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CUMMINS QUANTUM™ System K19 Series Engines Troubleshooting and Repair Manual – PDF DOWNLOAD


CUMMINS QUANTUM™ System K19 Series Engines Troubleshooting and Repair Manual

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CUMMINS QUANTUM™ System K19 Series Engines Troubleshooting and Repair Manual

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CUMMINS QUANTUM™ System K19 Series Engines Troubleshooting and Repair Manual

  • This manual provides instructions for troubleshooting and repairing this Engine in the chassis. Component and assembly rebuild procedures are provided in the Engine Shop Manual.
  • Refer to Section i – Introduction for instructions on how to use this manual. Read and follow all safety instructions. Refer to theWARNING in the General Safety Instructions in Section i – Introduction.
  • 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 (for example: Shop, 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. 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. Cummins Engine Company, Inc. encourages the user of this manual to report errors, omissions, and recommendations for improvement. Please use the postage paid, pre-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 or call 1-800-DIESELS (1-800-343-7357). The latest technology and the highest quality components are used to manufacture Cummins engines. When replacement parts are needed, we recommend using only genuine Cummins or ReConT exchange parts.

TABLE OF CONTENTS:

CUMMINS QUANTUM™ System K19 Series Engines Troubleshooting and Repair Manual

MAIN MENU....................................................................................  0
COVER PAGE...................................................................................  1
TABLE OF CONTENTS............................................................................  3
INTRODUCTION.................................................................................  4
	ABOUT THE MANUAL.........................................................................  5
	DEFINITION OF TERMS...................................................................... 14
	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 QUANTUM FUEL SYSTEM CONTROLLED VEHICLE.................................. 12
	GENERAL SAFETY INSTRUCTIONS.............................................................. 11
		IMPORTANT SAFETY NOTICE.............................................................. 11
	HOW TO USE THE MANUAL....................................................................  5
	ILLUSTRATIONS............................................................................ 10
	SIMBOLOS.................................................................................  7
	SYMBOLE..................................................................................  8
	SYMBOLES.................................................................................  9
	SYMBOLS..................................................................................  6
ENGINE IDENTIFICATION........................................................................ 18
	ENGINE IDENTIFICATION.................................................................... 19
		CUMMINS ENGINE NOMENCLATURE.......................................................... 19
		ENGINE DATAPLATE..................................................................... 19
		FUEL PUMP DATAPLATE.................................................................. 19
	EXTERNAL ENGINE COMPONENTS............................................................... 23
	GENERAL SPECIFICATIONS................................................................... 20
		AIR INDUCTION SYSTEM................................................................. 21
		COOLING SYSTEM....................................................................... 22
		ELECTRICAL SYSTEM.................................................................... 22
		EXHAUST SYSTEM....................................................................... 22
		FUEL SYSTEM.......................................................................... 22
		GENERAL ENGINE DATA.................................................................. 21
		LUBRICATING OIL SYSTEM............................................................... 21
TROUBLESHOOTING SYMPTOMS..................................................................... 26
	TROUBLESHOOTING PROCEDURES AND TECHNIQUES................................................ 28
	TROUBLESHOOTING SYMPTOMS CHARTS.......................................................... 28
		AIR COMPRESSOR AIR PRESSURE RISES SLOWLY............................................. 29
		AIR COMPRESSOR NOISE EXCESSIVE....................................................... 30
		AIR COMPRESSOR PUMPING EXCESS LUBRICATING OIL INTO AIR SYSTEM........................ 31
		AIR COMPRESSOR WILL NOT MAINTAIN ADEQUATE AIR PRESSURE - NOT PUMPING CONTINUOUSLY.... 32
		AIR COMPRESSOR WILL NOT PUMP AIR..................................................... 33
		AIR COMPRESSOR WILL NOT STOP PUMPING................................................. 34
		ALTERNATOR NOT CHARGING OR INSUFFICIENT CHARGING..................................... 35
		ALTERNATOR OVERCHARGING.............................................................. 36
		COMMUNICATION ERROR - ELECTRONIC SERVICE TOOL OR CONTROL DEVICE...................... 37
		CONNECTING ROD BEARING NOISE.........................................................118
		COOLANT LOSS - EXTERNAL.............................................................. 39
		COOLANT LOSS - INTERNAL.............................................................. 40
		COOLANT TEMPERATURE ABOVE NORMAL - GRADUAL OVERHEAT.................................. 41
		COOLANT TEMPERATURE ABOVE NORMAL - SUDDEN OVERHEAT................................... 44
		COOLANT TEMPERATURE BELOW NORMAL..................................................... 46
		CRANKCASE GASES (BLOWBY) - EXCESSIVE................................................. 47
		DRIVEABILITY - GENERAL INFORMATION...................................................119
		DRIVEABILITY/LOW POWER - CUSTOMER COMPLAINT FORM.....................................120
		DRIVEABLITY/LOW POWER/EXCESSIVE FUEL CONSUMPTION - CHECKLIST.........................120
		ENGINE ACCELERATION OR RESPONSE POOR................................................. 48
		ENGINE DECELERATES SLOWLY............................................................ 52
		ENGINE DIFFICULT TO START OR WILL  NOT START (EXHAUST SMOKE)......................... 54
		ENGINE DIFFICULT TO START OR WILL NOT START (NO EXHAUST SMOKE)....................... 58
		ENGINE NOISE DIAGNOSTIC PROCEDURES - GENERAL INFORMATION.............................118
		ENGINE NOISE EXCESSIVE............................................................... 60
		ENGINE NOISE EXCESSIVE - COMBUSTION KNOCKS........................................... 63
		ENGINE NOISE EXCESSIVE - CONNECTING ROD.............................................. 64
		ENGINE NOISE EXCESSIVE - MAIN BEARING................................................ 65
		ENGINE NOISE EXCESSIVE - PISTON...................................................... 66
		ENGINE NOISE EXCESSIVE - TURBOCHARGER................................................ 67
		ENGINE POWER OUTPUT LOW.............................................................. 68
		ENGINE RUNS ROUGH AT IDLE............................................................ 73
		ENGINE RUNS ROUGH OR MISFIRES........................................................ 76
		ENGINE SHUTS OFF UNEXPECTEDLY OR DIES DURING DECELERATION............................ 78
		ENGINE SPEED SURGES AT LOW OR HIGH IDLE.............................................. 80
		ENGINE VIBRATION - EXCESSIVE......................................................... 84
		ENGINE WILL NOT CRANK OR CRANKS SLOWLY (AIR STARTER)................................. 86
		ENGINE WILL NOT CRANK OR CRANKS SLOWLY (ELECTRIC STARTER)............................ 88
		ENGINE WILL NOT REACH RATED SPEED (RPM).............................................. 90
		ENGINE WILL NOT SHUT OFF............................................................. 92
		ENGINE STARTS BUT WILL NOT KEEP RUNNING.............................................. 82
		FAULT CODE WARNING LAMPS DO NOT ILLUMINATE........................................... 94
