Cummins QSK19 Series Engine Shop Manual – PDF DOWNLOAD

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Cummins QSK19 Series Engine Shop Manual – PDF DOWNLOAD

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Cummins QSK19 Series Engine Shop Manual – PDF DOWNLOAD

Language : English
Pages : 634
Downloadable : Yes
File Type : PDF
Size: 11.2 MB

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Cummins QSK19 Series Engine Shop Manual – PDF DOWNLOAD

The Cummins QSK19 is a heavy-duty diesel engine designed for use in a wide range of applications, including construction, mining, and power generation. The QSK19 series was introduced in the late 1990s and has since become a popular choice for many heavy equipment manufacturers.

The Cummins QSK19 engine shop manual is a comprehensive guide to the maintenance, repair, and overhaul of this powerful engine. The manual is organized into sections that cover everything from engine disassembly and reassembly to troubleshooting and fault diagnosis.

One of the key features of the QSK19 engine is its electronic control system, which is designed to optimize performance, fuel efficiency, and emissions. The shop manual provides detailed information on this system, including wiring diagrams and diagnostic procedures.

Other important topics covered in the manual include:

• Engine specifications and operating characteristics
• Lubrication system components and operation
• Cooling system components and operation
• Air intake and exhaust systems
• Fuel system components and operation
• Engine brakes and retarders
• Electrical system components and operation
• Overhaul procedures, including cylinder head removal and installation, piston and connecting rod removal and installation, and crankshaft and bearing removal and installation.

The manual is richly illustrated with detailed diagrams and photographs, making it easy to follow along with the procedures and understand the various engine components. In addition to the step-by-step instructions, the manual also includes important safety precautions and tips for avoiding common mistakes.

Overall, the Cummins QSK19 engine shop manual is an essential resource for anyone who works with or maintains these powerful diesel engines. With its comprehensive coverage and detailed instructions, it provides a valuable reference for diagnosing and repairing engine issues, as well as for performing routine maintenance and overhauls.

TABLE OF CONTENTS:

