Cummins K19 Series Diesel Engine Troubleshooting and Repair Manual – PDF DOWNLOAD

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Cummins K19 Series Diesel Engine Troubleshooting and Repair Manual

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Cummins K19 Series Diesel Engine Troubleshooting and Repair Manual

Language : English
Pages : 713
Downloadable : Yes
File Type : PDF
Size: 41.3 MB
Book Code: 3810307-00

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DESCRIPTION:

Cummins K19 Series Diesel Engine Troubleshooting and Repair Manual

FOREWORD:

This manual provides instructions for troubleshooting and repairing the K19 Engine in the chassis. Component and assembly rebuild procedure are provided in the K19 Engine Shop Manual. The manual is organized to guide a service technician through the logical steps of identifying and correcting problems related to the engine. This manual does not cover vehicle or equipment problems. Consult the vehicle or equipment manufacturer for repair procedures.

• A series of specific service manuals (Shop, Specifications, Alternative Repair, and so on.) are available and can be ordered by filling out and mailing the Literature Order Form located in the Service Literature Section 14. The repair procedures used in this manual are recommended by Cummins Engine Co., Inc. Some service procedures require the use of special service tools.
• Use the correct tools as described. Reporting of errors, omissions, and recommendations for improving this publication by the user is encouraged. Please use the postage paid, self addressed Literature Survey Form in the back of this manual for communicating your comments.
• 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, A Cummins Division Office, or the factory The latest technology and the highest quality components were used to produce this engine. When replacement parts are needed, we recommend using only genuine Cummins or ReConT exchange parts.

TABLE OF CONTENTS:

Cummins K19 Series Diesel Engine Troubleshooting and Repair Manual

MAIN MENU................................................................................  0
COVER PAGE...............................................................................  1
FOREWORD.................................................................................  3
TABLE OF CONTENTS........................................................................  4
SECTION I - INTRODUCTION.................................................................  6
	ABOUT THE MANUAL.....................................................................  7
	HOW TO USE THE MANUAL................................................................  7
	SYMBOLS..............................................................................  8
	SIMBOLOS.............................................................................  9
	SYMBOLE.............................................................................. 10
	SYMBOLES............................................................................. 11
	ILLUSTRATIONS........................................................................ 12
	GENERAL SAFETY INSTRUCTIONS.......................................................... 13
		IMPORTANT SAFETY NOTICE.......................................................... 13
	GENERAL REPAIR INSTRUCTIONS.......................................................... 14
	GENERAL CLEANING INSTRUCTIONS........................................................ 15
		SOLVENT AND ACID CLEANING........................................................ 15
		STEAM CLEANING................................................................... 15
		GLASS OR PLASTIC BEAD CLEANING................................................... 15
	DEFINITION OF TERMS.................................................................. 16
SECTION E - ENGINE AND COMPONENT IDENTIFICATION.......................................... 20
	ENGINE IDENTIFICATION................................................................ 21
		CUMMINS ENGINE NOMENCLATURE...................................................... 21
		ENGINE DATAPLATE................................................................. 21
		FUEL PUMP DATAPLATE.............................................................. 21
	GENERAL SPECIFICATIONS............................................................... 22
		GENERAL ENGINE DATA.............................................................. 23
		AIR INDUCTION SYSTEM............................................................. 24
		LUBRICATING OIL SYSTEM........................................................... 24