		FAULT CODE WARNING LAMPS STAY ON (NO APPARENT REASON)................................ 93
		FUEL CONSUMPTION - GENERAL INFORMATION...............................................121
		FUEL CONSUMPTION EXCESSIVE........................................................... 95
		FUEL IN COOLANT...................................................................... 98
		FUEL IN THE LUBRICATING OIL.......................................................... 99
		INTAKE MANIFOLD AIR TEMPERATURE ABOVE SPECIFICATION..................................100
		INTAKE MANIFOLD PRESSURE (BOOST) IS BELOW NORMAL.....................................101
		LOW IDLE ADJUST SWITCH DOES NOT WORK.................................................102
		LUBRICATING OIL CONSUMPTION EXCESSIVE................................................103
		LUBRICATING OIL PRESSURE - HIGH......................................................105
		LUBRICATING OIL PRESSURE - LOW.......................................................106
		LUBRICATING OIL SLUDGE IN THE ENGINE CRANKCASE EXCESSIVE.............................108
		LUBRICATING OIL TEMPERATURE ABOVE SPECIFICATION......................................110
		LUBRICATING OR TRANSMISSION OIL IN THE COOLANT.......................................111
		MAIN BEARING NOISE...................................................................118
		OIL CONSUMPTION......................................................................122
		PISTON NOISE.........................................................................118
		SMOKE, BLACK - EXCESSIVE.............................................................112
		SMOKE, WHITE - EXCESSIVE.............................................................114
		TURBOCHARGER LEAKS - ENGINE OIL OR FUEL..............................................117
SECTION  0 - COMPLETE ENGINE - GROUP 00......................................................126
	COMPLETE ENGINE - GENERAL INFORMATION (000-000-999)......................................127
	COMPLETE ENGINE - TOOL REQUIREMENTS - (022-001-500)......................................128
	ENGINE INSTALLATION (000-002)............................................................132
		INSTALL (000-002-026)................................................................132
	ENGINE REMOVAL (000-001).................................................................129
		REMOVE (000-001-002).................................................................129
SECTION 1 - CYLINDER BLOCK - GROUP 01........................................................136
	ACCESSORY DRIVE SEAL (001-003)...........................................................145
		INSTALL (001-003-026)................................................................146
		REMOVE (001-003-002).................................................................145
	ALTERNATOR DRIVE SEAL 001-001)...........................................................142
		INSTALL (001-001-026)................................................................143
		REMOVE (001-001-002).................................................................142
	BEARINGS, CONNECTING ROD (001-005).......................................................149
		INSTALL (001-005-026)................................................................150
		REMOVE (001-005-002).................................................................149
	BEARINGS, THRUST (001-007)...............................................................159
		INSPECT FOR REUSE (001-007-007)......................................................159
		INSTALL (001-007-026)................................................................160
		REMOVE (001-007-002).................................................................159
	CAMSHAFT (001-008).......................................................................160
		INSPECT (001-008-062)................................................................168
		INSTALL (001-008-026)................................................................164
		REMOVE (001-008-002).................................................................160
	CAMSHAFT BUSHINGS (001-010)..............................................................169
		INSPECT (001-010-062)................................................................171
		INSTALL (001-010-026)................................................................170
		REMOVE (001-010-002).................................................................169
	CAMSHAFT COVER PLATE (001-011)...........................................................171
		INSTALL (001-011-026)................................................................172
		REMOVE (001-011-002).................................................................171
	CAMSHAFT GEAR (CAMSHAFT INSTALLED)(001-012)..............................................172
		INSPECT (001-012-062)................................................................174
		INSTALL (001-012-026)................................................................173
		REMOVE (001-012-002).................................................................172
	CAMSHAFT IDLER GEAR (001-036)............................................................215
		INSTALL (001-036-026)................................................................215
		REMOVE (001-036-002).................................................................215
	CAMSHAFT THRUST BEARING (001-056)........................................................244
		INSPECT FOR REUSE (001-056-007)......................................................244
	CONNECTING ROD (001-014).................................................................175
		INSPECT FOR REUSE (001-014-007)......................................................175
	CRANKSHAFT (001-016).....................................................................176
		INITIAL CHECK (001-016-008)..........................................................176
	CRANKSHAFT GEAR, FRONT (CRANKSHAFT INSTALLED) (001-018)..................................176
		INSPECT FOR REUSE (001-018-007)......................................................177
		INSTALL (001-018-026)................................................................177
		REMOVE (001-018-002).................................................................176
	CRANKSHAFT SEAL, FRONT (001-023).........................................................178
		CLEAN (001-023-006)..................................................................179
		INSTALL (001-023-026)................................................................179
		REMOVE (001-023).....................................................................178
	CRANKSHAFT SEAL, REAR (001-024)..........................................................182
		CLEAN (001-024-006)..................................................................182
		INSTALL (001-024-026)................................................................183
		REMOVE (001-024-002).................................................................182
	CYLINDER BLOCK (001-026).................................................................185
		INSPECT FOR REUSE (001-026-007)......................................................185
		MAGNETIC CRACK INSPECTION (001-026-016)..............................................185
	CYLINDER BLOCK AND LINER SEATS (001-027).................................................186
		INSPECT FOR REUSE (001-027-007)......................................................187
		MEASURE (001-027-010)................................................................188
		PREPARATORY (001-027-001)............................................................186
	CYLINDER BLOCK - TOOL REQUIREMENTS (022-001-501).........................................138
	CYLINDER LINER (001-028).................................................................190
		CLEAN (001-028-006)..................................................................191
		INSPECT FOR REUSE (001-028-007)......................................................191
		INSTALL (001-028-026)................................................................193
		MEASURE (001-028-010)................................................................192
		REMOVE (001-028-002).................................................................190
