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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