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CUMMINS K19 Series User Manual

CUMMINS K19 Series
713 pages
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Troubleshooting and
Repair Manual
K19 Engines
Copyright® 1986
Cummins Engine Company, Inc.
Bulletin No. 3810307-00
Printed 9-86

Table of Contents

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CUMMINS K19 Series Specifications

General IconGeneral
Engine ModelK19 Series
Bore159 mm (6.25 in)
Stroke159 mm (6.25 in)
AspirationTurbocharged and Aftercooled
Engine TypeDiesel
ConfigurationInline
Displacement19 L (1150 cu in)
Fuel SystemPT (Pressure-Time)
Governor TypeMechanical
Governed Speed2100 RPM
Emissions ComplianceVaries by model and year of manufacture
Peak Torque2000 - 2200 lb-ft

Summary

Foreword

Section i - Introduction

About the Manual

Describes the manual's purpose, organization, and how to use it.

How to Use the Manual

Explains the manual's organization and how to follow troubleshooting logic charts.

Symbols

Lists and defines symbols used in the manual to communicate instructions.

General Safety Instructions

Lists essential safety precautions to follow before performing any repair work.

General Repair Instructions

Details general principles and practices for performing engine repairs.

General Cleaning Instructions

Outlines general procedures for cleaning engine parts during repair.

Definition Of Terms

Provides definitions for terms used throughout the manual.

Section E - Engine and Component Identification

Engine Identification

Covers engine nomenclature, dataplate, and fuel pump dataplate information.

General Specifications

Lists general engine specifications including bore, stroke, weight, and settings.

External Engine Components

Illustrates locations of major external engine components on the fuel pump and exhaust sides.

Section T - Troubleshooting

Procedures and Techniques

Outlines basic troubleshooting steps and emphasizes thorough analysis of the problem.

Troubleshooting Charts (Alphabetical Listing)

Provides an alphabetical list of engine troubleshooting symptoms and their corresponding page numbers.

Troubleshooting Charts (By System)

Organizes troubleshooting charts by engine system for easier problem identification.

Section 1 - Cooling System

Required Service Tools (01-00) Cooling System

Lists special tools recommended for procedures in Section 01.

General Information (01-01)

Explains the primary function of the cooling system and lists related publications.

Cooling System Specifications (01-02)

Provides detailed specifications for the cooling system, including capacity, thermostat range, and pressure.

Section 02 - Lubrication Oil System

Required Service Tools - (02-00) Lubricating Oil System

Lists special tools recommended for procedures in Section 02.

General Information (02-01)

Explains the primary function of the lubrication oil system and recommends oil types.

Lubricating Oil System Specifications (02-02)

Lists oil pressure, filter capacity, and oil pan capacity specifications.

Section 03 - Combustion Air System

Service Tools (03-04)

Lists special tools recommended for procedures in Section 03.

General Information - (03-01)

Explains the combustion air system, including intake, turbocharger, and exhaust piping.

Combustion Air System Specifications (03-02)

Provides specifications for air induction and exhaust systems, including intake restriction and pipe diameter.

Section 04 - Compressed Air System

General Information (04-01)

Describes the basic components of the compressed air system and compressor operation.

Compressed Air System Specifications - (04-02)

Lists specifications for single and two-cylinder air compressors, including dimensions and capacities.

Section 05 - Fuel System

General Information (05-01)

Explains the PT fuel system, its components, and operation.

Fuel System Specifications (05-02)

Lists basic application requirements for the fuel system, including idle speed and filter restrictions.

Section 06 - Electrical System

General Information - (06-01)

Describes the basic heavy-duty electrical system components and battery connections.

Electrical System Specifications - (06-02)

Lists minimum battery capacity, starting circuit resistance, and battery cable sizes.

Section 07 - Base Engine Components

Service Tools (07-01)

Lists special tools recommended for base engine component procedures.

General Information (07-02)

Describes the base engine components chapter and refers to the shop manual for rebuild instructions.

Section 08 - Engine Testing - ("In-Chassis")

General Engine Test Specifications and Procedures (08-01)

Lists limits to maintain during a chassis dynamometer test for air inlet, exhaust, blow-by, and oil pressure.

Section 09 - Engine Remove and Install

General Information (09-01)

Explains that engine replacement procedures vary by model and equipment, and advises using manufacturer's recommendations.

Service Tools (09-02)

Lists special tools recommended for engine removal and installation procedures.

Section 10 - Engine Component Specifications

General Information - (10-01)

Explains the content of the specifications section and refers to other publications for additional details.

Conversion Factors - (10-02)

Provides a table of common metric and U.S. customary unit conversion factors.

Pipe Plug Torque Values - (10-03)

Lists torque values for various pipe plug sizes in aluminum and cast iron/steel components.

Capscrew Markings and Torque Values - U.S. Customary

Explains SAE capscrew grading and provides torque values for common sizes in aluminum and cast iron/steel.

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