Cummins QSK19 Series Engine Shop Manual – PDF DOWNLOAD

MAIN MENU……………………………………………………. 0
TABLE OF CONTENTS…………………………………………….. 3
INTRODUCTION…………………………………………………. 4
ABOUT THE MANUAL………………………………………….. 5
GENERAL CLEANING INSTRUCTIONS………………………………. 13
GLASS OR PLASTIC BEAD CLEANING………………………….. 13
SOLVENT AND ACID CLEANING………………………………. 13
STEAM CLEANING………………………………………… 13
GENERAL REPAIR INSTRUCTIONS………………………………… 12
WELDING ON A VEHICLE WITH ELECTRONIC COMPONENTS…………… 12
GENERAL SAFETY INSTRUCTIONS………………………………… 4
IMPORTANT SAFETY NOTICE………………………………… 4
HOW TO USE THE MANUAL……………………………………… 5
ILLUSTRATIONS…………………………………………….. 10
SYMBOLS………………………………………………….. 6
ENGINE IDENTIFICATION…………………………………………. 15
ENGINE DIAGRAMS…………………………………………… 21
ENGINE VIEWS………………………………………….. 21
ENGINE IDENTIFICATION……………………………………… 16
CUMMINS ENGINE NOMENCLATURE…………………………….. 16
ECM DATAPLATE…………………………………………. 16
ENGINE DATAPLATE………………………………………. 16
SPECIFICATIONS……………………………………………. 17
AIR INTAKE SYSTEM……………………………………… 17
BATTERIES (SPECIFICATION GRAVITY)……………………….. 20
COOLING SYSTEM………………………………………… 19
ELECTRICAL SYSTEM……………………………………… 17
EXHAUST SYSTEM………………………………………… 19
FUEL SYSTEM…………………………………………… 17
GENERAL SPECIFICATIONS…………………………………. 17
LUBRICATING OIL SYSTEM…………………………………. 18
COMPLETE ENGINE – GROUP 00…………………………………….. 24
ENGINE ASSEMBLY…………………………………………… 82
ASSEMBLE……………………………………………… 82
ENGINE DIASSEMBLY…………………………………………. 32
DISASSEMBLE…………………………………………… 33
GENERAL INFORMATION……………………………………. 32
ASSEMBLY………………………………………….. 32
DISASSEMBLY……………………………………….. 32
SERVICE TOOLS…………………………………………….. 25
ENGINE DISASSEMBLY AND ASSEMBLY…………………………. 25
CYLINDER BLOCK – GROUP 01………………………………………179
BEARINGS, CONNECTING ROD……………………………………185
CLEAN…………………………………………………185
INSPECTION FOR REUSE……………………………………185
BEARINGS, MAIN…………………………………………….185
CLEAN…………………………………………………185
INSPECT FOR REUSE………………………………………186
MEASURE……………………………………………….186
BEARINGS, THRUST ………………………………………….186
ASSEMBLE………………………………………………187
INSPECT FOR REUSE………………………………………186
CAMSHAFT………………………………………………….187
CLEAN…………………………………………………187
INSPECT FOR REUSE………………………………………187
MAGNETIC CRACK INSPECTION……………………………….188
CAMSHAFT BUSHINGS………………………………………….195
INSPECT FOR REUSE………………………………………196
INSTALL……………………………………………….196
REMOVE………………………………………………..195
CAMSHAFT GEAR (CAMSHAFT REMOVED)…………………………….190
INSPECT FOR REUSE………………………………………191
INSTALL……………………………………………….194
MAGNETIC CRACK INSPECT………………………………….192
REMOVE………………………………………………..190
CONNECTING ROD…………………………………………….198
CLEAN…………………………………………………198
INSPECT FOR REUSE………………………………………198
MAGNETIC CRACK INSPECT………………………………….204
CRANKSHAFT………………………………………………..205
BEND AND TWIST INSPECTION……………………………….209
CLEAN…………………………………………………205
INSPECT FOR REUSE………………………………………206
MAGNETIC CRACK INSPECT………………………………….207
CRANKSHAFT GEAR, FRONT (CRANKSHAFT INSTALLED)…………………214
INSPECT FOR REUSE………………………………………215
INSTALL……………………………………………….215
REMOVE………………………………………………..214
CRANKSHAFT GEAR, REAR (CRANKSHAFT INSTALLED)………………….216
INSTALL……………………………………………….216
CRANKSHAFT PULLEY………………………………………….216
CLEAN…………………………………………………216
INSPECT FOR REUSE………………………………………217
CYLINDER BLOCK…………………………………………….218
CLEAN…………………………………………………219
INSPECT FOR REUSE………………………………………221
MAGNETIC CRACK INSPECT………………………………….225
WORKSHEET……………………………………………..218
CYLINDER BLOCK – GENERAL INFORMATION…………………………181
GENERAL INFORMATION…………………………………….181
CYLINDER BLOCK AND LINER SEATS………………………………227
GENERAL INFORMATION…………………………………….227
INSPECT FOR REUSE………………………………………227
LEAK TEST……………………………………………..231
MEASURE……………………………………………….229
CYLINDER BLOCK COUNTERBORE………………………………….245
MACHINE……………………………………………….245
CYLINDER LINER…………………………………………….231
CLEAN…………………………………………………231