		COOLING SYSTEM................................................................... 24
		EXHAUST SYSTEM................................................................... 24
		FUEL SYSTEM...................................................................... 25
		ELECTRICAL SYSTEM................................................................ 25
	EXTERNAL ENGINE COMPONENTS........................................................... 26
SECTION T - TROUBLESHOOTING.............................................................. 28
	PROCEDURES AND TECHNIQUES............................................................ 28
	TROUBLESHOOTING CHARTS  (ALPHABETICAL LISTING)....................................... 29
	TROUBLESHOOTING CHARTS (BY SYSTEM)................................................... 31
	COOLANT TEMPERATURE ABOVE NORMAL..................................................... 33
	COOLANT TEMPERATURE BELOW NORMAL..................................................... 35
	COOLANT LOSS......................................................................... 36
	FUEL IN COOLANT...................................................................... 37
	LUBRICATING OIL PRESSURE LOW......................................................... 38
	LUBRICATING OIL PRESSURE HIGH........................................................ 40
	LUBRICATING OIL TEMPERATURE ABOVE NORMAL............................................. 41
	LUBRICATING OR HYDRAULIC OIL IN THE COOLANT.......................................... 42
	LUBRICATING OIL CONSUMPTION EXCESSIVE................................................ 43
	LUBRICATING OIL SLUDGE IN THE ENGINE CRANKCASE EXCESSIVE............................. 45
	COOLANT IN THE LUBRICATING OIL....................................................... 46
	FUEL IN THE LUBRICATING OIL.......................................................... 47
	TURBOCHARGER NOISE................................................................... 48
	TURBOCHARGER BOOST PRESSURE LOW...................................................... 49
	TURBOCHARGER LEAKS (ENGINE OIL OR FUEL).............................................. 50
	AIR COMPRESSOR SLOW AIR PRESSURE RISE................................................ 51
	AIR COMPRESSOR WILL NOT MAINTAIN ADEQUATE AIR PRESSURE (NOT PUMPING CONTINUOUSLY).... 52
	AIR COMPRESSOR PUMPING EXCESSIVE LUBRICATING OIL..................................... 53
	AIR COMPRESSOR WILL NOT PUMP......................................................... 54
	AIR COMPRESSOR WILL NOT STOP PUMPING................................................. 55
	AIR COMPRESSOR NOISE EXCESSIVE....................................................... 56
	ENGINE CRANKS BUT WILL NOT START (NO SMOKE FROM EXHAUST)............................. 57
	ENGINE HARD TO START OR WILL NOT START (EXHAUST SMOKE PRESENT)....................... 59
	ENGINE STARTS BUT WILL NOT KEEP RUNNING.............................................. 60
	ENGINE RUNS ROUGH OR MISFIRES (WARM ENGINE).......................................... 62
	IDLE ROUGH........................................................................... 64
	ENGINE SURGES AT LOW IDLE............................................................ 65
	ENGINE WILL NOT REACH RATED RPM WHEN LOADED.......................................... 66
	ENGINE POWER OUTPUT LOW.............................................................. 67
		APPLICATION SPECIFIC PROBLEM - CONSTRUCTION...................................... 69
		APPLICATION SPECIFIC PROBLEM - GENSET ........................................... 69
		APPLICATION SPECIFIC PROBLEM - MARINE............................................ 70
	PERFORMANCE MEASUREMENT.............................................................. 71
	EXHAUST SMOKE EXCESSIVE UNDER LOAD................................................... 73
	ENGINE WILL NOT SHUT OFF............................................................. 74
	ENGINE DECELERATES POORLY............................................................ 75
	ENGINE SURGES UNDER LOAD............................................................. 76
	ENGINE SURGES AT HIGH IDLE........................................................... 77
	THROTTLE RESPONSE SLOW (ENGINE DIES GOING DOWN HILL)................................. 78
	FUEL CONSUMPTION EXCESSIVE........................................................... 79
	ENGINE WILL NOT CRANK OR CRANKS SLOWLY (AIR STARTER)................................. 80
	ENGINE WILL NOT CRANK OR CRANKS SLOWLY (ELECTRIC STARTER)............................ 81
	ALTERNATOR MALFUNCTIONING............................................................ 83
