Cummins K19 Engine
CUMMINS K19 ENGINE - WORKSHOP, SERVICE, REPAIR MANUAL
CUMMINS K19 ENGINE - WORKSHOP, SERVICE, REPAIR MANUAL - English Workshop Manual / Repair Manual, for Cummins K19 Engine. INDEX: SECTION I - INTRODUCTION - About The Manual - How To Use The Manual - Symbols - Simbolos - Symbole - Symboles - Illustrations - General Safety Instructions - General Repair Instructions - General Cleaning Instructions - Definition Of Terms SECTION E - ENGINE AND COMPONENT IDENTIFICATION - Engine Identification - General Specifications - External Engine Components SECTION T - TROUBLESHOOTING - Procedures And Techniques - Troubleshooting Charts (Alphabetical Listing) - Troubleshooting Charts (By System) - Coolant Temperature Above Normal - Coolant Temperature Below Normal - Coolant Loss - Fuel In Coolant - Lubricating Oil Pressure Low - Lubricating Oil Pressure High - Lubricating Oil Temperature Above Normal - Lubricating Or Hydraulic Oil In The Coolant - Lubricating Oil Consumption Excessive - Lubricating Oil Sludge In The Engine Crankcase Excessive - Coolant In The Lubricating Oil - Fuel In The Lubricating Oil - Turbocharger Noise - Turbocharger Boost Pressure Low - Turbocharger Leaks (Engine Oil Or Fuel) - Air Compressor Slow Air Pressure Rise - Air Compressor Will Not Maintain Adequate Air Pressure (Not Pumping Continuously) - Air Compressor Pumping Excessive Lubricating Oil - Air Compressor Will Not Pump - Air Compressor Will Not Stop Pumping - Air Compressor Noise Excessive - Engine Cranks But Will Not Start (No Smoke From Exhaust) - Engine Hard To Start Or Will Not Start (Exhaust Smoke Present) - Engine Starts But Will Not Keep Running - Engine Runs Rough Or Misfires (Warm Engine) - Idle Rough - Engine Surges At Low Idle - Engine Will Not Reach Rated Rpm When Loaded - Engine Power Output Low - Performance Measurement - Exhaust Smoke Excessive Under Load - Engine Will Not Shut Off - Engine Decelerates Poorly - Engine Surges Under Load - Engine Surges At High Idle - Throttle Response Slow (Engine Dies Going Down Hill) - Fuel Consumption Excessive - Engine Will Not Crank Or Cranks Slowly (Air Starter) - Engine Will Not Crank Or Cranks Slowly (Electric Starter) - Alternator Malfunctioning - Crankcase Gases (Blowby) Excessive - Engine Vibration Excessive - Engine Noise - Diagnostic Procedures - Engine Noise Excessive - Exhaust Smoke (White) At Idle Excessive (Warm Engine) SECTION 1 - COOLING SYSTEM - Service Tools (01-00) - General Information (01-01) - Cooling System Specifications (01-02) - Cooling System Flow Charts (01-03) - Cooling System Venting (01-04) - Cooling System - Maintenance (01-05) - Cooling System - Drain (01-06) - Cooling System - Fill (01-07) - Coolant Filter - Replace (01-08) - Diesel Coolant Additives (Dca4) (01-09) - Cooling System - Clean (01-10) - Cooling System - Test For Air Or Combustion Gases (01-11) - Cracked Or Porous Cylinder Liner - Defective Air Control Valve - Air Compressor Check - Cooling System - Pressure Test (01-12) - Hoses - Check (01-13) - Coolant Temperature Gauge - Check (01-14) - Radiator Pressure Cap - Check (01-15) - Radiator Fins - Inspect (01-16) - Radiator Baffle Leakage - Check (01-17) - Radiator - Check For Reverse Flow (01-18) - Radiator - Check For Obstruction (01-19) - Shutter Operation - Check (01-20) - Fan, And Fan Shroud - Inspect (01-21) - Fan - Replace (01-22) - Fan Drive Belt - Replace (01-23) - Fan Clutch - Check Operation (01-24) - Fan Rpm - Check (01-25) - Fan Hub (Belt Driven) - Replace (01-26) - Fan Hub (Gear Driven) - Replace (01-27) - Fan Hub Idler And Shock Absorber (Or Turnbuckle) - Replace (01-28) - Water Pump Block Pressure - Check (01-29) - Water Pump - Replace (01-30) - Water Pump - Check For Reuse (01-31) - Thermostat - Test (Thermostat In Chassis) (01-32) - Thermostat - Replace (01-33) - Thermostat - Check Operating Temperature (01-34) - Thermostat Housing - Replace (01-35) - Check For Coolant Leaks At Counterbore (01-36) SECTION 2 - LUBRICATION OIL SYSTEM - Service Tools (01-00) - General Information (02-01) - Specifications (02-02) - Flow Diagrams (02-03) - Internal Engine Damage - Check (02-04) - Oil Leaks (External) - Checks (02-05) - Oil System - Leak Check Using Dye (02-06) - Oil Pressure Gauge - Check (02-07) - Oil Temperature Gauge - Check (02-08) - Drain Oil (02-09) - Oil Pan - Fill (02-10) - Oil Filters (Full Flow And Bypass) - Replace (02-11) - Oil Filter (Full Flow) - Measure Pressure Drop (02-12) - Crankcase Breather And Tube - Replace (02-13) - Dipstick Tube - Replace (02-14) - Dipstick - Calibrate (02-15) - Oil Pan - Replace (02-16) - Oil Pan Adapter - Replace (02-17) - Oil Filter Head - Replace (02-18) - Oil Cooler - Measure Pressure Drop (02-19) - Oil Cooler Cover - Replace (02-20) - Torque Converter Cooler - Replace (02-21) - Oil Cooler Core - Replace (02-22) - Oil Cooler Core - Check For Reuse (02-23) - Torque Converter Cooler - Pressure Test (02-24) - Oil Cooler Housing - Replace (02-25) - Main Oil Pressure Regulator - Replace (02-26) - Oil Pump - Replace (02-27) - Lubricating Oil Pump - Check For Reuse (02-28) SECTION 3 - COMBUSTION AIR SYSTEM - General Information (03-01) - Specifications (03-02) - Flow Diagrams (03-03) - Service Tools (03-04) - Turbocharger Turbine Seal Leaks - Check (03-05) - Compressor Seal Leakage - Check (03-06) - Correct Turbocharger Installed - Check (03-07) - Intake Air Restriction - Check (03-08) - Exhaust Restriction - Check (03-09) - Air Leaks - Check (03-10) - Turbocharger Blade Damage - Check (03-11) - Turbocharger Axial And Radial Clearance - Check (03-12) - Turbocharger - Replace (03-13) - Series Turbocharger - Replace (03-14) - Exhaust Manifold - Replace (03-15) - Exhaust Manifold - Check (03-16) - Aftercooler - Replace (03-17) - Aftercooler Element - Replace (03-18) - Aftercooler Element - Test (03-19) - Intake Manifold Pressure - Check (03-20) SECTION 4 - COMPRESSED AIR SYSTEM - General Information (04-01) - Specifications (04-02) - Flow Diagrams (04-03) - Service Tools (04-04) - Carbon Buildup, Air Compressor - Check (04-05) - Gasket Leaks, Air Compressor - Check (04-06) - Air Governor - Check (Air Compressor Not Pumping) (04-07) - Air Governor - Check (Air Compressor Pumps Continuously) (04-08) - Lubricating Oil Usage, Air Compressor - Check (04-09) - Unloader Valve, Air Compressor - Replace (04-10) - Unloader Valve - Check (04-11) - Intake/Exhaust Valves, Air Compressor - Check (04-12) - Cylinder Head, Air Compressor - Rebuild On Engine (04-13) - Cylinder Head, Air Compressor - Replace (04-14) - Air Compressor (Single Cylinder) - Replace (04-15) - Air Compressor (Two Cylinder) - Replace (04-16) - Air Compressor - Check For Reuse (04-17) SECTION 5 - FUEL SYSTEM - General Information (05-01) - Specifications 05-02) - Flow Diagrams (05-03) - Service Tools (05-04) - Idle Speed - Check And Adjust (05-05) - Horsepower - Measure Engine Performance (05-06) - Fuel Rate - Adjust (05-07) - Afc No-Air Valve Setting - Check And Adjust (05-08) - Injectors - Replace (05-09) - Injectors - Clean Exterior For Reuse (05-10) - Fuel Pump - Replace (05-11) - Throttle Travel - Check (05-12) - Fuel System Maintenance (05-13) - Gear Pump Check Valve - Replace (05-14) - Variable Speed (Vs) Governor Leaking Fuel (05-15) - Fuel Shutoff Valve - Check (05-16) - Fuel Pump - Flow Check And Prime (05-17) - Fuel Pump Rotation Check (05-18) - Air Leaks (05-19) - Afc - Check For Air Leak (05-20) - Cylinder Misfire (05-21) - Engine Oil Dilution By Fuel (05-22) - Fuel Line Restriction (Suction) - Check (05-23) - Fuel Drain Restriction - Check (05-24) - Stc Oil Control Valve - Check (05-25) - Stc Fuel Pressure Switch - Check (05-26) - Stc Wiring Harness - Check For Reuse (05-27) - Stc Oil Control Valve - Replace (05-28) - Stc Wiring Harness - Replace (05-29) - Fuel Consumption Check (05-30) - Low Power Check (05-31) - Engine Stall Speed And Time Check (05-32) - Fuel Manifold - Replace (05-33) - Stc Oil Manifold - Replace (05-34) - Stall Speed Check List (05-35) - Driveability - Low Power Check List (05-36) - Fuel Consumption Check List (05-37) SECTION 6 - ELECTRICALSYSTEM - General Information (06-01) - Specifications (06-02) - Service Tools (06-03) - Battery Terminal Connections - Check (06-04) - Batteries - Check (06-05) - Starting Circuit - Check (06-06) - Alternator Belt - Adjust (06-07) - Alternator - Output Test (06-08) - Alternator - Replace (06-09) - Accessory/Alternator Drive Pulley - Check For Reuse (06-10) - Starting Motor - Replace (06-11) - Starter Motor - Check For Reuse (06-12) SECTION 7 - BASE ENGINE COMPONENTS - Service Tools (07-01) - General Information (07-02) - Crankcase Gas (Blowby) - Check (07-03) - Rocker Lever Cover - Replace (07-04) - Check/Adjust Valves And Injectors (07-05) - Jacobs Engine Brake - Adjust (07-06) - Jacobs Engine Brake - Replace (07-07) - Push Rod - Replace (07-08) - Rocker Lever Assembly - Replace (07-09) - Rocker Lever Assembly - Clean And Check For Reuse (07-10) - Rocker Lever Housing - Replace (07-11) - Check Cylinder Head Gasket For Combustion, Coolant, Or Oil Leak (07-12) - Power Cylinder - Locate Failed Cylinder (07-13) - Cylinder Head Gasket - Replace (07-14) - Cylinder Head - Clean And Check For Reuse (07-15) - Pressure Test Cylinder Head - Head Removed (07-16) - Cam Follower Assembly - Replace (07-17) - Cam Follower Assembly - Clean And Check For Reuse (07-18) - Injection Timing - General Information (07-19) - Measure The Injection Timing (07-20) - Piston Cooling Nozzle - Replace (07-21) - Main Crankshaft Bearing - Replace (07-22) - Connecting Rod Bearing - Replace (07-23) - Piston And Rod Assembly - Replace (07-24) - Piston - Clean And Check For Reuse (07-25) - Cylinder Liner - Remove (07-26) - Check Liner Protrusion (07-27) - Accessory Drive Pulley - Replace (07-28) - Wear Sleeve, Accessory Drive Pulley - Replace (07-29) - Accessory Drive Seal - Replace (07-30) - Accessory Drive Assembly - Replace (07-31) - Fuel Pump/Compressor Drive - Clean And Check For Reuse (07-32) - Vibration Damper - Replace (07-33) - Viscous Vibration Damper - Clean And Check For Reuse (07-34) - Rubber Vibration Damper - Clean And Check For Reuse (07-35) - Crankshaft Front Seal - Replace (07-36) - Water Pump Drive - Replace (07-37) - Water Pump Drive - Clean And Check For Reuse (07-38) - Gear Cover (One Piece) - Replace (07-39) - Camshaft Gear - Replace (Camshaft Installed) (07-40) - Gear Cover Plate (Spacer Plate) - Replace (07-41) - Gear Cover (Two Piece) - Replace (07-42) - Gear Housing (Two Piece Design) - Replace (07-43) - Check Gear Train Backlash (07-44) - Idler Shaft (Press-In) - Replace (07-45) - Front Engine Support - Replace (07-46) - Crankshaft Gear - Remove And Install (07-47) - Camshaft - Replace (07-48) - Camshaft Gear - Remove And Install (07-49) - Cylinder Block - Replace Camshaft Bushings (07-50) - Camshaft Rear Cover - Replace (07-51) - Flywheel - Replace (07-52) - Crankshaft Seal, Rear - Replace (07-53) - Flywheel Housing - Replace (07-54) - Flywheel Housing Redowel To Cylinder Block (07-55) - Pipe Plugs And Cup Plugs - Replace (07-56) SECTION 8 - ENGINE TESTING ("IN-CHASSIS") - Specifications And Procedures (08-01) - General Engine Test Procedures (08-01) - Chassis Dynamometer Operation (08-02) - Engine Run-In Procedure (Chassis Dynamometer) (08-03) - Engine Run-In Procedure "In-Chassis" (On And Off-Highway Vehicles) (08-04) - Engine Configurations And Models (08-05) SECTION 9 - ENGINE REMOVE AND INSTALL - General Information (09-01) - Service Tools (09-02) - Engine - Remove (09-03) - Engine Mount - Inspect (09-04) - Engine - Install (09-05) SECTION 10 - ENGINE COMPONENT SPECIFICATIONS - General Information (10-01) - Conversion Factors (10-02) - Pipe Plug Torque Values (10-03) - Capscrew Markings And Torque Values (10-04) - Decimal And Metric Equivalents (10-05) - Cooling System (10-06) - Lubricating Oil System (10-07) - Combustion Air System (10-08) - Compressed Air System (10-09) - Fuel System (10-10) - Electrical System (10-11) - Base Engine Components (10-12) SECTION 11 - INDEX - TROUBLESHOOTING AND REPAIR SECTION 12 - SERVICE LITERATURE - Service Literature Ordering Location - Service Literature Order Form SECTION 13 - COMPONENT MANUFACTURERS
Cummins K19 Engine - Workshop Manual / Repair Manual
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
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