INSPECT FOR REUSE………………………………………232
CYLINDER LINER PROTRUSION…………………………………..259
ADJUST………………………………………………..259
GEAR COVER ACCESSORY DRIVE BUSHING ………………………….260
INSTALL……………………………………………….260
REMOVE………………………………………………..260
GEAR COVER, FRONT………………………………………….235
CLEAN…………………………………………………235
INSPECT FOR REUSE………………………………………236
MEASURE……………………………………………….237
GEAR COVER SPACER PLATE…………………………………….235
CLEAN…………………………………………………235
INSPECT FOR REUSE………………………………………235
IDLER GEAR, CAMSHAFT……………………………………….237
CLEAN…………………………………………………237
INSPECT FOR REUSE………………………………………237
MAGNETIC CRACK INSPECT………………………………….238
IDLER GEAR, HYDRAULIC PUMP………………………………….239
CLEAN…………………………………………………239
INSPECT FOR REUSE………………………………………240
IDLER GEAR, WATER PUMP……………………………………..240
CLEAN…………………………………………………240
INSPECT FOR REUSE………………………………………240
PISTON……………………………………………………240
CLEAN…………………………………………………240
INSPECT FOR REUSE………………………………………241
SERVICE TOOLS……………………………………………..182
CYLINDER BLOCK…………………………………………182
VIBRATION DAMPER…………………………………………..243
CLEAN…………………………………………………243
INSPECT FOR REUSE………………………………………243
CYLINDER HEAD – GROUP 02……………………………………….261
CROSSHEAD…………………………………………………265
CLEAN…………………………………………………265
INSPECT FOR REUSE………………………………………265
CYLINDER HEAD……………………………………………..266
ASSEMBLE………………………………………………275
CLEAN…………………………………………………267
DISASSEMBLE……………………………………………274
EXPLODED VIEW………………………………………….266
INSPECT FOR REUSE………………………………………267
PRESSURE TEST………………………………………….269
VACUUM TEST……………………………………………271
CYLINDER HEAD – GENERAL INFORMATION………………………….262
GENERAL INFORMATION…………………………………….262
CYLINDER HEAD INJECTOR BORE…………………………………276
ADJUST………………………………………………..278
INSPECT FOR REUSE………………………………………276
SERVICE TOOLS……………………………………………..263
CYLINDER HEAD………………………………………….263
VALVE, CYLINDER HEAD……………………………………….283
GRIND…………………………………………………285
INSPECT FOR REUSE………………………………………284
INSTALL……………………………………………….287
LAP…………………………………………………..287
MAGNETIC CRACK INSPECT………………………………….284
REMOVE………………………………………………..283
VALVE GUIDE, CYLINDER HEAD………………………………….279
CLEAN…………………………………………………279
INSPECT……………………………………………….280
INSPECT FOR REUSE………………………………………279
INSTALL……………………………………………….280
REMOVE………………………………………………..279
VALVE SEAT BORE……………………………………………281
INITIAL CHECK………………………………………….281
VALVE SEAT INSERT, CYLINDER HEAD…………………………….281
GRIND…………………………………………………282
INSTALL……………………………………………….282
REMOVE………………………………………………..281
ROCKER LEVERS – GROUP – 03……………………………………..290
CRANKCASE BREATHER (EXTERNAL)……………………………….294
CLEAN…………………………………………………295
INSTALL……………………………………………….296
REMOVE………………………………………………..294
ROCKER LEVER………………………………………………297
ASSEMBLE………………………………………………299
DISASSEMBLE……………………………………………297
MAGNETIC CRACK INSPECT………………………………….298
ROCKER LEVER ASSEMBLY………………………………………300
ASSEMBLE………………………………………………304
CLEAN…………………………………………………302
DISASSEMBLE……………………………………………303
EXPLODED VIEW………………………………………….300
INSPECT FOR REUSE………………………………………302
ROCKER LEVER BUSHINGS………………………………………304
INSTALL……………………………………………….304
REMOVE………………………………………………..304
ROCKER LEVER COVER…………………………………………305
CLEAN…………………………………………………305
INSPECT FOR REUSE………………………………………305
ROCKER LEVER HOUSING……………………………………….305
ASSEMBLE………………………………………………306
CLEAN…………………………………………………305
INSPECT FOR REUSE………………………………………306
ROCKER LEVERS – GENERAL INFORMATION………………………….291
GENERAL INFORMATION…………………………………….291
SERVICE TOOLS……………………………………………..292
ROCKER LEVERS………………………………………….292
CAM FOLLOWERS/TAPPETS – GROUP 04………………………………..307
CAM FOLLOWER ASSEMBLY………………………………………309
ASSEMBLE………………………………………………312
CLEAN…………………………………………………310
DISASSEMBLE……………………………………………310
EXPLODED VIEW………………………………………….309
INSPECT FOR REUSE………………………………………311
CAM FOLLOWER COVER…………………………………………313