	CRANKCASE GASES (BLOWBY) EXCESSIVE................................................... 84
	ENGINE VIBRATION EXCESSIVE........................................................... 85
	ENGINE NOISE - DIAGNOSTIC PROCEDURES................................................. 86
		MAIN BEARING NOISE............................................................... 86
		CONNECTING ROD BEARING NOISE..................................................... 86
		PISTON NOISE..................................................................... 86
	ENGINE NOISE EXCESSIVE............................................................... 87
	EXHAUST SMOKE (WHITE) AT IDLE EXCESSIVE (WARM ENGINE)................................ 89
SECTION 1 - COOLING SYSTEM............................................................... 92
	SERVICE TOOLS (01-00)................................................................ 93
	GENERAL INFORMATION (01-01).......................................................... 94
	COOLING SYSTEM SPECIFICATIONS (01-02)................................................ 95
	COOLING SYSTEM FLOW CHARTS (01-03)...................................................100
	COOLING SYSTEM VENTING (01-04).......................................................102
	COOLING SYSTEM - MAINTENANCE (01-05).................................................103
	COOLING SYSTEM - DRAIN (01-06).......................................................104
	COOLING SYSTEM - FILL (01-07)........................................................105
	COOLANT FILTER - REPLACE (01-08).....................................................107
	DIESEL COOLANT ADDITIVES (DCA4) (01-09)..............................................108
	COOLING SYSTEM - CLEAN (01-10).......................................................112
	COOLING SYSTEM - TEST FOR AIR OR COMBUSTION GASES (01-11)............................112
	CRACKED OR POROUS CYLINDER LINER.....................................................114
	DEFECTIVE AIR CONTROL VALVE..........................................................116
	AIR COMPRESSOR CHECK.................................................................116
	COOLING SYSTEM - PRESSURE TEST (01-12)...............................................117
	HOSES - CHECK (01-13)................................................................120
	COOLANT TEMPERATURE GAUGE - CHECK (01-14)............................................120
	RADIATOR PRESSURE CAP - CHECK (01-15)................................................121
	RADIATOR FINS - INSPECT (01-16)......................................................121
	RADIATOR BAFFLE LEAKAGE - CHECK (01-17)..............................................122
	RADIATOR - CHECK FOR REVERSE FLOW (01-18)............................................122
	RADIATOR - CHECK FOR OBSTRUCTION (01-19).............................................123
	SHUTTER OPERATION - CHECK (01-20)....................................................124
	FAN, AND FAN SHROUD - INSPECT (01-21)................................................126
	FAN - REPLACE (01-22)................................................................127
	FAN DRIVE BELT - REPLACE (01-23).....................................................128
	FAN CLUTCH - CHECK OPERATION (01-24).................................................130
	FAN RPM - CHECK (01-25)..............................................................133
	FAN HUB (BELT DRIVEN) - REPLACE (01-26)..............................................135
	FAN HUB (GEAR DRIVEN) - REPLACE (01-27)..............................................136
	FAN HUB IDLER AND SHOCK ABSORBER (OR TURNBUCKLE) - REPLACE (01-28)...................138
	WATER PUMP BLOCK PRESSURE - CHECK (01-29)............................................140
	WATER PUMP - REPLACE (01-30).........................................................142
	WATER PUMP - CHECK FOR REUSE (01-31).................................................146
	THERMOSTAT - TEST (THERMOSTAT IN CHASSIS) (01-32)....................................147
	THERMOSTAT - REPLACE (01-33).........................................................149
	THERMOSTAT - CHECK OPERATING TEMPERATURE (01-34).....................................153
	THERMOSTAT HOUSING - REPLACE (01-35).................................................154
	CHECK FOR COOLANT LEAKS AT COUNTERBORE (01-36).......................................157
SECTION 2 - LUBRICATION OIL SYSTEM.......................................................159
	SERVICE TOOLS (01-00)................................................................160
	GENERAL INFORMATION (02-01)..........................................................162