	GEAR COVER, FRONT (001-031)..............................................................202
		INSPECT FOR REUSE (001-031-007)......................................................207
		INSTALL (001-031-026)................................................................208
		REMOVE (001-031-002).................................................................202
	GEAR COVER SPACER PLATE (001-029)........................................................196
		INSPECT FOR REUSE (001-029-007)......................................................198
		INSTALL (001-029-026)................................................................198
		REMOVE (001-029-002).................................................................196
	GEAR TRAIN BACKLASH, FRONT (001-055).....................................................243
		MEASURE (001-055-010)................................................................243
	HYDRAULIC PUMP IDLER GEAR (001-039)......................................................217
		INSTALL (001-039-026)................................................................217
		REMOVE (001-039-002).................................................................217
	MAIN BEARINGS (001-006)..................................................................153
		GENERAL INFORMATION (001-006-999)....................................................153
		INSTALL (001-006-026)................................................................155
		REMOVE (001-006-002).................................................................153
	PISTON (001-043).........................................................................220
		CLEAN (001-043-006)..................................................................220
		INSPECT FOR REUSE (001-043-007)......................................................222
	PISTON AND CONNECTING ROD ASSEMBLY (001-054).............................................233
		ASSEMBLE, ARTICULATED (001-054-025)..................................................237
		DISASSEMBLE (001-054-003)............................................................236
		INSTALL (001-054-026)................................................................238
		REMOVE (001-054-002).................................................................233
	PISTON COOLING NOZZLES (001-046).........................................................223
		CLEAN (001-046-006)..................................................................226
		INSPECT FOR REUSE (001-046-007)......................................................226
		INSTALL (001-046-026)................................................................226
		REMOVE (001-046-002).................................................................223
	PISTON RINGS (001-047)...................................................................228
		INSTALL (001-047-026)................................................................229
		MEASURE (001-047-010)................................................................228
	VIBRATION DAMPER, SINGLE (001-052).......................................................229
		ECCENTRICITY CHECK (001-052-064).....................................................232
		INSPECT FOR REUSE 001-052-007........................................................230
		INSTALL (001-052-026)................................................................231
		REMOVE (001-052-002).................................................................229
		WOBBLE CHECK (001-052-065)...........................................................232
	WATER PUMP IDLER GEAR (001-040)..........................................................219
		INSTALL (001-040-026)................................................................219
		REMOVE (001-040-002).................................................................219
SECTION 2 - CYLINDER HEAD - GROUP 02.........................................................245
	CYLINDER HEAD - GENERAL INFORMATION (002-999-999)........................................246
	CYLINDER HEAD - SPECIFICATIONS (018-001-502).............................................247
	CYLINDER HEAD - TOOL REQUIREMENTS (022-001-502)..........................................248
	CYLINDER HEAD (002-004)..................................................................249
		CLEAN (002-004-006)..................................................................252
		INSPECT FOR REUSE (002-004-007)......................................................253
		INSTALL (002-004-026)................................................................256
		PRESSURE TEST (002-004-013)..........................................................253
		REMOVE (002-004-002).................................................................249
	CYLINDER HEAD GASKET (002-021)...........................................................261
		LEAK TEST (002-021-014)..............................................................261
	CYLINDER HEAD VALVE (002-0020)...........................................................260
		REMOVE (002-020-002).................................................................260
SECTION 3 - ROCKER LEVER - GROUP 03..........................................................265
	OVERHEAD SET (OUTER BASE CIRCLE).........................................................269
		ADJUST (003-006-029).................................................................269
			DETERMINE THE CYLINDER IN POSITION FOR VALVE SET.................................269
		WORKSHEET (003-006-056)..............................................................273
	ROCKER LEVER ASSEMBLY (003-009)..........................................................274
		INSPECT FOR REUSE (003-009-007)......................................................274
		INSTALL (003-009-026)................................................................275
		REMOVE (003-009-002).................................................................274
	ROCKER LEVER COVER (003-011).............................................................276
		INSPECT FOR REUSE (003-011-007)......................................................277
		INSTALL (003-011-026)................................................................277
		REMOVE (003-011-002).................................................................276
	ROCKER LEVER HOUSING (003-013)...........................................................278
		INSPECT FOR REUSE (003-013-007)......................................................279
		INSTALL (003-013-026)................................................................280
		REMOVE (003-013-002).................................................................278
	ROCKER LEVER - GENERAL INFORAMATION (003-999-999)........................................266
	ROCKER LEVER - SPECIFICATIONS (018-003-201)..............................................267
	ROCKER LEVER - TOOL REQUIREMENTS (022-001-503)...........................................268
SECTION 4 - CAM FOLLOWERS/TAPPETS - GROUP 04.................................................283
	CAM FOLLOWER  - SPECIFICATIONS (018-001-201).............................................285
	CAM FOLLOWER ASSEMBLY (004-001)..........................................................286
		INSPECT FOR REUSE (004-001-007)......................................................287
		INSTALL (004-001-026)................................................................288
		REMOVE (004-001-002).................................................................286
	CAM FOLLOWER - GENERAL INFORMATION (003-999-999).........................................284
	PUSH RODS (004-014)......................................................................290
		INSPECT FOR REUSE (004-014-007)......................................................290
		INSTALL (004-014-026)................................................................291
		REMOVE (004-014-002).................................................................290
SECTION 5 - FUEL SYSTEM - GROUP 05...........................................................293
	ELECTRONIC FUEL CONTROL VALVE ASSEMBLY (005-053).........................................311
		INSTALL (005-053-026)................................................................313
		REMOVE (005-053-002).................................................................311
	FUEL CONSUMPTION (005-010)...............................................................302