CLEAN…………………………………………………313
GENERAL INFORMATION…………………………………….313
INSPECT FOR REUSE………………………………………313
CAM FOLLOWERS/TAPPETS – GENERAL INFORMATION…………………..308
PUSH RODS OR TUBES…………………………………………314
CLEAN…………………………………………………314
GENERAL INFORMATION…………………………………….314
INSPECT FOR REUSE………………………………………314
FUEL SYSTEM – GROUP 05…………………………………………316
FUEL PUMP…………………………………………………322
CALIBRATE……………………………………………..323
CLEAN…………………………………………………322
INSPECT FOR REUSE………………………………………322
FUEL SHUTOFF VALVE (FSOV)…………………………………..325
CLEAN…………………………………………………326
INSPECT FOR REUSE………………………………………326
INSTALL……………………………………………….327
REMOVE………………………………………………..325
FUEL SYSTEM – GENERAL INFORMATION……………………………317
GENERAL INFORMATION…………………………………….317
SERVICE TOOLS……………………………………………..320
FUEL SYSTEM……………………………………………320
INJECTORS AND FUEL LINES – GROUP 06……………………………..329
FUEL FILTER HEAD…………………………………………..331
INSTALL……………………………………………….331
REMOVE………………………………………………..331
FUEL MANIFOLD (SUPPLY)……………………………………..332
CLEAN…………………………………………………332
INSPECT FOR REUSE………………………………………333
FUEL SUPPLY LINES………………………………………….333
CLEAN…………………………………………………333
INSPECT FOR REUSE………………………………………334
FUEL CONTROL SUPPLY LINE…………………………….334
FUEL INLET LINE…………………………………….335
FUEL RAIL SUPPLY LINE……………………………….334
FUEL TANK-TO-FUEL FILTER…………………………….334
FUEL TIMING SUPPLY LINE……………………………..334
INJECTOR………………………………………………….335
CLEAN…………………………………………………335
INSPECT FOR REUSE………………………………………335
INJECTORS AND FUEL LINES – GENERAL INFORMATION………………..330
GENERAL INFORMATION…………………………………….330
LUBRICATING OIL SYSTEM – GROUP 7………………………………..338
LUBRICATING OIL COOLER……………………………………..341
CLEAN…………………………………………………342
EXPLODED VIEW………………………………………….341
GENERAL INFORMATION…………………………………….342
INSPECT FOR REUSE………………………………………342
LUBRICATING OIL FILTER HEAD…………………………………343
ASSEMBLE………………………………………………348
CLEAN…………………………………………………347
DISASSEMBLE……………………………………………346
EXPLODED VIEW………………………………………….344
GENERAL INFORMATION…………………………………….343
INSPECT FOR REUSE………………………………………347
LUBRICATING OIL FILTER HEAD ADAPTER………………………….351
CLEAN…………………………………………………351
GENERAL INFORMATION…………………………………….351
INSPECT FOR REUSE………………………………………351
LUBRICATING OIL FILTER HEAD (REMOTE-MOUNTED)………………….349
ASSEMBLE………………………………………………350
CLEAN…………………………………………………350
DISASSEMBLE……………………………………………349
INSPECT FOR REUSE………………………………………350
LUBRICATING OIL PAN………………………………………..353
GENERAL INFORMATION…………………………………….353
OIL PAN CAPACITY……………………………………353
LUBRICATING OIL PAN ADAPTER…………………………………354
CLEAN…………………………………………………354
INSPECT FOR REUSE………………………………………354
LUBRICATING OIL PUMP……………………………………….355
ASSEMBLE………………………………………………360
CLEAN…………………………………………………357
DISASSEMBLE……………………………………………357
EXPLODED VIEW………………………………………….356
GENERAL INFORMATION…………………………………….355
INSPECT FOR REUSE………………………………………358
LUBRICATING OIL SYSTEM – GENERAL INFORMATION………………….339
GENERAL INFORMATION…………………………………….339
OIL TRANSFER CONNECTION…………………………………….361
ASSEMBLE………………………………………………362
CLEAN…………………………………………………361
DISASSEMBLE……………………………………………361
INSPECT FOR REUSE………………………………………361
SERVICE TOOLS……………………………………………..340
LUBRICATING OIL SYSTEM………………………………….340
COOLING SYSTEM – GROUP 08………………………………………363
COOLANT THERMOSTAT…………………………………………367
INSTALL……………………………………………….369
CONVENTIONAL AFTERCOOLING……………………………369
LOW TEMPERATURE AFTERCOOLING…………………………370
REMOVE………………………………………………..367
TEST………………………………………………….371
ENGINE THEMOSTATS…………………………………..371
LOW TEMPERATURE AFTERCOOLING THERMOSTAT……………….372
COOLANT THERMOSTAT HOUSING SUPPORT…………………………..373
GENERAL INFORMATION…………………………………….373
LTA COOLING SYSTEM………………………………….373
THERMOSTAT…………………………………………373
THERMOSTAT SEAL…………………………………….373
THERMOSTAT SUPPORT………………………………….373