	SPECIFICATIONS (02-02)...............................................................163
	FLOW DIAGRAMS (02-03)................................................................164
	INTERNAL ENGINE DAMAGE - CHECK (02-04)...............................................167
	OIL LEAKS (EXTERNAL) - CHECKS (02-05)................................................168
	OIL SYSTEM - LEAK CHECK USING DYE (02-06)............................................169
	OIL PRESSURE GAUGE - CHECK (02-07)...................................................170
	OIL TEMPERATURE GAUGE - CHECK (02-08)................................................170
	DRAIN OIL (02-09)....................................................................171
	OIL PAN - FILL (02-10)...............................................................172
	OIL FILTERS (FULL FLOW AND BYPASS) - REPLACE (02-11).................................173
	OIL FILTER (FULL FLOW) - MEASURE PRESSURE DROP (02-12)...............................174
	CRANKCASE BREATHER AND TUBE - REPLACE (02-13)........................................175
	DIPSTICK TUBE - REPLACE (02-14)......................................................177
	DIPSTICK - CALIBRATE (02-15).........................................................177
	OIL PAN - REPLACE (02-16)............................................................179
	OIL PAN ADAPTER - REPLACE (02-17)....................................................181
	OIL FILTER HEAD - REPLACE (02-18)....................................................188
	OIL COOLER - MEASURE PRESSURE DROP (02-19)...........................................190
	OIL COOLER COVER - REPLACE (02-20)...................................................191
	TORQUE CONVERTER COOLER - REPLACE (02-21)............................................195
	OIL COOLER CORE - REPLACE (02-22)....................................................200
	OIL COOLER CORE - CHECK FOR REUSE (02-23)............................................201
	TORQUE CONVERTER COOLER - PRESSURE TEST (02-24)......................................201
	OIL COOLER HOUSING - REPLACE (02-25).................................................202
	MAIN OIL PRESSURE REGULATOR - REPLACE (02-26)........................................205
	OIL PUMP - REPLACE (02-27)...........................................................207
	LUBRICATING OIL PUMP - CHECK FOR REUSE (02-28).......................................209
SECTION 3 - COMBUSTION AIR SYSTEM........................................................211
	GENERAL INFORMATION (03-01)..........................................................212
	SPECIFICATIONS (03-02)...............................................................213
	FLOW DIAGRAMS (03-03)................................................................214
	SERVICE TOOLS (03-04)................................................................216
	TURBOCHARGER TURBINE SEAL LEAKS - CHECK (03-05)......................................217
	COMPRESSOR SEAL LEAKAGE - CHECK (03-06)..............................................219
	CORRECT TURBOCHARGER INSTALLED - CHECK (03-07).......................................221
	INTAKE AIR RESTRICTION - CHECK (03-08)...............................................221
	EXHAUST RESTRICTION - CHECK (03-09)..................................................223
	AIR LEAKS - CHECK (03-10)............................................................224
	TURBOCHARGER BLADE DAMAGE - CHECK (03-11)............................................226
	TURBOCHARGER AXIAL AND RADIAL CLEARANCE - CHECK (03-12)..............................227
	TURBOCHARGER - REPLACE (03-13).......................................................228
	SERIES TURBOCHARGER - REPLACE (03-14)................................................234
	EXHAUST MANIFOLD - REPLACE (03-15)...................................................242
	EXHAUST MANIFOLD - CHECK (03-16).....................................................247
	AFTERCOOLER - REPLACE (03-17)........................................................248
	AFTERCOOLER ELEMENT - REPLACE (03-18)................................................254
	AFTERCOOLER ELEMENT - TEST (03-19)...................................................258
	INTAKE MANIFOLD PRESSURE - CHECK (03-20).............................................259
SECTION 4 - COMPRESSED AIR SYSTEM........................................................261
	GENERAL INFORMATION (04-01)..........................................................262
	SPECIFICATIONS (04-02)...............................................................263