		INITIAL CHECK (005-010-001)..........................................................302
		TEST (005-010-012)...................................................................302
	FUEL PUMP (005-016)......................................................................303
		INSPECT FOR REUSE (005-016-007)......................................................304
		INSTALL (005-016-026)................................................................306
		PRESSURE TEST (005-016-013)..........................................................304
		PRIME (005-016-050)..................................................................307
		REMOVE (005-016-002).................................................................303
	FUEL SHUTOFF VALVE (005-043).............................................................308
		INSPECT FOR REUSE (005-043-007)......................................................309
		INSTALL (005-043-026)................................................................310
		REMOVE (005-043-002).................................................................308
	FUEL SYSTEM - GENERAL INFORMATION (005-999-999)..........................................294
	FUEL SYSTEM FLOW DIAGRAMS (200-001-202)..................................................296
	FUEL SYSTEM - SERVICE TOOLS (022-001-505)................................................297
	FUEL SYSTEM - SPECIFICATIONS (018-001-202)...............................................298
		INSTALLATION RECOMMENDATIONS (005-999-248)...........................................299
SECTION 6 - INJECTORS AND FUEL LINES - GROUP 06..............................................317
	AIR-IN-FUEL (006-003)....................................................................325
		GENERAL INFORMATION (006-003-999)....................................................325
		TEST (006-003-012)...................................................................325
	FUEL DRAIN LINE RESTICTION (006-012).....................................................327
		MEASURE (006-012-010)................................................................327
	FUEL DRAIN LINES (006-013)...............................................................328
		INSPECT FOR REUSE (006-013-007)......................................................329
		INSTALL (006-013-026)................................................................330
		REMOVE (006-013-002).................................................................328
	FUEL FILTER (006-015)....................................................................330
		INSTALL (006-015-026)................................................................331
		REMOVE (006-015-002).................................................................330
	FUEL INLET RESTRICTION (006-020).........................................................331
		MEASURE (006-020-010)................................................................331
	FUEL MANIFOLD (006-022)..................................................................332
		INSPECT FOR REUSE (006-022-007)......................................................333
		INSTALL (006-022-026)................................................................335
		REMOVE (006-022-002).................................................................332
	FUEL SUPPLY LINES (006-024)..............................................................337
		INSPECT FOR REUSE (006-024-007)......................................................338
		INSTALL (006-024-026)................................................................340
		REMOVE (006-024-002).................................................................337
	INJECTOR AND FUEL LINES - QUANTUM INJECTOR...............................................321
	INJECTORS (006-026)......................................................................342
		CALIBRATE (006-026-030)..............................................................342
		INSPECT FOR REUSE (006-026-007)......................................................343
		INSTALL (006-026-026)................................................................345
		REMOVE (006-026-002).................................................................342
	INJECTORS AND FUEL LINES (006-999).......................................................318
		GENERAL INFORMATION (006-999-999)....................................................318
	INJECTORS AND FUEL LINES - FLOW DIAGRAM (200-001-202)....................................320
	INJECTORS AND FUEL LINES - REQUIRED SERVICE TOOLS (022-001-505)..........................323
	INJECTORS AND FUEL LINES - SPECIFICATIONS (018-001-202)..................................322
SECTION 7 - LUBRICATING OIL SYSTEM - GROUP 07................................................349
	CYLINDER SMOKES (BLUE SMOKE) (007-050)...................................................395
		FLUORESCENT DYE TRACER (007-050-054).................................................395
	LUBRICATING OIL CONTAMINATION............................................................386
		FLUORESCENT DYE TRACER TEST (007-044-054)............................................387
			OIL DILUTED WITH FUEL............................................................387
		GENERAL INFORMATION (007-044-999)....................................................386
		PRESSURE TEST (007-044-013)..........................................................387
			OIL DILUTED WITH COOLANT.........................................................387
	LUBRICATING OIL COOLER (007-003).........................................................357
		PRESSURE DIFFERENTIAL TEST (007-003-063).............................................357
	LUBRICATING OIL COOLER COVER (007-045)...................................................389
		INSPECT FOR REUSE (007-045-007)......................................................390
		INSTALL (007-045-026)................................................................391
		REMOVE (007-045-002).................................................................389
	LUBRICATING OIL COOLER ELEMENT (007-007).................................................358
		INSTALL (007-007-026)................................................................359
		PRESSURE TEST (007-007-013)..........................................................358
		REMOVE (007-007-002).................................................................358
	LUBRICATING OIL COOLER HOUSING ..........................................................393
		INSPECT FOR REUSE (007-046-007)......................................................394
		INSTALL (007-046-026)................................................................394
		REMOVE (007-046-002).................................................................393
	LUBRICATING OIL DIPSTICK (007-009).......................................................359
		CALIBRATE (007-009-030)..............................................................359
	LUBRICATING OIL DIPSTICK TUBE (007-011...................................................360
		INSTALL (007-011-026)................................................................360
		REMOVE (007-011-002..................................................................360
	LUBRICATING OIL FILTER (007-013..........................................................361
		INSPECT (007-013-062)................................................................361
		PRESSURE DIFFERENTIAL TEST (007-013-063).............................................363
		REMOVE (007-013-002).................................................................361
	LUBRICATING OIL FILTER HEAD (007-015)....................................................364
		INSPECT FOR REUSE (007-015-007)......................................................364
		INSTALL (007-015-026)................................................................365
		REMOVE (007-015-002).................................................................364
	LUBRICATING OIL FILTER HEAD ADAPTER (007-018)............................................365
		INSPECT FOR REUSE (007-018-007)......................................................366
		INSTALL (007-018-026)................................................................366
		REMOVE (007-018-002).................................................................365