COOLING SYSTEM – GENERAL INFORMATION…………………………364
GENERAL INFORMATION…………………………………….364
FAN, COOLING………………………………………………381
GENERAL INFORMATION…………………………………….381
FAN DRIVE IDLER ARM ASSEMBLY………………………………..374
ASSEMBLE………………………………………………375
CLEAN…………………………………………………374
DISASSEMBLE……………………………………………374
INSPECT FOR REUSE………………………………………374
FAN DRIVE IDLER PULLEY ASSEMBLY……………………………..375
CLEAN…………………………………………………375
INSPECT FOR REUSE………………………………………376
FAN HUB, BELT DRIVEN……………………………………….377
ASSEMBLE………………………………………………379
CLEAN…………………………………………………378
GENERAL INFORMATION…………………………………….377
INSPECT FOR REUSE………………………………………378
SERVICE TOOLS……………………………………………..366
COOLING SYSTEM…………………………………………366
TORQUE CONVERTER COOLER…………………………………….389
ASSEMBLE………………………………………………390
CLEAN…………………………………………………391
DISASSEMBLE……………………………………………391
EXPLODED VIEW………………………………………….389
GENERAL INFORMATION…………………………………….389
INSPECT FOR REUSE………………………………………390
WATER PUMP………………………………………………..382
ASSEMBLE………………………………………………385
CLEAN…………………………………………………384
DISASSEMBLE……………………………………………382
INSPECT……………………………………………….384
INSPECT FOR REUSE………………………………………382
WATER PUMP BEARINGS ……………………………………….391
INSTALL……………………………………………….392
MEASURE……………………………………………….391
REMOVE………………………………………………..391
DRIVE UNITS – GROUP 09…………………………………………394
ACCESSORY DRIVE PULLEY……………………………………..398
INSPECT FOR REUSE………………………………………398
INSTALL……………………………………………….398
REMOVE………………………………………………..398
DRIVE UNITS – GENERAL INFORMATION……………………………396
GENERAL INFORMATION…………………………………….396
FUEL PUMP DRIVE……………………………………………400
ASSEMBLE………………………………………………405
CLEAN…………………………………………………402
DISASSEMBLE……………………………………………404
EXPLODED VIEW………………………………………….401
GENERAL INFORMATION…………………………………….400
INSPECT FOR REUSE………………………………………402
FUEL PUMP DRIVE GEAR AND SHAFT………………………………406
ASSEMBLE………………………………………………407
DISASSEMBLE……………………………………………406
HYDRAULIC PUMP DRIVE……………………………………….409
ASSEMBLE ……………………………………………..411
CLEAN…………………………………………………410
DISASSEMBLE……………………………………………410
EXPLODED VIEW………………………………………….409
GENERAL INFORMATION…………………………………….409
INSPECT FOR REUSE………………………………………410
HYDRAULIC PUMP DRIVE GEAR AND SHAFT………………………….412
ASSEMBLE………………………………………………413
DISASSEMBLE……………………………………………412
HYDRAULIC PUMP SUPPORT BUSHING………………………………452
INSPECT FOR REUSE………………………………………453
INSTALL……………………………………………….453
REMOVE………………………………………………..452
OUTER HYDRAULIC PUMP SUPPORT DRIVE…………………………..448
ASSEMBLE………………………………………………451
DISASSEMBLE……………………………………………448
INSPECT FOR REUSE………………………………………449
INSTALL……………………………………………….450
REAR GEAR DRIVE (LOWER ASSEMBLY)…………………………….413
ASSEMBLE………………………………………………421
DISASSEMBLE……………………………………………420
EXPLODED VIEW………………………………………….418
INSPECT FOR REUSE………………………………………421
INSTALL……………………………………………….424
REMOVE………………………………………………..413
REAR GEAR DRIVE (UPPER ASSEMBLY)…………………………….430
ASSEMBLE………………………………………………437
DISASSEMBLE……………………………………………432
EXPLODED VIEW………………………………………….430
INSPECT FOR REUSE………………………………………435
SERVICE TOOLS……………………………………………..397
DRIVE UNITS……………………………………………397
WATER PUMP DRIVE BUSHING……………………………………447
ASSEMBLE………………………………………………447
DISASSEMBLE……………………………………………447
WATER PUMP DRIVER GEAR AND SHAFT…………………………….446
ASSEMBLE………………………………………………447
DISASSEMBLE……………………………………………446
WATER PUMP DRIVE PULLEY…………………………………….447
CLEAN…………………………………………………447
INSPECT FOR REUSE………………………………………448
AIR INTAKE SYSTEM – GROUP 10……………………………………454
AFTERCOOLER ASSEMBLY……………………………………….457
ASSEMBLE………………………………………………459
CLEAN…………………………………………………458
DISASSEMBLE……………………………………………458
EXPLODED VIEW………………………………………….457
INSPECT FOR REUSE………………………………………458
AFTERCOOLER COOLANT TUBE……………………………………460
CLEAN…………………………………………………460
INSPECT FOR REUSE………………………………………460