	FLOW DIAGRAMS (04-03)................................................................265
	SERVICE TOOLS (04-04)................................................................266
	CARBON BUILDUP, AIR COMPRESSOR - CHECK (04-05).......................................267
	GASKET LEAKS, AIR COMPRESSOR - CHECK (04-06).........................................269
	AIR GOVERNOR - CHECK (AIR COMPRESSOR NOT PUMPING) (04-07)............................269
	AIR GOVERNOR - CHECK (AIR COMPRESSOR PUMPS CONTINUOUSLY) (04-08).....................270
	LUBRICATING OIL USAGE, AIR COMPRESSOR - CHECK (04-09)................................272
	UNLOADER VALVE, AIR COMPRESSOR - REPLACE (04-10).....................................273
	UNLOADER VALVE - CHECK (04-11).......................................................276
	INTAKE/EXHAUST VALVES, AIR COMPRESSOR - CHECK (04-12)................................277
	CYLINDER HEAD, AIR COMPRESSOR - REBUILD ON ENGINE (04-13)............................279
	CYLINDER HEAD, AIR COMPRESSOR - REPLACE (04-14)......................................283
	AIR COMPRESSOR (SINGLE CYLINDER) - REPLACE (04-15)...................................287
	AIR COMPRESSOR (TWO CYLINDER) - REPLACE (04-16)......................................290
	AIR COMPRESSOR - CHECK FOR REUSE (04-17).............................................294
SECTION 5 - FUEL SYSTEM..................................................................297
	GENERAL INFORMATION (05-01)..........................................................298
	SPECIFICATIONS 05-02)................................................................299
	FLOW DIAGRAMS (05-03)................................................................304
	SERVICE TOOLS (05-04)................................................................310
	IDLE SPEED - CHECK AND ADJUST (05-05)................................................315
	HORSEPOWER - MEASURE ENGINE PERFORMANCE (05-06)......................................318
	FUEL RATE - ADJUST (05-07)...........................................................324
	AFC NO-AIR VALVE SETTING - CHECK AND ADJUST (05-08)..................................326
	INJECTORS - REPLACE (05-09)..........................................................330
	INJECTORS - CLEAN EXTERIOR FOR REUSE (05-10).........................................335
	FUEL PUMP - REPLACE (05-11)..........................................................335
	THROTTLE TRAVEL - CHECK (05-12)......................................................339
	FUEL SYSTEM MAINTENANCE (05-13)......................................................340
	GEAR PUMP CHECK VALVE - REPLACE (05-14)..............................................343
	VARIABLE SPEED (VS) GOVERNOR LEAKING FUEL (05-15)....................................344
	FUEL SHUTOFF VALVE - CHECK (05-16)...................................................347
	FUEL PUMP - FLOW CHECK AND PRIME (05-17).............................................349
	FUEL PUMP ROTATION CHECK (05-18).....................................................351
	AIR LEAKS (05-19)....................................................................352
	AFC - CHECK FOR AIR LEAK (05-20).....................................................356
	CYLINDER MISFIRE (05-21).............................................................360
	ENGINE OIL DILUTION BY FUEL (05-22)..................................................361
	FUEL LINE RESTRICTION (SUCTION) - CHECK (05-23)......................................365
	FUEL DRAIN RESTRICTION - CHECK (05-24)...............................................367
	STC OIL CONTROL VALVE - CHECK (05-25)................................................369
	STC FUEL PRESSURE SWITCH - CHECK (05-26).............................................371
	STC WIRING HARNESS - CHECK FOR REUSE (05-27).........................................372
	STC OIL CONTROL VALVE - REPLACE (05-28)..............................................373
	STC WIRING HARNESS - REPLACE (05-29).................................................375
	FUEL CONSUMPTION CHECK (05-30).......................................................375
	LOW POWER CHECK (05-31)..............................................................380
	ENGINE STALL SPEED AND TIME CHECK (05-32)............................................382
	FUEL MANIFOLD - REPLACE (05-33)......................................................386
	STC OIL MANIFOLD - REPLACE (05-34)...................................................388
	STALL SPEED CHECK LIST (05-35).......................................................389
	DRIVEABILITY - LOW POWER CHECK LIST (05-36)..........................................391