	LUBRICATING OIL LEAKS (007-024)..........................................................366
		FLUORESCENT DYE TRACER (007-024-054).................................................367
		INSPECT (007-024-062)................................................................366
	LUBRICATING OIL PAN (007-025)............................................................369
		FILL (007-025-028)...................................................................371
		INSPECT FOR REUSE (007-025-007)......................................................369
		INSTALL (007-025-026)................................................................370
		REMOVE (007-025-002).................................................................369
	LUBRICATING OIL PAN ADAPTER (007-026)....................................................372
		INSPECT FOR REUSE (007-026-007)......................................................374
		INSTALL (007-026-026)................................................................374
		REMOVE (007-026-002).................................................................372
	LUBRICATING OIL PAN ADAPTER COVER PLATE (007-027)........................................378
		INSPECT FOR REUSE (007-027-007)......................................................379
		INSTALL (007-027-026)................................................................379
		REMOVE (007-027-002).................................................................378
	LUBRICATING OIL PRESSURE GAUGE (007-028).................................................380
		INSPECT FOR REUSE (007-028-007)......................................................380
	LUBRICATING OIL PRESSURE REGULATOR (MAIN RIFLE) (007-029)................................380
		INSPECT FOR REUSE (007-029-007)......................................................381
		INSTALL (007-029-026)................................................................382
		REMOVE (007-029-002).................................................................380
	LUBRICATING OIL PUMP (007-031)...........................................................382
		INSPECT FOR REUSE (007-031-007)......................................................383
		INSTALL (007-031-026)................................................................384
		REMOVE (007-031-002).................................................................382
	LUBRICATING OIL SYSTEM - FLOW DIAGRAMS (200-002-047).....................................352
	LUBRICATING OIL SYSTEM - GENERAL INFORMATION (007-999-999)...............................351
	LUBRICATING OIL SYSTEM - SPECIFICATIONS (018-001-203)....................................355
	LUBRICATING OIL SYSTEM - TOOL REQUIREMENTS (022-001-507).................................356
	LUBRICATING OIL TEMPERATURE GAUGE (007-038)..............................................385
		INSPECT FOR REUSE (007-038-007)......................................................385
SECTION 8 - COOLING SYSTEM - GROUP 08........................................................399
	BELT, COOLING FAN DRIVE (008-002)........................................................413
		ADJUST (008-002-029).................................................................414
		INSPECT FOR REUSE (008-002-007)......................................................413
		INSTALL (008-002-026)................................................................414
		REMOVE (008-002-002).................................................................413
	COOLANT FILTER (008-006).................................................................415
		INSTALL (008-006-026)................................................................415
		REMOVE (008-006-002).................................................................415
	COOLANT TEMPERATURE GAUGE (008-004)......................................................415
		INITIAL CHECK (008-004-008)..........................................................415
	COOLANT THERMOSTAT (008-013).............................................................416
		INSPECT FOR REUSE (008-013-007)......................................................419
		INSTALL (008-013-026)................................................................423
		LEAK TEST (008-013-014)..............................................................421
		REMOVE (008-013-002).................................................................416
		TEST (008-013-012)...................................................................419
	COOLANT THERMOSTAT HOUSING SUPPORT (008-015).............................................426
		INSTALL (008-015-026)................................................................428
		REMOVE (008-018-002).................................................................426
	COOLANT THERMOSTAT SEAL (008-016)........................................................432
		INSTALL (008-016-026)................................................................433
		REMOVE (008-016-002).................................................................432
	COOLANT VENT LINES (008-017).............................................................433
		GENERAL INFORMATION (008-017-999)....................................................433
	COOLING SYSTEM (008-018).................................................................435
		DRAIN (008-018-005)..................................................................435
		FILL (008-018-028)...................................................................441
		FLUSH (008-018-009)..................................................................436
		PRESSURE TEST (008-018-013)..........................................................438
	COOLING SYSTEM DIAGNOSTICS (008-020).....................................................448
		PRESSURE TEST (008-020-013)..........................................................448
	COOLING SYSTEM - AIR OR COMBUSTION GAS (008-019).........................................443
		TEST (008-019-012)...................................................................443
	COOLING SYSTEM - FLOW DIAGRAMS (200-003-204).............................................406
		JACKET WATER-AFTERCOOLED.............................................................407
		LTA..................................................................................408
		LTA TORQUE CONVERTER.................................................................409
	COOLING SYSTEM - GENERAL INFORMATION (008-999-999).......................................401
		FLEETGUARD PRODUCTS FOR CUMMINS ENGINES..............................................403
	COOLING SYSTEM - REQUIRED TOOLS (022-001-508)............................................411
	COOLING SYSTEM - SPECIFICATIONS (018-001-204)............................................410
	COOLING SYSTEM SERVICE REQUIREMENTS (008-022)............................................449
		GENERAL INFORMATION (008-022-999)....................................................449
	FAN, COOLING (008-040)...................................................................454
		INITIAL CHECK (008-040-001)..........................................................454
		INSTALL (008-040-026)................................................................455
		REMOVE (008-040-002).................................................................454
		ROTATION CHECK (008-040-052).........................................................456
	FAN DRIVE IDLER ASSEMBLY (008-029).......................................................450
		INSPECT FOR REUSE (008-029-007)......................................................451
		INSTALL (008-029-026)................................................................452
		REMOVE (008-029-002).................................................................450
	FAN HUB, BELT DRIVEN (008-036)...........................................................452
		INSPECT FOR REUSE (008-036-007)......................................................453
		INSTALL (008-036-026)................................................................453
		REMOVE (008-036-002).................................................................452
	RADIATOR (008-042).......................................................................457
		INITIAL CHECK (008-042-008)..........................................................458
		TEST (008-042-012)...................................................................457
