft Differences Clearance 0.003 mm 0.0001 in Interference 0.018 mm 0.0007 in…
  • Page 603
    Cooling System — Torque Values Section V — Specifications Page V-33 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Cooling System — Torque Values Coolant Thermostat (008-013) Thermostat Housing Capscrews 45 N•m 35 ft-lb Thermostat Housing Capscrews 45 N•m 35 ft-lb Hose Clamp 6 N•m 50 in-lb…
  • Page 604
    Cooling System — Torque Values Page V-34 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Water Pump (008-062) Water Pump Shut Off Valve Capscrew 20 N•m 15 ft-lb 45 N•m 35 ft-lb Water Pump Inlet Connection Capscrews 40 N•m 30 ft-lb Torque Converter Cooler (007-018)
  • Page 605
    Drive Units — Specifications Section V — Specifications Page V-35 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Drive Units — Specifications Fuel Pump Drive (009-011) Fuel Pump/Compressor Drive End Clearance 0.05 mm 0.002 in 0.30 mm 0.012 in Bushing I.D. 33.43 mm 1.316 in 33.50 mm…
  • Page 606
    Drive Units — Specifications Page V-36 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Fuel Pump Drive Gear and Shaft (009-013) Gear I.D. 39.73 mm 1.564 in 39.75 mm 1.565 in Shaft O.D. 39.789 mm 1.5665 in 39.802 mm 1.5670 in Fuel Pump Drive Gear to Shaft…
  • Page 607
    Drive Units — Specifications Section V — Specifications Page V-37 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Idler Gear Backlash 0.05 mm 0.002 in 0.51 mm 0.020 in Rear Gear Drive (Upper Assembly) (009-024) Upper to Lower Housing Gasket Thickness-Nominal (New*) Part No.
  • Page 608
    Drive Units — Specifications Page V-38 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Center Drive Gear to Outer Drive Gear Backlash 0.10 mm 0.004 in 0.51 mm 0.020 in Center Drive Gear to Outer Drive Gear Backlash 0.10 mm 0.004 in…
  • Page 609
    Drive Units — Specifications Section V — Specifications Page V-39 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Hydraulic Drive Gear End Clearance 0.10 mm 0.004 in 0.51 mm 0.020 in Hydraulic Pump Support Bushing (009-037) Hydraulic Pump Support Bore I.D. 53.86 mm 2.121 in 53.92 mm…
  • Page 610
    Drive Units — Torque Values Page V-40 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Drive Units — Torque Values Rear Gear Drive (Lower Assembly) (009-023) Drain Plugs 100 N•m 75 ft-lb 11 N•m 8 in-lb 20 N•m 15 ft-lb Rear Gear Drive Capscrews Step 1…
  • Page 611
    Drive Units — Torque Values Section V — Specifications Page V-41 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Adapter 95 N•m 70 ft-lb Cover Plate SAE C/SAE B Drive 95 N•m 70 ft-lb Cover Plate SAE A Drive 40 N•m 35 ft-lb 40 N•m 30 ft-lb…
  • Page 612
    Air Intake System — Specifications Page V-42 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Air Intake System — Specifications Aftercooler Assembly (010-002) Air Pressure 415 kPa 60 psi Turbocharger, Water-Cooled (010-037) Turbocharger End Clearance 0.05 mm 0.002 in 0.13 mm 0.005 in…
  • Page 613
    Air Intake System — Torque Values Section V — Specifications Page V-43 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Air Intake System — Torque Values Aftercooler Assembly (010-002) 35 N•m 25 ft-lb Step 1 35 N•m 25 ft-lb Step 2 50 N•m 35 ft-lb Turbocharger Heat Shield (010-076)
  • Page 614
    Exhaust System — Specifications Page V-44 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Exhaust System — Specifications Exhaust Manifold, Dry (011-007) Exhaust Manifold Capscrew Holes 191.5 mm 7.54 in 193.5 mm 7.62 in…
  • Page 615
    Electrical Equipment — Specifications Section V — Specifications Page V-45 Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Electrical Equipment — Specifications Drive Belt, Alternator (013-005) Alternator Belt Tension 670 N 150 lbf…
  • Page 616
    Engine Testing — Specifications Page V-46 Section V — Specifications Component or Assembly (Procedure) Ref.No./Steps Metric U.S. Engine Testing — Specifications Engine Testing (Chassis Dynamometer) (014-005) Maximum Coolant Pressure with Closed Thermostat and No Pressure Cap 241 kPa 35 psi Hose Temperature (Minimum) 260 °C 500 °F…
  • Page 617
    Drive Belt Tension Section V — Specifications Page V-47 Drive Belt Tension SAE Belt Size Belt Tension Gauge Part No. Belt Tension New Belt Tension Range Used* Click-type Burroughs 0.380 in 3822524 270 to 490 60 to 110 0.440 in 3822524 270 to 490 60 to 110…
  • Page 618
    Capscrew Markings and Torque Values Page V-48 Section V — Specifications Capscrew Markings and Torque Values CAUTION When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew being replaced. Using the wrong capscrews can result in engine damage. Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface of the nuts.