	FUEL CONSUMPTION CHECK LIST (05-37)..................................................394
SECTION 6 - ELECTRICALSYSTEM.............................................................397
	GENERAL INFORMATION (06-01)..........................................................398
	SPECIFICATIONS (06-02)...............................................................399
	SERVICE TOOLS (06-03)................................................................400
	BATTERY TERMINAL CONNECTIONS - CHECK (06-04).........................................401
	BATTERIES - CHECK (06-05)............................................................401
	STARTING CIRCUIT - CHECK (06-06).....................................................402
	ALTERNATOR BELT - ADJUST (06-07).....................................................408
	ALTERNATOR - OUTPUT TEST (06-08).....................................................410
	ALTERNATOR - REPLACE (06-09).........................................................411
	ACCESSORY/ALTERNATOR DRIVE PULLEY - CHECK FOR REUSE (06-10)..........................414
	STARTING MOTOR - REPLACE (06-11).....................................................414
	STARTER MOTOR - CHECK FOR REUSE (06-12)..............................................415
SECTION 7 - BASE ENGINE COMPONENTS.......................................................417
	SERVICE TOOLS (07-01)................................................................419
	GENERAL INFORMATION (07-02)..........................................................425
	CRANKCASE GAS (BLOWBY) - CHECK (07-03)...............................................425
	ROCKER LEVER COVER - REPLACE (07-04).................................................429
	CHECK/ADJUST VALVES AND INJECTORS (07-05)............................................433
	JACOBS ENGINE BRAKE - ADJUST (07-06).................................................442
	JACOBS ENGINE BRAKE - REPLACE (07-07)................................................445
	PUSH ROD - REPLACE (07-08)...........................................................447
	ROCKER LEVER ASSEMBLY - REPLACE (07-09)..............................................449
	ROCKER LEVER ASSEMBLY - CLEAN AND CHECK FOR REUSE (07-10)............................451
	ROCKER LEVER HOUSING - REPLACE (07-11)...............................................453
	CHECK CYLINDER HEAD GASKET FOR COMBUSTION, COOLANT, OR OIL LEAK (07-12)..............459
	POWER CYLINDER - LOCATE FAILED CYLINDER (07-13)......................................461
	CYLINDER HEAD GASKET - REPLACE (07-14)...............................................463
	CYLINDER HEAD - CLEAN AND CHECK FOR REUSE (07-15)....................................474
	PRESSURE TEST CYLINDER HEAD - HEAD REMOVED (07-16)...................................476
	CAM FOLLOWER ASSEMBLY - REPLACE (07-17)..............................................480
	CAM FOLLOWER ASSEMBLY - CLEAN AND CHECK FOR REUSE (07-18)............................484
	INJECTION TIMING - GENERAL INFORMATION (07-19).......................................485
	MEASURE THE INJECTION TIMING (07-20).................................................487
	PISTON COOLING NOZZLE - REPLACE (07-21)..............................................496
	MAIN CRANKSHAFT BEARING - REPLACE (07-22)............................................496
	CONNECTING ROD BEARING - REPLACE (07-23).............................................504
	PISTON AND ROD ASSEMBLY - REPLACE (07-24)............................................509
	PISTON - CLEAN AND CHECK FOR REUSE (07-25)...........................................521
	CYLINDER LINER - REMOVE (07-26)......................................................524
	CHECK LINER PROTRUSION (07-27).......................................................535
	ACCESSORY DRIVE PULLEY - REPLACE (07-28).............................................536
	WEAR SLEEVE, ACCESSORY DRIVE PULLEY - REPLACE (07-29)................................537
	ACCESSORY DRIVE SEAL - REPLACE (07-30)...............................................539
	ACCESSORY DRIVE ASSEMBLY - REPLACE (07-31)...........................................541
	FUEL PUMP/COMPRESSOR DRIVE - CLEAN AND CHECK FOR REUSE (07-32).......................545
	VIBRATION DAMPER - REPLACE (07-33)...................................................545
	VISCOUS VIBRATION DAMPER - CLEAN AND CHECK FOR REUSE (07-34).........................548
	RUBBER VIBRATION DAMPER - CLEAN AND CHECK FOR REUSE (07-35)..........................549
	CRANKSHAFT FRONT SEAL - REPLACE (07-36)..............................................550
	WATER PUMP DRIVE - REPLACE (07-37)...................................................553