	RADIATOR HOSE, LOWER (008-045)...........................................................460
		INSPECT FOR REUSE (008-045-007)......................................................460
		INSTALL (008-045-026)................................................................460
		REMOVE (008-045-002).................................................................460
	RADIATOR HOSE, UPPER (008-046)...........................................................461
		INSPECT FOR REUSE (008-046-007)......................................................462
		INSTALL (008-046-026)................................................................462
		REMOVE (008-046-002).................................................................461
	RADIATOR PRESSURE CAP (008-047)..........................................................464
		INSPECT FOR REUSE (008-047-007)......................................................464
		PRESSURE TEST (008-047-013)..........................................................464
	RADIATOR SHROUD (008-048)................................................................464
		INSPECT FOR REUSE (008-048-007)......................................................464
	RADIATOR TOP TANK (008-051)..............................................................464
		LEAK TEST (008-051-014)..............................................................464
	SUPPLEMENTAL COOLANT ADDITIVE (SCA)(008-060).............................................465
		INSPECT FOR REUSE (008-060-007)......................................................465
	TORQUE CONVERTER COOLER (008-065)........................................................472
		INSPECT FOR REUSE (008-065-007)......................................................474
		INSTALL (008-065-026)................................................................475
		PRESSURE TEST (008-065-013)..........................................................474
		REMOVE (008-065-002).................................................................472
	WATER PUMP (008-062).....................................................................466
		INSPECT (008-062-062)................................................................468
		INSTALL (008-062-026)................................................................469
		REMOVE (008-062-002).................................................................466
SECTION 9 - DRIVE UNITS - GROUP 09...........................................................479
	ACCESSORY DRIVE (009-001)................................................................484
		CLEAN (009-001-006)..................................................................485
		INSPECT FOR REUSE (009-001-007)......................................................485
		INSTALL (009-001-026)................................................................486
		REMOVE (009-001-002).................................................................484
	ACCESSORY DRIVE PULLEY (009-004).........................................................488
		INSPECT FOR REUSE (009-004-007)......................................................488
		INSTALL (009-004-026)................................................................489
		REMOVE (009-004-002).................................................................488
	DRIVE UNITS - GENERAL INFORMATION (009-999-999)..........................................480
	DRIVE UNITS - SPECIFICATIONS.............................................................481
	DRIVE UNITS - TOOL REQUIREMENTS (022-001-509)............................................483
	WATER PUMP DRIVE (009-029)...............................................................490
		INSPECT FOR REUSE (009-029-007)......................................................491
		INSTALL (009-029-026)................................................................492
		REMOVE (009-029-002).................................................................490
SECTION 10 - AIR INTAKE SYSTEM - GROUP 10....................................................495
	AFTERCOOLER ASSEMBLY (010-002)...........................................................500
		INSPECT FOR REUSE (010-002-007)......................................................502
		INSTALL (010-002-026)................................................................502
		REMOVE (010-002-002).................................................................500
	AFTERCOOLER ELEMENT (010-008)BINSTALL (010-008-026)......................................505
		INSTALL (010-008-026)................................................................507
		PRESSURE TEST (010-008-013)..........................................................506
		REMOVE (010-008-002).................................................................505
	AIR INTAKE INFORMATION - GENERAL INFORMATION (010-999-999)...............................496
	AIR INTAKE SYSTEM - SPECIFICATIONS (018-001-205).........................................498
	AIR INTAKE SYSTEM - TOOL REQUIREMENTS (022-001-510)......................................499
	AIR INTAKE SYSTEM - FLOW DIAGRAMS (010-200-281)..........................................497
	AIR LEAKS, AIR INTAKE SYSTEM (010-024)...................................................509
		INSPECT FOR REUSE (010-024-007)......................................................509
	BOOST PRESSURE (010-057).................................................................524
		MEASURE (010-057-010)................................................................524
	INTAKE AIR RESTRICTION (010-031).........................................................511
		MEASURE (010-031-010)................................................................511
	TURBOCHARGER AXIAL CLEARANCE (010-038)...................................................518
		MEASURE (010-038-010)................................................................518
	TURBOCHARGER BLADE DAMAGE (010-039)......................................................518
		INSPECT FOR REUSE (010-039-007)......................................................518
	TURBOCHARGER COMPRESSOR SEAL LEAKS (010-040).............................................519
		INSPECT (010-040-062)................................................................519
	TURBOCHARGER RADIAL BEARING CLEARANCE (010-047)..........................................521
		MEASURE (010-047-010)................................................................521
	TURBOCHARGER TURBINE SEAL LEAKS (010-049)................................................522
		FLUORESCENT DYE TRACER (010-049-054).................................................522
	TURBOCHARGER (WATER-COOLED) (010-037)....................................................512
		CHECK FOR CORRECT COMPONENT (010-037-048)............................................517
		INSTALL (010-037-026)................................................................514
		REMOVE (010-037-002).................................................................512
SECTION 11 - EXHAUST SYSTEM - GROUP 11.......................................................525
	EXHAUST MANIFOLD (DRY ) (011-007)........................................................529
		ASSEMBLE (011-007-025)...............................................................531
		INSPECT FOR REUSE (011-007-007)......................................................530
		INSTALL (011-007-026)................................................................531
		REMOVE (011-007-002).................................................................529
	EXHAUST RESTRICTION (011-009)............................................................532
		MEASURE (011-009-010)................................................................532
	EXHAUST SYSTEM - FLOW DIAGRAMS (200-005-206).............................................527
	EXHAUST SYSTEM - GENERAL INFORMATION (011-999-999).......................................526
	EXHAUST SYSTEM - SPECIFICATIONS (018-001-206)............................................526
	EXHAUST SYSTEM - TOOL REQUIREMENTS (022-001-511).........................................528
SECTION 12 - COMPRESSED AIR SYSTEM - GROUP 12................................................535
	AIR COMPRESSOR CARBON BUILDUP (012-003)..................................................543
		INSPECT FOR REUSE (012-003-007)......................................................543