AIR CROSSOVER……………………………………………..461
CLEAN…………………………………………………461
INSPECT FOR REUSE………………………………………461
AIR INTAKE SYSTEM – GENERAL INFORMATION………………………455
PREPARATORY……………………………………………455
CHARGE AIR COOLER (CAC)…………………………………….462
CLEAN…………………………………………………462
INSPECT FOR REUSE………………………………………462
LEAK TEST……………………………………………..463
SERVICE TOOLS……………………………………………..456
AIR INTAKE SYSTEM………………………………………456
TURBOCHARGER HEAT SHIELD……………………………………465
CLEAN…………………………………………………465
MARINE APLICATIONS………………………………….465
INSPECT FOR REUSE………………………………………465
MARINE APPLICATIONS…………………………………465
INSTALL ………………………………………………465
MARINE APPLICATIONS…………………………………465
REMOVE………………………………………………..465
MARINE APPLICATIONS…………………………………465
TURBOCHARGER, WATER-COOLED………………………………….464
CLEAN…………………………………………………464
INSPECT FOR REUSE………………………………………464
EXHAUST SYSTEM – GROUP 11………………………………………467
EXHAUST MANIFOLD, DRY………………………………………468
ASSEMBLE………………………………………………470
CLEAN…………………………………………………468
MARINE APPLICATIONS…………………………………469
DISASSEMBLE……………………………………………469
INSPECT FOR REUSE………………………………………469
MARINE APPLICATIONS…………………………………470
EXHAUST MANIFOLD HEAT SHIELD………………………………..470
CLEAN…………………………………………………470
INSPECT FOR REUSE………………………………………471
EXHAUST SYSTEM – GENERAL INFORMATION…………………………468
GENERAL INFORMATION…………………………………….468
COMPRESSED AIR SYSTEM – GROUP 12………………………………..472
COMPRESSED AIR SYSTEM – GENERAL INFORMATION…………………..473
GENERAL INFORMATION…………………………………….473
ELECTRICAL EQUIPMENT – GROUP 13…………………………………475
ALTERNATOR ADJUSTING LINK…………………………………..479
CLEAN…………………………………………………479
INSPECT FOR REUSE………………………………………479
ALTERNATOR BRACKET…………………………………………477
CLEAN…………………………………………………477
INSPECT FOR REUSE………………………………………477
DRIVE BELT, ALTERNATOR……………………………………..477
ADJUST………………………………………………..477
ELECTRICAL EQUIPMENT – GENERAL INFORMATION……………………476
GENERAL INFORMATION…………………………………….476
STARTING MOTOR…………………………………………….478
CLEAN…………………………………………………478
INSPECT FOR REUSE………………………………………479
ENGINE TESTING – GROUP 14………………………………………480
DYNAMOMETER WORKSHEET………………………………………490
WORKSHEET……………………………………………..490
ENGINE RUN-IN (CHASSIS DYNAMOMETER)………………………….503
GENERAL INFORMATION…………………………………….503
ENGINE THROTTLE CONTROL……………………………..504
RUN-IN INSTRUCTIONS…………………………………….506
ENGINE RUN-IN (ENGINE DYNAMOMETER)…………………………..522
GENERAL INFORMATION…………………………………….522
RUN-IN INSTRUCTIONS…………………………………….524
ENGINE RUN-IN (WITHOUT DYNAMOMETER)………………………….508
PREPARATORY……………………………………………508
GENERAL ENGINE TEST PROCEDURES……………………….508
RUN-IN INSTRUCTIONS…………………………………….510
GENERATOR SET………………………………………510
OFF-HIGHWAY………………………………………..510
ENGINE TESTING – GENERAL INFORMATION…………………………481
FUEL FLOW MEASUREMENT ON ENGINE OR CHASSIS DYNAMOMETER……..482
INSTALLATION……………………………………….482
OPERATION………………………………………….483
GENERAL INFORMATION…………………………………….481
ENGINE TESTING (CHASSIS DYNAMOMETER)…………………………491
SETUP…………………………………………………491
TEST………………………………………………….494
ENGINE TESTING (ENGINE DYNAMOMETER)………………………….511
INSTALL……………………………………………….511
TEST………………………………………………….514
ENGINE TESTING (IN CHASSIS)…………………………………527
STALL SPEED CHECK………………………………………527
TIME SPEED CHECK……………………………………….530
SERVICE TOOLS……………………………………………..488
ENGINE TESTING…………………………………………488
SPECIFICATIONS…………………………………………….486
COOLING SYSTEM…………………………………………487
ENGINE TESTING…………………………………………486
EXHAUST SYSTEM…………………………………………487
LUBRICATING OIL SYSTEM………………………………….487
MOUNTING ADAPTATIONS – GROUP 16…………………………………535
ENGINE SUPPORT BRACKET, FRONT……………………………….539
CLEAN…………………………………………………539
INSPECT FOR REUSE………………………………………539
FLYWHEEL………………………………………………….539
CLEAN…………………………………………………539
INSPECT FOR REUSE………………………………………540
FLYWHEEL HOUSING…………………………………………..541