	WATER PUMP DRIVE - CLEAN AND CHECK FOR REUSE (07-38).................................557
	GEAR COVER (ONE PIECE) - REPLACE (07-39).............................................557
	CAMSHAFT GEAR - REPLACE (CAMSHAFT INSTALLED) (07-40).................................571
	GEAR COVER PLATE (SPACER PLATE) - REPLACE (07-41)....................................576
	GEAR COVER  (TWO PIECE) - REPLACE (07-42)............................................582
	GEAR HOUSING (TWO PIECE DESIGN) - REPLACE (07-43)....................................592
	CHECK GEAR TRAIN BACKLASH (07-44)....................................................604
	IDLER SHAFT (PRESS-IN) - REPLACE (07-45).............................................604
	FRONT ENGINE SUPPORT - REPLACE (07-46)...............................................607
	CRANKSHAFT GEAR - REMOVE AND INSTALL (07-47).........................................609
	CAMSHAFT - REPLACE (07-48)...........................................................611
	CAMSHAFT GEAR - REMOVE AND INSTALL (07-49)...........................................620
	CYLINDER BLOCK - REPLACE CAMSHAFT BUSHINGS (07-50)...................................623
	CAMSHAFT REAR COVER - REPLACE (07-51)................................................625
	FLYWHEEL - REPLACE (07-52)...........................................................626
	CRANKSHAFT SEAL, REAR - REPLACE (07-53)..............................................629
	FLYWHEEL HOUSING - REPLACE (07-54)...................................................630
	FLYWHEEL HOUSING REDOWEL TO CYLINDER BLOCK (07-55)...................................639
	PIPE PLUGS AND CUP PLUGS - REPLACE (07-56)...........................................643
SECTION 8 - ENGINE TESTING ("IN-CHASSIS")................................................647
	SPECIFICATIONS AND PROCEDURES (08-01)................................................648
	GENERAL ENGINE TEST PROCEDURES (08-01)...............................................649
	CHASSIS DYNAMOMETER OPERATION (08-02)................................................651
	ENGINE RUN-IN PROCEDURE (CHASSIS DYNAMOMETER) (08-03)................................653
	ENGINE RUN-IN PROCEDURE "IN-CHASSIS" (ON AND OFF-HIGHWAY VEHICLES) (08-04)...........656
	ENGINE CONFIGURATIONS AND MODELS (08-05).............................................658
SECTION 9 - ENGINE REMOVE AND INSTALL....................................................661
	GENERAL INFORMATION (09-01)..........................................................662
	SERVICE TOOLS (09-02)................................................................663
	ENGINE - REMOVE (09-03)..............................................................664
	ENGINE MOUNT - INSPECT (09-04).......................................................667
	ENGINE - INSTALL (09-05).............................................................667
SECTION 10 - ENGINE COMPONENT SPECIFICATIONS.............................................671
	GENERAL INFORMATION (10-01)..........................................................672
	CONVERSION FACTORS (10-02)...........................................................673
	PIPE PLUG TORQUE VALUES (10-03)......................................................674
	CAPSCREW MARKINGS AND TORQUE VALUES (10-04)..........................................674
	DECIMAL AND METRIC EQUIVALENTS (10-05)...............................................676
	COOLING SYSTEM (10-06)...............................................................677
	LUBRICATING OIL SYSTEM (10-07).......................................................680
	COMBUSTION AIR SYSTEM (10-08)........................................................682
	COMPRESSED AIR SYSTEM (10-09)........................................................684
	FUEL SYSTEM (10-10)..................................................................686
	ELECTRICAL SYSTEM (10-11)............................................................687
	BASE ENGINE COMPONENTS (10-12).......................................................688
SECTION 11 - INDEX - TROUBLESHOOTING AND REPAIR..........................................697
SECTION 12 - SERVICE LITERATURE..........................................................706
	SERVICE LITERATURE ORDERING LOCATION.................................................707
	SERVICE LITERATURE ORDER FORM........................................................708
SECTION 13 - COMPONENT MANUFACTURERS.....................................................710

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• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.