	AIR COMPRESSOR CYLINDER HEAD, SINGLE CYLINDER (012-008)..................................545
		ASSEMBLE (012-008-025)...............................................................549
		DISASSEMBLE (012-008-003)............................................................546
		INSPECT (012-008-062)................................................................547
		INSPECT FOR REUSE (012-008-007)......................................................547
		INSTALL (012-008-026)................................................................550
		REMOVE (012-008-002).................................................................545
	AIR COMPRESSOR (OIL CARRYOVER) (012-020).................................................571
		INSPECT FOR REUSE (012-020-007)......................................................571
	AIR COMPRESSOR PIN BORE WEAR (012-010)...................................................552
		INSPECT FOR REUSE (012-010-007)......................................................552
		INSTALL (012-010-026)................................................................554
		REMOVE (012-010-002).................................................................552
	AIR COMPRESSOR, SINGLE CYLINDER (012-014)................................................560
		INSPECT FOR REUSE (012-014-007.......................................................561
		INSTALL (012-014-026)................................................................562
		REMOVE (012-014-002).................................................................560
	AIR COMPRESSOR, TWO CYLINDER (012-015)...................................................564
		INSPECT FOR REUSE (012-015-007)......................................................565
		INSTALL (012-015-026)................................................................565
		REMOVE (012-015-002).................................................................564
	AIR COMPRESSOR UNLOADER AND VALVE ASSEMBLY (012-013).....................................554
		INSPECT FOR REUSE (012-013-007)......................................................555
		INSTALL (012-013-026)................................................................559
		REMOVE (012-013-002).................................................................554
		VACUUM TEST (012-013-015)............................................................557
	AIR GOVERNOR (AIR COMPRESSOR PUMPS CONTINUOUSLY) (012-018)...............................568
		INSPECT FOR REUSE (012-017-007)......................................................568
	AIR GOVERNOR (AIR COMPRESSOR WILL NOT PUMP)(012-017).....................................568
		INSPECT FOR REUSE (012-017-007)......................................................568
	AIR LEAKS, COMPRESSED AIR SYSTEM (012-019)...............................................570
		INSPECT FOR REUSE (012-019-007)......................................................570
	COMPRESSED AIR SYSTEM - FLOW DIAGRAMS (200-006-207)......................................538
	COMPRESSED AIR SYSTEM - GENERAL INFORMATION (012-999-999)................................536
	COMPRESSED AIR SYSTEM - SPECIFICATIONS (018-001-207).....................................539
		13.2 CFM SINGLE CYLINDER AIR COMPRESSOR (SS296)......................................539
		15.0 CFM SINGLE CYLINDER AIR COMPRESSOR (SS338)......................................539
	COMPRESSED AIR SYSTEM - TOOL REQUIREMENTS (022-001-512)..................................541
SECTION 13 - ELECTRICAL EQUIPMENT - GROUP 13.................................................573
	ALTERNATOR (013-001).....................................................................577
		INSPECT FOR REUSE (013-001-007)......................................................577
		INSTALL (013-001-026)................................................................579
		REMOVE (013-001-002)BTEST (013-001-012)..............................................577
		TEST (013-001-012)...................................................................578
	ALTERNATOR DRIVE BELTS (013-005).........................................................581
		ADJUST (013-005-029).................................................................582
		INSPECT FOR REUSE (013-005-007)......................................................581
		INSTALL (013-005-026)................................................................581
		REMOVE (013-005-002).................................................................581
	ALTERNATOR PULLEY (013-006)..............................................................583
		INSPECT FOR REUSE (013-006-007)......................................................583
	BATTERIES (013-007)......................................................................583
		INSPECT (013-007-062)................................................................583
	BATTERY CABLES AND CONNECTIONS (013-009).................................................584
		INSPECT FOR REUSE (013-009-007)......................................................584
	ELECTRICAL EQUIPMENT - GENERAL INFORMATION (013-999-999).................................574
	ELECTRICAL EQUIPMENT - SPECIFICATIONS (018-001-208)......................................575
	ELECTRICAL EQUIPMENT - TOOL REQUIREMENTS (022-001-513)...................................576
	STARTER MAGNETIC SWITCH (013-017)........................................................585
		INSPECT FOR REUSE (013-017-007.......................................................585
	STARTER SOLENOID (013-019)...............................................................589
		VOLTAGE CHECK (013-019-041)..........................................................589
	STARTER SWITCH (013-018).................................................................587
		INSPECT FOR REUSE (013-018-007)......................................................587
	STARTING MOTOR (013-020).................................................................591
		INSPECT FOR REUSE (013-020-007)......................................................591
		INSTALL (013-020-026)................................................................592
		REMOVE (013-020-002).................................................................591
SECTION 14 - ENGINE TESTING - GROUP 14.......................................................593
	DYNAMOMETER WORKSHEET (014-001)..........................................................599
		WORKSHEET (014-001-056)..............................................................599
	ENGINE RUN-IN (CHASSIS DYNAMOMETER) (014-002)............................................600
		GENERAL INFORMATION (014-002-999)....................................................600
			GENERAL ENGINE TEST PROCEDURES ..................................................600
		RUN-IN INSTRUCTIONS (014-002-276)....................................................602
	ENGINE RUN-IN (ENGINE DYNAMOMETER) (014-003).............................................604
		GENERAL INFORMATION (014-003-999)....................................................604
			GENERAL ENGINE TEST PROCEDURES ..................................................604
		RUN-IN INSTRUCTIONS (014-003-276)....................................................607
	ENGINE RUN-IN (WITHOUT DYNAMOMETER)(014-004).............................................610
		RUN-IN INSTRUCTIONS (014-004-276)....................................................610
	ENGINE TESTING - GENERAL INFORMATION (014-999-999).......................................595
	ENGINE TESTING - SPECIFICATIONS (018-001-275)............................................596
	ENGINE TESTING - TOOL REQUIREMENTS (022-001-514).........................................597
	ENGINE TESTING (CHASSIS DYNMOMETER)(014-005).............................................611
		SETUP (014-005-011)..................................................................611
			GENERAL ENGINE TEST PROCEDURES...................................................612
		TEST (014-005-012)...................................................................614
			AIR COMPRESSOR...................................................................623
			COOLANT PRESSURE.................................................................622
			ENGINE BLOWBY....................................................................617
			ENGINE SPEED (RPM) WITH A VERIFIED TACHOMETER....................................614