CLEAN…………………………………………………541
INSPECT FOR REUSE………………………………………541
REDOWEL……………………………………………….542
FLYWHEEL RING GEAR…………………………………………545
ASSEMBLE………………………………………………546
DISASSEMBLE……………………………………………545
MOUNTING ADAPTATIONS – GENERAL INFORMATIONBGENERAL INFORMATION….536
GENERAL INFORMATION…………………………………….536
SERVICE TOOLS……………………………………………..538
MOUNTING ADAPTATIONS……………………………………538
ELECTRONIC ENGINE CONTROLS – GROUP 19……………………………548
ELECTRONIC ENGINE CONTROLS – GENERAL INFORMATION………………549
GENERAL INFORMATION…………………………………….549
CONNECTOR PINS – CHECKING……………………………551
CONTINUITY CHECK……………………………………555
HOW TO FIND THE INTERNAL RESISTANCE OF THE METER……….550
HOW TO MEASURE CURRENT………………………………549
HOW TO MEASURE RESISTANCE……………………………550
HOW TO MEASURE VOLTAGE………………………………550
HOW TO TEST FOR CONTINUITY…………………………..550
HOW TO USE A DIGITAL VOLT/OHM METER…………………..549
POLARITY CHECK……………………………………..554
RESISTANCE CHECK – COIL……………………………..556
SHORT CIRCUIT FROM PIN TO PIN – CHECK…………………553
SHORT CIRCUIT TO GROUND – CHECK………………………552
USE OF SPECIAL TEST LEADS……………………………549
VOLTAGE CHECKING……………………………………553
ENGINE WIRING HARNESS…………………………………..556
INSPECT FOR REUSE…………………………………..556
OEM INTERFACE HARNESS…………………………………..557
GENERAL INFORMATION…………………………………557
OEM WIRING HARNESS……………………………………..557
GENERAL INFORMATION…………………………………557
SERVICE LITERATURE…………………………………………….559
ADDITIONAL SERVICE LITERATURE……………………………….560
LITERATURE ORDER FORM………………………………………562
SERVICE LITERATURE ORDERING LOCATION…………………………561
COMPONENT MANUFACTURERS………………………………………..564
COMPONENT MANUFACTURERS’ ADDRESSES…………………………..565
AIR COMPRESSORS………………………………………..565
AIR CYLINDERS………………………………………….565
AIR HEATERS……………………………………………565
AIR STARTING MOTORS…………………………………….565
ALTERNATORS……………………………………………565
AUXILIARY BRAKES……………………………………….565
BELTS…………………………………………………565
CATALYTIC CONVERTERS……………………………………565
CLUTCHES………………………………………………565
COOLANT HEATERS ……………………………………….566
COOLANT LEVEL SWITCHES………………………………….565
DRIVE PLATES…………………………………………..566
ELECTRIC STARTING MOTORS………………………………..566
ELECTRONIC SWITCHES…………………………………….566
ENGINE PROTECTION CONTROLS………………………………566
FAN CLUTCHES…………………………………………..566
FANS………………………………………………….566
FAULT LAMPS……………………………………………566
FILTERS……………………………………………….566
FLEXPLATES…………………………………………….566
FUEL COOLERS…………………………………………..566
FUEL WARMERS…………………………………………..566
GAUGES………………………………………………..566
GOVERNORS……………………………………………..567
HEAT SLEEVES…………………………………………..567
HYDRAULIC AND POWER STEERING PUMPS……………………….567
IN-LINE CONNECTORS……………………………………..567
OIL HEATERS……………………………………………567
PRELUBRICATIONS SYSTEMS…………………………………567
RADIATORS……………………………………………..567
THROTTLE ASSEMBLIES…………………………………….567
TORQUE CONVERTERS………………………………………567
SPECIFICATIONS………………………………………………..569
AIR INTAKE SYSTEM – SPECIFICATIONS…………………………..612
AFTERCOOLER ASSEMBLY……………………………………612
TURBOCHARGER, WATER-COOLED………………………………612
AIR INTAKE SYSTEM – TORQUE VALUES……………………………613
AFTERCOOLER ASSEMBLY……………………………………613
TURBOCHARGER HEAT SHIELD………………………………..613
CAM FOLLOWERS/TAPPETS – SPECIFICATIONS……………………….594
CAM FOLLOWER ASSEMBLY…………………………………..594
CAPSCREW MARKINGS AND TORQUE VALUES………………………….618
CAPSCREW MARKINGS AND TORQUE VALUES – METRIC……………..619
CAPSCREW MARKINGS AND TORQUE VALUES – U.S. CUSTOMARY……….620
COMPLETE ENGINE – SPECIFICATIONS…………………………….571
ENGINE ASSEMBLY………………………………………..571
COMPLETE ENGINE – TORQUE VALUES……………………………..573
ENGINE ASSEMBLY………………………………………..573
ENGINE DISASSEMBLY……………………………………..573
COOLING SYSTEM – SPECIFICATIONS……………………………..601
FAN DRIVE IDLER PULLEY ASSEMBLY………………………….601
FAN HUB, BELT DRIVEN……………………………………601
TORQUE CONVERTER COOLER…………………………………601
WATER PUMP…………………………………………….601
WATER PUMP BEARINGS…………………………………….602
