Factory Troubleshooting And Repair Manual For Cummins Engine. Manual Contains Illustrations, Instructions, Diagrams For Step By Step Remove And Install, Assembly And Disassembly, Service, Inspection, Repair, Troubleshooting, Tune-Ups.
Format: PDF
Language: English
Pages: 713
Number: 3810307-00 (september 1986)
Bookmarks: Yes
Model
Cummins Engine
K19
Contents
-INTRODUCTION
About The Manual
How to Use The Manual
Symbols
Illustrations
General Safety Instructions
General Repair Instructions
General Cleaning Instructions
Definition Of Terms
-ENGINE AND COMPONENT IDENTIFICATION
Engine Identification
General Specifications
External Engine Components
-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)
-COOLING SYSTEM
Service Tools
General Information
Cooling System Specifications
Cooling System Flow Charts
Cooling System Venting
Cooling System – Maintenance
Cooling System – Drain
Cooling System – Fill
Coolant Filter – Replace
Diesel Coolant Additives (DCA4)
Cooling System – Clean
Cooling System – Test For Air Or Combustion Gases
Cracked Or Porous Cylinder Liner
Defective Air Control Valve
Air Compressor Check
Cooling System – Pressure Test
Hoses-Check
Coolant Temperature Gauge – Check
Radiator Pressure Cap – Check
Radiator Fins – Inspect
Radiator Baffle Leakage – Check
Radiator – Check For Reverse Flow
Radiator – Check For Obstruction
Shutter Operation – Check
Fan, And Fan Shroud – Inspect
Fan – Replace
Fan Drive Belt – Replace
Fan Clutch – Check Operation
Fan Rpm – Check
Fan Hub (Belt Driven) – Replace
Fan Hub (Gear Driven) – Replace
Fan Hub Idler And Shock Absorber (Or Turnbuckle) – Replace
Water Pump Block Pressure – Check
Water Pump – Replace
Water Pump – Check For Reuse
Thermostat – Test (Thermostat In Chassis)
Thermostat – Replace
Thermostat – Check Operating Temperature
Thermostat Housing – Replace
Check For Coolant Leaks At Counterbore
-LUBRICATION OIL SYSTEM
Service Tools
General Information
Specifications
Flow Diagrams
Internal Engine Damage – Check
Oil Leaks (External) – Checks
Oil System – Leak Check Using Dye
Oil Pressure Gauge – Check
Oil Temperature Gauge – Check
Drain Oil
Oil Pan – Fill
Oil Filters (Full Flow And Bypass) – Replace
Oil Filter (Full Flow) – Measure Pressure Drop
Crankcase Breather And Tube – Replace
Dipstick Tube – Replace
Dipstick – Calibrate
Oil Pan – Replace
Oil Pan Adapter – Replace
Oil Filter Head – Replace
Oil Cooler – Measure Pressure Drop
Oil Cooler Cover – Replace
Torque Converter Cooler – Replace
Oil Cooler Core – Replace
Oil Cooler Core – Check For Reuse
Torque Converter Cooler – Pressure Test
Oil Cooler Housing – Replace
Main Oil Pressure Regulator – Replace
Oil Pump – Replace
Lubricating Oil Pump – Check For Reuse
-COMBUSTION AIR SYSTEM
General Information
Specifications
Flow Diagrams
Service Tools
Turbocharger Turbine Seal Leaks – Check
Compressor Seal Leakage – Check
Correct Turbocharger Installed – Check
Intake Air Restriction – Check
Exhaust Restriction – Check
Air Leaks-Check
Turbocharger Blade Damage – Check
Turbocharger Axial And Radial Clearance – Check
Turbocharger – Replace
Series Turbocharger – Replace
Exhaust Manifold – Replace
Exhaust Manifold – Check
Aftercooler – Replace
Aftercooler Element – Replace
Aftercooler Element – Test
Intake Manifold Pressure
-COMPRESSED AIR SYSTEM
General Information
Specifications
Flow Diagrams
Service Tools
Carbon Buildup, Air Compressor – Check
Gasket Leaks, Air Compressor – Check
Air Governor – Check (Air Compressor Not Pumping)
Air Governor – Check (Air Compressor Pumps Continuously)
Lubricating Oil Usage, Air Compressor – Check
Unloader Valve, Air Compressor – Replace
Unloader Valve – Check
Intake/Exhaust Valves. Air Compressor – Check
Cylinder Head, Air Compressor – Rebuild On Engine
Cylinder Head, Air Compressor – Replace
Air Compressor (Single Cylinder) – Replace
Air Compressor (Two Cylinder) – Replace
Air Compressor – Check For Reuse
-FUEL SYSTEM
General Information
Specifications
Flow Diagrams
Service Tools
Idle Speed – Check And Adjust