			EXHAUST RESTRICTION..............................................................617
			FUEL DRAIN LINE RESTRICTION......................................................615
			FUEL INLET RESTRICTION...........................................................615
			FUEL PRESSURE....................................................................615
			FUEL RATE........................................................................615
			INTAKE AIR RESTRICTION...........................................................617
			INTAKE AIR TEMPERATURE CONTROL - CHASSIS DYNAMOMETER TEST........................616
			INTAKE MANIFOLD PRESSURE.........................................................616
			LUBRICATING OIL PRESSURE.........................................................622
			LUBRICATING OIL TEMPERATURE......................................................622
			STARTING MOTOR...................................................................623
	ENGINE TESTING (ENGINE DYNAMOMETER)(014-006).............................................623
		INSTALL (014-006-026)................................................................623
			COOLANT PLUMBING ................................................................624
			ENGINE THROTTLE CONTROL..........................................................627
			GENERAL ENGINE TEST PROCEDURES...................................................625
		TEST (014-006-012)...................................................................627
			AIR COMPRESSOR...................................................................634
			COOLANT PRESSURE.................................................................634
			ENGINE BLOWBY SETUP (014-005-011)................................................630
			ENGINE SPEED (RPM) WITH A VERIFIED TACHMOMETER...................................628
			EXHAUST RESTRICTION..............................................................629
			FUEL DRAIN LINE RESTRICTION......................................................629
			FUEL INLET RESTRICTION...........................................................628
			FUEL PRESSURE....................................................................628
			FUEL RATE........................................................................628
			INTAKE AIR RESTRICTION...........................................................629
			INTAKE MANIFOLD PRESSURE.........................................................629
			LUBRICATING OIL PRESSURE ........................................................634
			LUBRICATING OIL TEMPERATURE......................................................634
			STARTING MOTOR...................................................................635
	ENGINE TESTING (FUEL FLOW RATE)(014-007).................................................642
		MEASURE (014-007-010)................................................................642
			OPERATION........................................................................643
	ENGINE TESTING (IN-CHASSIS)(014-008).....................................................635
		STALL SPEED CHECK(014-008-280).......................................................635
		TIME SPEED CHECK (014-008-281).......................................................638
			STALL SPEED CHECK LIST...........................................................640
SECTION 16 - MOUNTING ADAPTATIONS - GROUP 16.................................................647
	ENGINE SUPPORT BRACKET, FRONT (016-002)..................................................651
		INSPECT FOR REUSE (016-002-007)......................................................652
		INSTALL (016-002-026)................................................................652
		REMOVE (016-002-002).................................................................651
	FLYWHEEL (016-005).......................................................................653
		INSPECT FOR REUSE (016-005-007)......................................................654
		INSTALL (016-005-026)................................................................655
		REMOVE (016-005-002).................................................................653
	FLYWHEEL HOUSING (016-006)...............................................................657
		INSPECT FOR REUSE (016-006-007)......................................................659
		INSTALL (016-006-026)................................................................664
		REDOWEL (016-006-023)................................................................660
		REMOVE (016-006-002).................................................................657
	MOUNTING ADAPTATIONS - GENERAL INFORMATION (016-999-999).................................648
	MOUNTING ADAPTATIONS - SPECIFICATIONS (018-001-516)......................................649
	MOUNTING ADAPTATIONS - TOOL REQUIREMENTS (022-001-516)...................................650
COMPONENT MANUFACTURERS......................................................................671
	COMPONENT MANUFACTURERS' ADDRESSES.......................................................672
		AIR COMPRESSORS......................................................................672
		AIR CYLINDER.........................................................................672
		AIR HEATERS .........................................................................672
		AIR STARTING MOTORS..................................................................672
		ALTERNATORS..........................................................................672
		AUXILIARY BRAKES.....................................................................672
		BELTS................................................................................672
		CATALYTIC CONVERTERS.................................................................672
		CLUTCHES.............................................................................672
		COOLANT HEATERS......................................................................672
		DRIVE PLATES.........................................................................672
		ELECTRIC STARTING MOTORS.............................................................673
		ENGINE PROTECTION CONTROLS...........................................................673
		FAN CLUTCHES.........................................................................673
		FANS.................................................................................673
		FILTERS..............................................................................673
		FLEXPLATES...........................................................................673
		FUEL WARMERS.........................................................................673
		GAUGES...............................................................................673
		GOVERNORS............................................................................673
		HYDRAULIC AND POWER STEERING PUMPS...................................................674
		OIL HEATERS..........................................................................674
		TORQUE CONVERTERS....................................................................674
SPECIFICATIONS AND TORQUE VALUES.............................................................675
	CAPSCREW MARKINGS AND TORQUE VALUES......................................................682
		CAPSCREW MARKINGS AND TORQUE VALUES - METRIC.........................................682
		CAPSCREW MARKINGS AND TORQUE VALUES - U.S. CUSTOMARY.................................683
	ENGINE COMPONENTS - GENERAL INFORMATION..................................................676
	FRACTION, DECIMAL, MILLIMETER CONVERSIONS................................................679
	NEWTON-METER TO FOOT-POUND CONVERSION CHART..............................................681
	PIPE PLUG TORQUE VALUES..................................................................683
	STRAIGHT THREADED O-RING PLUGS...........................................................677
	TAP-DRILL CHART - U.S. CUSTOMARY & METRIC................................................684
	WEIGHT AND MEASURES - CONVERSSION FACTORS................................................680
INDEX........................................................................................685

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