COOLING SYSTEM – TORQUE VALUES………………………………603
COOLANT THERMOSTAT……………………………………..603
FAN HUB, BELT DRIVEN……………………………………603
TORQUE CONVERTER COOLER…………………………………604
WATER PUMP…………………………………………….604
CYLINDER BLOCK – SPECIFICATIONS……………………………..583
BEARINGS, MAIN…………………………………………583
CAMSHAFT………………………………………………583
CAMSHAFT BUSHINGS………………………………………583
CAMSHAFT GEAR (CAMSHAFT REMOVED)…………………………583
CONNECTING ROD…………………………………………584
CRANKSHAFT…………………………………………….585
CRANKSHAFT GEAR, FRONT (CRANKSHAFT INSTALLED)……………..585
CRANKSHAFT PULLEY………………………………………585
CYLINDER BLOCK…………………………………………585
CYLINDER BLOCK AND LINER SEATS…………………………..585
CYLINDER BLOCK COUNTERBORE………………………………588
CYLINDER LINER…………………………………………586
GEAR COVER ACCESSORY DRIVE BUSHING……………………….588
GEAR COVER, FRONT………………………………………587
GEAR COVER SPACER PLATE…………………………………587
IDLER GEAR, CAMSHAFT……………………………………587
MEASURE THE CONNECTING ROD BEND (BORE ALIGHNMENT)………….584
MEASURE THE CONNECTING ROD TWIST…………………………585
PISTON………………………………………………..587
CYLINDER BLOCK – TORQUE VALUES………………………………589
CONNECTING ROD…………………………………………589
CRANKSHAFT PULLEY………………………………………589
CYLINDER BLOCK…………………………………………589
CYLINDER BLOCK COUNTERBORE………………………………589
CYLINDER HEAD – SPECIFICATIONS………………………………590
CYLINDER HEAD …………………………………………590
CYLINDER HEAD INJECTOR BORE……………………………..590
VALVE, CYLINDER HEAD……………………………………591
VALVE GUIDE, CYLINDER HEAD………………………………590
VALVE SEAT BORE………………………………………..591
VALVE SEAT INSERT, CYLINDER HEAD…………………………591
DRIVE BELT TENSION…………………………………………617
DRIVE UNITS – SPECIFICATIONS………………………………..605
FUEL PUMP DRIVE………………………………………..605
FUEL PUMP DRIVE GEAR AND SHAFT…………………………..606
HYDRAULIC PUMP DRIVE……………………………………606
HYDRAULIC PUMP SUPPORT BUSHING…………………………..609
OUTER HYDRAULIC PUMP SUPPORT DRIVE……………………….608
REAR GEAR DRIVE (LOWER ASSEMBLY)…………………………606
REAR GEAR DRIVE (UPPER ASSEMBLY)…………………………607
WATER PUMP DRIVE……………………………………….608
DRIVE UNITS – TORQUE VALUES…………………………………610
OUTER HYDRUALIC PUMP SUPPORT DRIVE……………………….611
REAR GEAR DRIVE (LOWER ASSEMBLY)…………………………610
REAR GEAR DRIVE (UPPER ASSEMBLY)…………………………610
ELECTRICAL EQUIPMENT – SPECIFICATIONS………………………..615
DRIVE BELT, ALTERNATOR………………………………….615
ENGINE TESTING – SPECIFICATIONS……………………………..616
ENGINE TESTING (CHASSIS DYNAMOMETER)……………………..616
ENGINE TESTING (ENGINE DYNAMOMETER)………………………616
EXHAUST SYSTEM – SPECIFICATIONS……………………………..614
EXHAUST MANIFOLD, DRY…………………………………..614
FRACTION, DECIMAL, MILLIMETER CONVERSIONS…………………….621
FUEL SYSTEM – TORQUE VALUES…………………………………595
FUEL SHUTOFF VALVE (FSOV)……………………………….595
INJECTORS AND FUEL LINES – TORQUE VALUES……………………..596
FUEL MANIFOLD(SUPPLY)…………………………………..596
LUBRICATING OIL SYSTEM – SPECIFICATIONS………………………597
LUBRICATING OIL FITER HEAD………………………………597
LUBRICATING OIL FILTER HEAD (LF670)………………………597
LUBRICATING OIL FILTER HEAD (REMOTE-MOUNTED)………………597
LUBRICATING OIL PAN…………………………………….597
LUBRICATING OIL PUMP……………………………………597
OIL TRANSFER CONNECTION…………………………………598
LUBRICATING OIL SYSTEM – TORQUE VALUES……………………….599
LUBRICATING OIL COOLER………………………………….599
LUBRICATING OIL FILTER HEAD……………………………..599
LUBRICATING OIL FILTER HEAD (REMOTE-MOUNTED)………………599
LUBRICATING OIL PUMP……………………………………599
OIL TRANSFER CONNECTION…………………………………600
NEWTON-METER TO FOOT-POUND CONVERSION CHART…………………..622
PIPE PLUG TORQUE VALUES…………………………………….623
ROCKER LEVERS – SPECIFICATIONS………………………………593
ROCKER LEVER…………………………………………..593
ROCKER LEVER ASSEMBLY…………………………………..593
ROCKER LEVER BUSHINGS…………………………………..593
TAP-DRILL CHART – U.S. CUSTOMARY AND METRIC…………………..624
WEIGHTS AND MEASURES – CONVERSION FACTORS…………………….625
INDEX………………………………………………………..627

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