Horsepower – Measure Engine Performance
Fuel Rate – Adjust
AFC No-Air Valve Setting – Check And Adjust
Injectors – Replace
Injectors – Clean Exterior For Reuse
Fuel Pump – Replace
Throttle Travel – Check
Fuel System Maintenance
Gear Pump Check Valve – Replace
Variable Speed (VS) Governor Leaking Fuel
Fuel Shutoff Valve – Check
Fuel Pump – Flow Check And Prime
Fuel Pump Rotation Check
Air Leaks
AFC – Check For Air Leak
Cylinder Misfire
Engine Oil Dilution By Fuel
Fuel Line Restriction (Suction) – Check
Fuel Drain Restriction – Check
STC Oil Control Valve – Check
STC Fuel Pressure Switch – Check
STC Wiring Harness – Check For Reuse
STC Oil Control Valve – Replace
STC Wiring Harness – Replace
Fuel Consumption Check
Low Power Check
Engine Stall Speed And Time Check
Fuel Manifold – Replace
STC Oil Manifold – Replace
Stall Speed Check List
Driveability – Low Power Check List
Fuel Consumption Check List
-ELECTRICAL SYSTEM
General Information
Specifications
Service Tools
Battery Terminal Connections – Check
Batteries- Check
Starting Circuit – Check
Alternator Belt – Adjust
Alternator – Output Test
Alternator – Replace
Accessory/Alternator Drive Pulley – Check For Reuse
Starting Motor – Replace
Starter Motor – Check For Reuse
-BASE ENGINE COMPONENTS
Service Tools
General Information
Crankcase Gas (Blowby) – Check
Rocker Lever Cover – Replace
Check/Adjust Valves And Injectors
Jacobs Engine Brake – Adjust
Jacobs Engine Brake – Replace
Push Rod – Replace
Rocker Lever Assembly – Replace
Rocker Lever Housing – Replace
Check Cylinder Head Gasket For Combustion, Coolant, Or Oil Leak
Power Cylinder – Locate Failed Cylinder
Cylinder Head Gasket – Replace
Cylinder Head – Clean And Check For Reuse
Pressure Test Cylinder Head – Head Removed
Cam Follower Assembly – Replace
Cam Follower Assembly – Clean And Check For Reuse
Injection Timing – General Information
Measure The Injection Timing
Piston Cooling Nozzle – Replace
Main Crankshaft Bearing – Replace
Connecting Rod Bearing – Replace
Piston And Rod Assembly – Replace
Piston – Clean And Check For Reuse
Cylinder Liner – Remove
Check Liner Protrusion
Accessory Drive Pulley – Replace
Wear Sleeve. Accessory Drive Pulley – Replace
Accessory Drive Seal – Replace
Accessory Drive Assembly – Replace
Fuel Pump/Compressor Drive – Clean And Check For Reuse
Vibration Damper – Replace
Viscous Vibration Damper – Clean And Check For Reuse
Rubber Vibration Damper – Clean And Check For Reuse
Crankshaft Front Seal – Replace
Water Pump Drive – Replace
Water Pump Drive – Clean And Check For Reuse
Gear Cover (One Piece) – Replace
Camshaft Gear – Replace (Camshaft Installed)
Gear Cover Plate (Spacer Plate) – Replace
Gear Cover (Two Piece) – Replace
Gear Housing (Two Piece Design) – Replace
Check Gear Train Backlash
Idler Shaft (Press-In) – Replace
Front Engine Support – Replace
Crankshaft Gear – Remove And Install
Camshaft – Replace
Camshaft Gear – Remove And Install
Cylinder Block – Replace Camshaft Bushings
Camshaft Rear Cover – Replace
Flywheel – Replace
Crankshaft Seal, Rear – Replace
Flywheel Housing – Replace
Pipe Plugs And Cup Plugs
-ENGINE TESTING (“IN-CHASSIS”)
Specifications And Procedures
General Engine Test Procedures
Chassis Dynamometer Operation
Engine Run-In Procedure (Chassis Dynamometer)
Engine Run-In Procedure “In-Chassis” (On And Off-Highway Vehicles)
Engine Configurations And Models
-ENGINE REMOVE AND INSTALL
General Information
Service Tools
Engine – Remove
Engine Mount – Inspect
Engine – Install
-ENGINE COMPONENT SPECIFICATIONS
General Information
Conversion Factors
Pipe Plug Torque Values
Capscrew Markings And Torque Values
Decimal And Metric Equivalents
Cooling System
Lubricating Oil System
Combustion Air System
Compressed Air System
Fuel System
Electrical System
Base Engine Components
INDEX – TROUBLESHOOTING AND REPAIR
-SERVICE LITERATURE
Service Literature Ordering Location
Service Literature Order Form
COMPONENT MANUFACTURERS
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