  • Page 619
    Capscrew Markings and Torque Values Section V — Specifications Page V-49 Capscrew Markings and Torque Values — Metric Body Size Torque Torque Torque Diam. Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb…
  • Page 620
    Capscrew Markings and Torque Values Page V-50 Section V — Specifications Capscrew Markings and Torque Values — U.S. Customary Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum N•m ft-lb N•m ft-lb N•m ft-lb N•m ft-lb 1/4 — 20 — 28 5/16 — 18 — 24 3/8 — 16…
  • Page 621
    Fraction, Decimal, Millimeter Conversions Section V — Specifications Page V-51 Fraction, Decimal, Millimeter Conversions Fraction inch Fraction inch 1/64 0.0156 0.397 33/64 0.5156 13.097 1/32 0.0313 0.794 17/32 0.5313 13.494 3/64 0.0469 1.191 35/64 0.5469 13.891 1/16 0.0625 1.588 9/16 0.5625 14.288 5/64…
  • Page 622
    Newton-Meter to Foot-Pound Conversion Chart Page V-52 Section V — Specifications Newton-Meter to Foot-Pound Conversion Chart N•m ft-lb N•m ft-lb N•m ft-lb 8.850756 in-lb 44 in-lb 53 in-lb 62 in-lb 71 in-lb 80 in-lb 89 in-lb 0.737562 ft-lb NOTE: To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803. g-01 (newton)
  • Page 623
    Pipe Plug Torque Values Section V — Specifications Page V-53 Pipe Plug Torque Values Size Torque Torque In Cast Iron or Thread Actual Thread O.D. In Aluminum Components Steel Components N•m ft-lb N•m ft-lb 1/16 0.32 45 in-lb 0.41 0.54 0.68 0.85 1.05…
  • Page 624
    Tap-Drill Chart — U.S. Customary and Metric Page V-54 Section V — Specifications Tap-Drill Chart — U.S. Customary and Metric g-01 (tap)
  • Page 625
    Weights and Measures — Conversion Factors Section V — Specifications Page V-55 Weights and Measures — Conversion Factors Quantity U.S. Customary Metric From U.S. From Metric Customary To U.S. To Metric Customary Multiply By Multiply By Unit Name Abbr. Unit Name Abbr.
  • Page 626
    Weights and Measures — Conversion Factors Page V-56 Section V — Specifications NOTES…
  • Page 627
    Index Page 1 About the Manual…………..i-1 Complete Engine — Torque Values ……….. V-3 Accessory Drive Pulley …………9-3 Engine Assembly …………..V-3 Inspect for Reuse …………..9-3 Engine Disassembly …………… V-3 Install ………………9-3 Component Manufacturers’ Addresses ……..M-1 Remove ……………..
  • Page 628
    Leak Test…………….1-51 Disassembly …………..0-8 Measure …………….1-49 Engine Identification …………… E-1 Cylinder Block Counterbore ……….1-65 Cummins Engine Nomenclature ……….E-1 Machine …………….1-65 ECM Dataplate …………..E-1 Cylinder Head …………….2-5 Engine Dataplate …………..E-1 Assemble …………….2-14 Engine Run-in (Chassis Dynamometer)…….
  • Page 629
    Index Page 3 Engine Testing (Chassis Dynamometer) ……14-11 Clean ………………6-4 Setup …………….. 14-11 Inspect for Reuse …………..6-5 Test ………………14-14 Fuel Control Supply Line………… 6-5 Engine Testing (Engine Dynamometer) ……. 14-31 Fuel Inlet Line …………..6-6 Install …………….. 14-31 Fuel Rail Supply Line…………
  • Page 630
    Index Page 4 General Information …………. 7-13 Assemble …………….3-14 Inspect for Reuse …………..7-13 Clean ………………. 3-12 Lubricating Oil Filter Head (Remote-Mounted) …… 7-11 Disassemble ……………. 3-13 Assemble …………….7-12 Exploded View …………..3-10 Clean ………………. 7-12 Inspect for Reuse …………..3-12 Disassemble ……………..
  • Page 631
    Index Page 5 Inspect …………….. 2-19 Inspect for Reuse …………..2-18 Install ………………. 2-19 Remove …………….2-18 Valve Seat Bore …………..2-20 Initial Check …………….. 2-20 Valve Seat Insert, Cylinder Head ……….. 2-20 Grind ………………2-21 Install ………………. 2-21 Remove …………….2-20 Vibration Damper …………..
  • Page 632
    IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO. 15, COLUMBUS INDIANA –POSTAGE WILL BE PAID BY ADDRESSEE— CUMMINS ENGINE COMPANY, INC. MAIL CODE 41302 BOX 3005 COLUMBUS, IN 47202-3005 Do not use this form to order additional literature. Refer to…
  • Page 633
    Literature Survey Form 3666232-00 Bulletin No.: We are always open to any suggestions or recommendations that will aid in improving our manuals. Use this postage paid survey form to evaluate this manual. Please check the appropriate response and use the space provided below to list any additional comments: Is the needed information easy to locate in the manual? Is the information easy to read? Is the information easy to understand?
  • Page 634
    Cummins Engine Company, Inc. Box 3005 Columbus, Indiana, U.S.A., 47202 Cable: CUMDIEX COLUMBUS Registered Office Cummins Engine Company, Ltd. 46-50 Coombe Road New Malden, Surrey KT3 4QL, England Cable: CUMEUR G Registration No. 573951 England Copyright 1997 Cummins Engine Company, Inc.
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